Manuale Officina Audi A6 11-18

Service
Maintenance
Audi A6 2011 ➤
Audi A7 Sportback 2011 ➤
Edition 06.2015
© satelettronica
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
Maintenance
Heading
1. General information
2. Preparations
3. Maintenance
© satelettronica
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt D3E802EDBDC

Audi A6 2011 ➤ , Audi A7 Sportback 2011 ➤
Maintenance - Edition 06.2015
Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 --- Change history --- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Overview of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Warnings for high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Vehicle: raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Engine cover panel: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Noise insulation: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Window regulators: activating automatic open/close function . . . . . . . . . . . . . . . . . . . . . . 23
2.5 Vehicle diagnostic tester: connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Diesel particulate filter: reading out ash deposit volume . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Event memory: reading out and erasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Service interval display: resetting service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
© satelettronica
3.4 Transport mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5 Shipping mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 Battery: reading out status and sending diagnostic log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.7 Battery: checking that battery and battery cables are securely fitted . . . . . . . . . . . . . . . . . . 33
3.8 Battery: checking electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.9 Battery: connecting to a stationary battery charging unit for sustained charging . . . . . . . . 39
3.10 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.11 Brake fluid: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.12 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder
screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.13 Brake pads: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.14 Tyres: checking condition and wear pattern, and checking and recording tread depth . . . . 50
3.15 Tyres: checking tyre pressures and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . 51
3.16 Tyre Pressure Loss Indicator: storing changed tyre pressures . . . . . . . . . . . . . . . . . . . . . . 52
3.17 Tyre repair kit: checking that set is complete, and checking and recording expiry date . . 53
3.18 Tool kit: checking that all components necessary in the event of a breakdown are present
........................................................................ 53
3.19 Wheel bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.20 Suspension struts on front and rear axle: removing locking elements . . . . . . . . . . . . . . . . 54
3.21 Components of front and rear axles: checking play, secure attachment and protective
boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.22 Engine, gearbox, final drive and steering: checking for leaks and damage . . . . . . . . . . . . 60
3.23 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage,
and checking that they are properly secured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.24 Roof insert: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.25 Roof insert - sliding/tilting sunroof: cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . 61
3.26 Roof insert - panorama sunroof: cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.27 unless
permitted Rear spoiler
authorised hinges:
by AUDI AG. AUDI lubricating . . . . or. .accept
AG does not guarantee . . . any
. . .liability
.................................. 68
3.28
with respectBonnet arrester
to the correctness hook: inlubricating
of information . . . . . by. .AUDI
this document. Copyright . . .AG.
.................................. 68
3.29 Windscreen/rear window washer system: checking spray pattern and adjusting if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.30 Wiper blades: checking for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.31 Headlight washer system: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.32 Headlights: checking for correct adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.33 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning
lights: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.34 Luggage compartment lighting: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.35 Glove box light, interior lighting and reading light: checking operation . . . . . . . . . . . . . . . . 75
Contents i
3.36 Horn: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.37 Front passenger's airbag: checking key switch on / off and setting to "on" . . . . . . . . . . . . 76
3.38 Seat belts: checking that retaining rivets are fitted, and checking locking action of automatic
belt retractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.39 Instrument cluster: checking warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.40 Warning triangle: checking availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.41 First-aid kit: checking and recording expiry date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.42 Vehicle keys: checking operation and recording number of keys given to customer . . . . . . 78
3.43 Engine oil: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.44 Engine oil: extracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.45 Engine oil: renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.46 Engine oil: filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.47 Engine oil: checking oil level and correcting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.48 Poly V-belts for ancillaries: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.49 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.50 Cooling system: checking anti-freeze and coolant level, and correcting if necessary . . . . 102
3.51 Air cleaner: renewing filter element and cleaning housing . . . . . . . . . . . . . . . . . . . . . . . . 105
3.52 Plenum chamber and water drains: checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.53 Dust and pollen filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.54 Fuel filter: draining . . . . . .Protected
. . . . .by. .copyright.
. . . . .Copying
. . . . .for. private
. . . . or. commercial
. . . . . . .purposes,
. . . . . in. part
. . .or. in. whole,
. . . .is. not
.... 117
© satelettronica
3.55 Fuel filter: renewing . . . . . . with. . .respect
. . . .to.the
. .correctness
. . . . . . of. information
. . . . . . in. .this. .document.
. . . . . Copyright
. . . . . .by. AUDI . . . AG.
...... 118
3.56 Fuel tank: adding fuel additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.57 Reducing agent (AdBlue®): filling up tank completely . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.58 Body: checking vehicle paintwork for damage and corrosion from below and with bonnet, rear
lid and doors open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.59 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.60 Stock vehicles: observing measures specified in Maintenance table for stock vehicles (see
“Before handing vehicle over to customer”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.61 Rear final drive: changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.62 Rear final drive: changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.63 Display instruments: setting language, time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.64 Automatic gearbox (multitronic): changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.65 Automatic gearbox (tiptronic): changing ATF fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.66 Dual clutch gearbox (S tronic): changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.67 Dual clutch gearbox (S tronic): changing ATF and renewing exchangeable ATF filter . . . . 128
3.68 Interior mirror: calibrating compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.69 Poly V-belt for supercharger with charge air coolers: renewing . . . . . . . . . . . . . . . . . . . . . . 129
3.70 Poly V-belts for ancillaries: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.71 Poly V-belts for ancillaries and pulleys for coolant pump and power steering pump:
renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.72 Instrument cluster: resetting driver information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.73 Toothed belt for camshaft drive: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.74 Toothed belt for camshaft drive, and drive sprockets for camshaft, crankshaft and high-
pressure pump: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.75 Toothed belt for camshaft drive and tensioning roller: renewing . . . . . . . . . . . . . . . . . . . . 130
3.76 Poly V-belts for ancillaries and pulley for power steering pump: renewing . . . . . . . . . . . . 130
ii Contents
1 General information
(AIGG000682; Edition 06.2015)
Change history ⇒ page 1
Overview of engines ⇒ page 1
Engine number ⇒ page 6
Vehicle identification number ⇒ page 9
Vehicle data sticker ⇒ page 9
Warnings for high-voltage vehicles ⇒ page 10
1.1 --- Change history ---

N Date Chapter Changes made
o.
5 29.06.20 Fuel filter: renewing ⇒ page 118 Water separator added to fuel filter
15
Fuel filter: draining ⇒ page 117 Chapter added
4 26.05.20 Battery: connecting to a stationary battery charging unit Procedure for A7 modified
© satelettronica
15 for sustained charging ⇒ page 39
Engine, gearbox, final drive and steering: checking for Procedure modified to include:
leaks and damage ⇒ page 60 Removing noise insulation for cer‐
tain service procedures
Headlights: checking for correct adjustment ⇒ page 72 List of required tools modified
Cooling system: checking anti-freeze and coolant level, Note added warning against over‐
and correcting if necessary ⇒ page 102 filling coolant expansion tank
Fuel tank: adding fuel additive ⇒ page 121 Procedure modified
Dual clutch gearbox (S tronic): changing ATF fluid Chapter added
⇒ page 128
3 02.03.20 Rear spoiler hinges: lubricating ⇒ page 68 New chapter
15
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
For greater clarity, only the last three updates to the document
are listed.
1.2 Overview of engines

Petrol engines ⇒ page 1
Diesel engines ⇒ page 4
1.2.1 Petrol engines

Engine Engine Capaci‐ Injection Power out‐ Torque Cam‐ Stroke Bore Com‐
code type/ ty [ltr.] system put [kW] [Nm] shaft [mm] [mm] pression
number (rpm) (rpm) drive ratio
of cylin‐ [:1]
ders
CAEB 4-cyl. in- 2.0 TFSI 155 350 Timing 92.8 82.5 9.6
line ( ( chain
4300-6000 1500-42
) 00)
CAED 4-cyl. in- 2.0 TFSI 162 350 Timing 92.8 82.5 9.6
line chain
1. General information 1
of cylin‐ [:1]
ders
( (
4300-6000 3000-50
) 00)
CDNB 4-cyl. in- 2.0 TFSI 132 320 Timing 92.8 82.5 9.6
line ( ( chain
4000-6000 1500-39
) 00)
CDZA 4-cyl. in- 2.0 TFSI 132 320 Timing 92.8 82.5 9.6
line ( ( chain
4200-6000 1500-40
) 00)
CEUC V8 4.0 TFSI 309 550 Timing 89.0 84.5 10.1
( ( chain
5500-6400 1400-52
) 00)
CGWB V6 3.0 TFSI 220 440 Timing 89.0 84.5 10.5
© satelettronica
( ( chain
5250-6500 2900-45
) 00)
CGWD V6 3.0 TFSI 228 440 Timing 89.0 84.5 10.5
( ( chain
5500-6500 2900-45
) 00)
CGXB V6 3.0 TFSI 228 440 Timing 89.0 84.5 10.5
( ( chain
5500-6500 2900-45
) 00)
CHJA 4-cyl. in- 2.0 TFSI hy‐ 155 350 Timing 92.8 82.5 9.6
line brid ( ( chain
4200-6000 1500-42
) 00)
CHMA V6 3.0 TFSI 220 440 Timing 89.0 84.5 10.5
(5500) (1600) chain
CHVA V6 by copyright.
Protected 2.8Copying forFSI 150 purposes,280
private or commercial in part or inTiming
whole, is not 82.4 84.5 12.0
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or acceptchain
( ( any liability
5250-6500 3000-50
) 00)
CLXA V6 2.5 FSI 140 250 Timing 82.4 80.2 12.3
(5500) ( chain
3250-47
50)
CLXB V6 2.5 FSI 150 250 Timing 82.4 80.2 12.3
(6000) ( chain
3250-47
50)
CNYA V6 2.8 FSI 150 280 Timing 82.4 84.5 12.0
( ( chain
5750-6800 3250-50
) 00)
CNYB V6 2.8 FSI 162 280 Timing 82.4 84.5 12.0
( ( chain
5750-6800 3250-50
) 00)
2 1. General information
of cylin‐ [:1]
ders
CRDB V8 4.0 TFSI 412 700 Timing 89.0 84.5 9.3
( ( chain
5700-6600 1750-55
) 00)
CREC V6 3.0 TFSI 245 440 Timing 89.0 84.5 10.8
( ( chain
5300-6500 2900-53
) 00)
CTDB V6 3.0 TFSI 200 400 Timing 89.0 84.5 10.8
( ( chain
4850-6500 2500-48
) 50)
CTGB V8 4.0 TFSI 320 550 Timing 89.0 84.5 10.1
( ( chain
5100-6400 1500-50
) 00)
© satelettronica
CTGE V8 4.0 TFSI 331 550 Timing 89.0 84.5 10.1
( ( chain
5800-6400 1400-57
) 00)
CTTA V6 3.0 TFSI 228 440 Timing 89.0 84.5 10.5
( ( chain
5500-6500 2900-45
) 00)
CTUA V6 3.0 TFSI 228 440 Timing 89.0 84.5 10.5
( ( chain
5500-6500 2900-45
) 00)
CVPA V6 2.8 FSI 162 280 Timing 82.4 84.5 12.0
( ( chain
Protected5750-6500 3000-50
by copyright. Copying for private or commercial purposes, in part or in whole, is not
) 00)
CWUB V8 4.0 TFSI 412 700 Timing 89.0 84.5 9.3
( ( chain
5700-6600 1750-55
) 00)
CWUC V8 4.0 TFSI 445 750 Timing 89.0 84.5 9.3
( ( chain
5900-6600 1750-58
) 00)
CYGA 4-cyl. in- 1.8 TFSI 140 320 Timing 84.1 82.5 9.6
line ( ( chain
4200-6200 1400-41
) 00)
CYNB 4-cyl. in- 2.0 TFSI 185 370 Timing 92.8 82.5 9.6
line ( ( chain
4900-5900 1600-47
) 00)
CYPA 4-cyl. in- 2.0 TFSI 185 370 Timing 92.8 82.5 9.6
line ( ( chain
4900-5900 1600-47
) 00)
of cylin‐ [:1]
ders
CYPB 4-cyl. in- 2.0 TFSI 183 370 Timing 92.8 82.5 9.6
line ( ( chain
4900-5900 1600-47
) 00)
1.2.2 Diesel engines

of cylin‐ [:1]
ders
CDUC V6 3.0 TDI 180 500 Timing 91.4 83.0 16.8
common ( ( chain
rail 4000-4500 1400-32
© satelettronica
) 50)
CDUD V6 3.0 TDI 180 580 Timing 91.4 83.0 16.8
common ( ( chain
rail 4000-4500 1750-25
) 00)
CGLC 4-cyl. in- 2.0 TDI 130 380 Toothed 95.5 81.0 16.0
line common (4200) ( belt
rail 1750-25
00)
CGLD 4-cyl. in- 2.0 TDI 120 380 Toothed 95.5 81.0 16.0
rail 1750-25
00)
CGLE 4-cyl. in- 2.0 TDI 100 350 Toothed 95.5 81.0 16.0
rail 1750-25
00)
CGQB V6 Copying3.0
Protected by copyright. TDI
for private or commercial 230 in part or in650
purposes, Timing
whole, is not 91.4 83.0 16.5
common ( AG. chain
with respect to the correctness of information in this document.( Copyright by AUDI
rail 3900-4500 1450-28
) 00)
CKVB V6 3.0 TDI 180 500 Timing 91.4 83.0 16.8
common ( ( chain
rail 4000-4500 1400-32
) 50)
CKVC V6 3.0 TDI 180 580 Timing 91.4 83.0 16.8
common ( ( chain
rail 4000-4500 1750-25
) 00)
CLAA V6 3.0 TDI 150 450 Timing 91.4 83.0 16.8
common ( ( chain
rail 3250-4500 1250-30
) 00)
CLAB V6 3.0 TDI 150 400 Timing 91.4 83.0 16.8
common ( ( chain
rail 3750-4500 1250-35
) 00)
of cylin‐ [:1]
ders
CMGB 4-cyl. in- 2.0 TDI 130 380 Toothed 95.5 81.0 16.0
rail 1750-25
00)
CNHA 4-cyl. in- 2.0 TDI 140 400 Toothed 95.5 81.0 15.5
rail 1900-35
00)
CPNB V6 3.0 TDI 176 580 Timing 91.4 83.0 16.8
common (4000) (2100) chain
rail
CRTD V6 3.0 TDI 200 580 Timing 91.4 83.0 16.0
common (4000) ( chain
rail 1700-27
50)
CRTE V6 3.0 TDI 160 500 Timing 91.4 83.0 16.0
© satelettronica
rail 1700-27
50)
CRTF V6 3.0 TDI 155 500 Timing 91.4 83.0 16.0
rail 1700-27
50)
CSUD 4-cyl. in- 2.0 TDI 110 350 Toothed 95.5 81.0 16.2
line common
Protected by copyright. Copying for private or commercial purposes, in part orbelt
( ( in whole, is not
railAUDI AG.
permitted unless authorised by
3500-4000 1500-30
AUDI AG does not guarantee or accept any liability
) 00)
CSUE 4-cyl. in- 2.0 TDI 100 350 Toothed 95.5 81.0 16.2
line common ( ( belt
rail 2750-4400 1500-27
) 50)
CTCB V6 3.0 TDI 155 400 Timing 91.4 83.0 16.8
rail 1250-35
00)
CTCC V6 3.0 TDI 160 400 Timing 91.4 83.0 16.8
rail 1250-35
00)
CVUA V6 3.0 TDI 235 650 Timing 91.4 83.0 15.5
rail 1450-28
00)
CVUB V6 3.0 TDI 240 650 Timing 91.4 83.0 15.5
rail 1450-28
00)
CZJA 4-cyl. in- 2.0 TDI 140 400 Toothed 95.5 81.0 15.5
rail 1750-42
00)
of cylin‐ [:1]
ders
CZVA V6 3.0 TDI 140
500 Timing 91.4 83.0 16.0
common (4000)
( chain
rail 1250-32
00)
CZVB V6 3.0 TDI 160 400 Timing 91.4 83.0 16.0
rail 1250-32
00)
CZVC V6 3.0 TDI 155 500 Timing 91.4 83.0 16.0
rail 1250-32
00)
CZVD V6 3.0 TDI 155 400 Timing 91.4 83.0 16.0
rail 1250-32
00)
© satelettronica
CZVE V6 3.0 TDI 140 400 Timing 91.4 83.0 16.0
common ( ( chain
rail 3500-5000 1250-32
) 50)
CZVF V6 3.0 TDI 140 500 Timing 91.4 83.0 16.0
common ( ( chain
rail 2750-5000 1250-25
) 00)
1.3 Engine number
Note
The engine number consists of the engine code letters (3 or 4

characters) and the serial number.
4-cyl. petrol engine 1.8 ltr./2.0 ltr. TFSI/2.0 ltr. TFSI hybrid
⇒ page 7
6-cyl. petrol engine 2.5 ltr./2.8 ltr. FSI ⇒ page 7
6-cyl. petrol engine 3.0 ltr. TFSI ⇒ page 8
4-cyl. diesel engine 2.0 ltr. TDI ⇒ page 8
1.3.1 4-cyl. petrol engine 1.8 ltr./2.0 ltr. TFSI/

2.0 ltr. TFSI hybrid
DANGER!
Risk of fatal injury if high-voltage components are damaged.

♦ Observe warnings for high-voltage system:
♦ Handling high-voltage wires ⇒ page 12 .
♦ For work in the vicinity of high-voltage components
⇒ page 11 .
© satelettronica
The engine number is stamped on the left side at the joint between
the engine and the gearbox -arrow-.
The engine number is also given on the sticker on the toothed belt
cover (top).
In addition, the engine code letters are listed on the vehicle data
sticker ⇒ page 9 .
1.3.2 6-cyl. petrol engine 2.5 ltr./2.8 ltr. FSI

The engine number is stamped onunless
permitted the authorised
left sidebyatAUDI
theAG. joint
AUDIbetween
AG does not guarantee or accept any liability
the engine and the gearboxwith
-arrow-.
respect to the correctness of information in this document. Copyright by AUDI AG.
cover (top).
1.3.3 6-cyl. petrol engine 3.0 ltr. TFSI

cover (top).

cover (top) -arrow A-.
© satelettronica
1.3.5 4-cyl. diesel engine 2.0 ltr. TDI

cover (top).

cover (top).
1.4 Vehicle identification number

Depending on the equipment and country-specific version, the
vehicle identification number is located:
♦ Optional: In the MMI under »Car systems«
♦ At the bottom left edge of the windscreen
♦ On the right side of the engine compartment under a cover
♦ On the bulkhead of the engine compartment
♦ On the vehicle data sticker ⇒ page 9
The vehicle identification number consists of the following:

WAU ZZZ 4G Z B A/N 000 234
Manufactur‐ Filler charac‐ Type Filler charac‐ Model year Production lo‐ Serial number
er's mark ters ters cation
1.5 Vehicle data sticker
© satelettronica
The vehicle data sticker is located:
♦ In the Service Schedule
♦ In the area of the spare wheel well under the floor covering
-arrow-
The vehicle data sticker contains the following vehicle data:

1 - Vehicle identification number
2 - Vehicle model, manufacturer's code, engine type and power
output, production month and year
3 - Engine and gearbox code letters (not specified on some export
models)
4 - Paint number, interior equipment number
5 - Numbers for optional extras
6 - Fuel consumption: urban, extra urban, combined, CO2 (not
specified on some export models)
1.6 Warnings for high-voltage vehicles

Overview of high-voltage components and wires ⇒ page 10
Working in the vicinity of high-voltage components ⇒ page 11
Handling high-voltage wires ⇒ page 12
Work that must be performed with the ignition switched on
⇒ page 13
Work that must be performed with the ignition switched off
⇒ page 13
1.6.1 Overview of high-voltage components

and wires
The high-voltage system of the Audi A6 is comprised of the fol‐
lowing components:
1 - Combustion engine
2 - High-voltage wire for elec‐
trical air conditioner
Protected compres‐
sor permitted
- P3- unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
❑ Red warning label
3 - Power and control electron‐
ics for electric drive - JX1-
❑ Electric drive control
unit - J841-
❑ Voltage converter - A19-
❑ DC/AC converter for
drive motor - A37-
❑ Coded high-voltage
connections
4 - Drive battery - A2-
❑ Maintenance connector
for high-voltage system
- TW-
❑ Red warning label and
battery warning label
connections
5 - Air duct for cooling drive
battery - A2-
6 - Cooling module for drive
battery - A2-
7 - High-voltage system wiring
junction - TV1-
8 - Air supply duct for cooling
drive battery - A2-
9 - High-voltage wire for hybrid
battery - PX1-
❑ High-voltage wiring harness for high-voltage battery, positive terminal - P1- (red coloured ring)
❑ High-voltage wiring harness for hybrid battery, negative terminal - P2- (brown coloured ring)
❑ Coding of high-voltage connections to drive battery - A2-
❑ Coding of high-voltage connections to power and control electronics for electric drive - JX1-
10 - High-voltage wiring harness for drive motor - PX2-

❑ High-voltage wire 1 for drive motor - P4- (U) blue coloured ring/coding lug on right side
❑ High-voltage wire 1 for drive motor - P5- (V) green coloured ring/coding lug on left side
❑ High-voltage wire 1 for drive motor - P6- (W) violet coloured ring/two coding lugs
❑ Coding of high-voltage connections to electric drive motor - V141-
11 - Electric drive motor - V141-
❑ Coded high-voltage connections
12 - Electrical air conditioner compressor - V470-
❑ Coding of high-voltage connection: red coloured ring
1.6.2 Working in the vicinity of high-voltage

components
DANGER!
© satelettronica
Observe the following when working in the vicinity of high-volt‐
age components or wiring:
♦ It is not permitted to use cutting or forming tools, other
sharp-edged tools or heat sources such as welding, braz‐
ing, soldering, hot air or thermal bonding equipment.

♦ Before starting work, visually inspect the high-voltage
components in the areas involved.
♦ Before working in the engine compartment, visually in‐
spect the power and control electronics for electric drive -
JX1- , electric drive motor - V141- , air conditioner
compressor - V470- and high-voltage wiring.
♦ Before working on the vehicle underbody, visually inspect
the high-voltage wiring and covers.
♦ Before working on the rear section of the vehicle, visually
inspect the high-voltage wiring and the electro-box with
the maintenance connector for high-voltage system - TW
-.
♦ Visually inspect all potential equalisation lines.
Check the following when making the visual inspection:
♦ There must be no external damage on any component.
♦ The insulation of the high-voltage wiring and potential
equalisation lines must not be damaged.
♦ There must be no unusual deformation of the high-voltage
wiring.
♦ All high-voltage components must be identified by a red
warning sticker.
Note
♦ Certain qualifications are required to perform different types of

work on high-voltage vehicles ⇒ Basic information on high-
voltage vehicles; Rep. gr. 00 ; Qualification of internal/external
personnel .
♦ Note distinguishing features of Audi high-voltage vehicles, de‐
scription of high-voltage technology etc. ⇒ Basic information
on high-voltage vehicles; Rep. gr. 00 ; Distinguishing features
of Audi high-voltage vehicles .
♦ Overview of high-voltage components and wires ⇒ page 10 .
1.6.3 Handling high-voltage wires
WARNING
Handling high-voltage wires:

• Do not support yourself or tools on high-voltage wiring or
associated components --> this can damage the insula‐
© satelettronica
tion.
• High-voltage wiring must not be excessively bent or
kinked --> this can damage the insulation.
• The round high-voltage
permitted connectors
unless authorised areAG
by AUDI AG. AUDI colour-coded with
does not guarantee or accept any liability
an external coloured
with respect to the ring andofare
correctness provided
information with mechan‐
in this document. Copyright by AUDI AG.
ical coding or guide lugs. It is important to observe this
coding when joining up the round high-voltage connec‐
tors, otherwise the connectors can be damaged.
Note

personnel .
1.6.4 Work that must be performed with the

ignition switched on
DANGER!
When working on a vehicle with the ignition switched on or

while the drive system is active, the engine can start unex‐
pectedly and exhaust fumes can cause a health hazard in
closed rooms. Moving parts can trap or draw in parts of the
body and/or clothing (safety hazard).
Before switching on the ignition, perform the following steps:
♦ Move selector lever to position P
♦ Activate parking brake
♦permitted
Switch offauthorised
unless ignitionby AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Open bonnet
♦ Connect battery charger (e.g. charger - VAS 5095A- ) to
jump-start connections of 12 V electrical system
♦ Switch on ignition.
© satelettronica
Note

personnel .

ignition switched off
WARNING
Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.
Note

personnel .
♦ Overview of high-voltage componentsProtected
and wires ⇒ page
by copyright. 10for.private or commercial purposes, in part or in whole, is not
Copying
© satelettronica
2 Preparations
Vehicle: raising ⇒ page 15
Engine cover panel: removing and installing ⇒ page 17
Noise insulation: removing and installing ⇒ page 21
Window regulators: activating automatic open/close function
⇒ page 23
Vehicle diagnostic tester: connecting ⇒ page 23
2.1 Vehicle: raising
Caution
Risk of damage to vehicle due to incorrect use of lifting plat‐

form.
♦ Do not exceed the permissible lifting capacity of the lifting
platform.
♦ The vehicle should be lifted only at the points shown in the
© satelettronica
illustration.
♦ Position support plates so that they are aligned centrally
below the lifting points.
♦ Ensure sufficient clearance between low-mounted vehicle
components and the lifting platform.
Procedure:
– For vehicles with adaptive air suspension: Activate jacking
mode before lifting vehicle ⇒ page 16 .
– Applies to RS models: Pull side member extension covers
downwards -arrow- and remove.
2. Preparations 15
– Front: Position support plates of lifting platform under plastic

mountings -arrow- on underside of side member trim.
– Rear: Position support plates of lifting platform under plastic

© satelettronica
Note
The location of the lifting points is indicated by markings stamped

on the side member trim.
2.1.1 Activating jacking mode
WARNING
Risk of injury as engine of high-voltage vehicle can start un‐

expectedly!
♦ For work that must be performed with the ignition switched
on ⇒ page 13 .
Procedure:
– Switch on ignition and activate MMI.
– Press function selector button CAR .
– Under »Systems«, navigate through following menu structure:
♦ adaptive air suspension
♦ SETUP
16 2. Preparations
– Use MMI rotary pushbutton to select “Jacking mode” and set

to “on”.
Note
♦ Jacking mode is switched off again automatically once a

speed higher than 15 km/h is reached.
♦ If jacking mode is activated for a longer period of time, the
pressure in the suspension struts may dissipate, thereby low‐
ering the vehicle. If necessary, start the engine briefly to
reactivate jacking mode.
2.2 Engine cover panel: removing and in‐

stalling
4-cyl. petrol engine 2.0 ltr. TFSI (version 1) ⇒ page 18
4-cyl. petrol engine 2.0 ltr. TFSI/2.0 ltr. TFSI hybrid (version 2)
⇒ page 18
© satelettronica
6-cyl. petrol engine 2.5 ltr. FSI/2.8 ltr. FSI/3.0 ltr. TFSI (version 1)
⇒ page 18
6-cyl. petrol engine 2.5 ltr./2.8 ltr. FSI (version 2) ⇒ page 19
6-cyl. petrol engine 3.0 ltr. TFSI (version 2) ⇒ page 19
4-cyl. diesel engine 2.0 ltr. TDI ⇒Protected
page by 20copyright. Copying for private or commercial purposes, in part or in whole, is not
6-cyl. diesel engine 3.0 ltr. TDI (version 1) ⇒
with respect page
to the 20 of information in this document. Copyright by AUDI AG.
correctness
6-cyl. diesel engine 3.0 ltr. TDI (version 2) ⇒ page 21


Procedure for removing:
– Carefully pull engine cover panel off retaining pins one after
another -arrows-.
Procedure for installing:
– Position engine cover panel on retaining pins and then use
your hands to press it onto retaining pins, one after the other.
2. Preparations 17
2.2.2 4-cyl. petrol engine 2.0 ltr. TFSI (version

1)
another -arrows-.
Note
There is more than one version of the engine cover panel for the
4-cylinder 2.0 ltr. TFSI petrol engine ⇒ page 18 .
2.2.3 4-cyl. petrol engine 2.0 ltr. TFSI/2.0 ltr.

TFSI hybrid Protected
(version 2)
© satelettronica
another -arrows-.
Note
2.2.4 6-cyl. petrol engine 2.5 ltr. FSI/2.8 ltr.

FSI/3.0 ltr. TFSI (version 1)
another -arrows-.
Note
♦ There is more than one version of the engine cover panel for
the 6-cylinder 2.5 ltr. FSI/2.8 ltr. FSI petrol engine
⇒ page 19 .
the 6-cylinder 3.0 ltr. TFSI petrol engine ⇒ page 19 .
18 2. Preparations

(version 2)
– Carefully pull engine cover panels off retaining pins one after
another -arrows-.
– Position engine cover panels on retaining pins and then use
Note
6-cylinder 2.5 ltr. FSI/2.8 ltr. FSI petrol engine ⇒ page 18 .
© satelettronica
2.2.6 6-cyl. petrol engine 3.0 ltr. TFSI (version
2)
– Carefully pull engine cover panels -1- and -2- off retaining pins
one after another.
Note
2. Preparations 19

– Carefully pull engine cover panel off rear retaining pins -1-.
– Carefully pull engine cover panel off front retaining pins -2-.

another -arrows-.
© satelettronica
2.2.9 6-cyl. diesel engine 3.0 ltr. TDI (version

1)
another -arrows-.
Note
6-cylinder 3.0 ltr. TDI diesel engine ⇒ page 21 .
20 2. Preparations

2)
another -arrows-.
Note
2.2.11 6-cyl.Copying
Protected by copyright. diesel engine
for private 3.0purposes,
or commercial ltr. TDI (version
in part or in whole, is not
with respect3)
© satelettronica
to the correctness of information in this document. Copyright by AUDI AG.

another -arrows-.
Note
2.3 Noise insulation: removing and installing
DANGER!

⇒ page 12 .
Noise insulation (front) ⇒ page 21

Noise insulation (rear) ⇒ page 22
2.3.1 Noise insulation (front)

Special tools and workshop equipment required
♦ Torque wrench - VAS 6583- , measuring range 3 to 60 Nm
2. Preparations 21
Table of tightening torques for installation:

Component/fastener [Nm]
Bolt M8 -2- 20
Bolt M6 -3- 3.5

– Remove bolts -1- and -2-.
– Unscrew quick-release fasteners -3- and -4-.
– Pull noise insulation -5- towards rear out of bottom section of
bumper cover and detach.
Install in reverse sequence. Note tightening torques (see table of
tightening torques for installation ⇒ page 22 ).
© satelettronica
Note
♦ Ensure that you feel the quick-release fasteners engage when

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

♦ Torque screwdriver - V.A.G 1624- , measuring range 1 to 5
Nm
Bolt M6 -1- 3.6
22 2. Preparations

– Remove bolts -1- at connection to noise insulation (front).
– Pull noise insulation -3- towards rear out of noise insulation
(front) and detach.
Note
Ensure that you feel the quick-release fasteners engage when

installing.
2.4 Window
Protected byregulators:
copyright. Copying foractivating
private or commercialautomatic
purposes, in part or in whole, is not
open/close function
© satelettronica
WARNING

expectedly!
on ⇒ page 13 .
If the vehicle battery was disconnected, the automatic open/close

function for the electric windows must be reactivated.
Procedure:
– Pull up on window regulator switch until windows are com‐
pletely closed.
– Release switch and pull on it again for at least one second.
– Repeat procedure with all window regulators.
2.5 Vehicle diagnostic tester: connecting
WARNING

expectedly!
on ⇒ page 13 .
2. Preparations 23
♦ Diagnosis system - VAS 6160 A-
♦ Remote diagnosis head - VAS 5054A-

♦ Or: Diagnosis interface - VAS 5055-
Procedure:
– Plug connector for remote diagnosis head - VAS 5054A- into
diagnostic connection in vehicle.
© satelettronica
– Switch on diagnostic system - VAS 6160 A- .
– Switch on ignition.
– Follow the menu on the screen to start the desired functions.
24 2. Preparations
© satelettronica
3. Maintenance 25
3 Maintenance
Rear final drive: changing gear oil ⇒ page 127
Rear final drive: changing ATF ⇒ page 128
Display instruments: setting language, time and date
⇒ page 128
Automatic gearbox (multitronic): changing ATF ⇒ page 128
Automatic gearbox (tiptronic): changing ATF fluid ⇒ page 128
Battery: checking that battery and battery cables are securely fit‐
ted ⇒ page 33
Battery: checking electrolyte level ⇒ page 36
Battery: reading out status and sending diagnostic log
⇒ page 31
Components of front and rear axles: checking play, secure at‐
tachment and protective boots ⇒ page 56
Front passenger's airbag: checking key switch on / off and setting
to "on" ⇒ page 76
© satelettronica
Tyres: checking tyre pressures and adjusting if necessary
⇒ page 51
Tyres: checking condition and wear pattern, and checking and
recording tread depth ⇒ page 50
Tool kit: checking that all components necessary in the event of
a breakdown are present ⇒ page 53
Brake system: checking condition of brake hoses, and checking
that caps are fitted on bleeder screws ⇒ page 48
Brake pads: checking thickness ⇒ page 49
Brake fluid: checking fluid level ⇒ page 48
Brake fluid: changing ⇒ page 43
Roof insert - panorama sunroof: cleaning and lubricating
⇒ page 64 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Roof insert - sliding/tilting sunroof: cleaning and lubricating
⇒ page 61
Diesel particulate filter: reading out ash deposit volume

⇒ page 28
Dual clutch gearbox (S tronic): changing ATF fluid ⇒ page 128
Dual clutch gearbox (S tronic): changing ATF and renewing ex‐
changeable ATF filter ⇒ page 128
Event memory: reading out and erasing ⇒ page 29
Headlights and reversing lights, side lights, number plate lights,
turn signals, hazard warning lights: checking operation
⇒ page 73
Vehicle keys: checking operation and recording number of keys
given to customer ⇒ page 78
Bonnet arrester hook: lubricating ⇒ page 68
Suspension struts on front and rear axle: removing locking ele‐
ments ⇒ page 54
Glove box light, interior lighting and reading light: checking oper‐
ation ⇒ page 75
Interior mirror: calibrating compass ⇒ page 128
26 3. Maintenance
Body: checking vehicle paintwork for damage and corrosion from

below and with bonnet, rear lid and doors open ⇒ page 126
Poly V-belt for supercharger with charge air coolers: renewing
⇒ page 129
Poly V-belts for ancillaries and for pulleys for coolant pump and
power steering pump: renewing ⇒ page 129
Poly V-belts for ancillaries and pulley for power steering pump:
renewing ⇒ page 130
Poly V-belts for ancillaries: renewing ⇒ page 129
Poly V-belts for ancillaries: checking ⇒ page 92
Luggage compartment lighting: checking operation ⇒ page 74
Instrument cluster: resetting driver information system
⇒ page 129
Instrument cluster: checking warning lamps ⇒ page 77
Fuel tank: adding fuel additive ⇒ page 121
Fuel filter: draining ⇒ page 117
Fuel filter: renewing ⇒ page 118
© satelettronica
Cooling system: checking anti-freeze and coolant level, and cor‐
recting if necessary ⇒ page 102
Air cleaner: renewing filter element and cleaning housing
⇒ page 105
Engine, gearbox, final drive and steering: checking for leaks and
damage ⇒ page 60
Engine oil: draining ⇒ page 79
Engine oil: extracting ⇒ page 81
Engine oil: renewing oil filter ⇒ page 82
Engine oil: filling up ⇒ page 89
Engine oil: checking oil level and correcting if necessary
⇒ page 90
Battery: connecting to a stationary battery charging unit for sus‐
tained charging ⇒ page 39
Road test ⇒ page 126
Wheel bolts: tightening to specified torque ⇒ page 54
Reducing agent (AdBlue®): filling up tank completely
⇒ page 122
Tyre Pressure Loss Indicator: storing changed tyre pressures
⇒ page 52
Tyre repair kit: checking that set is complete, and checking and
recording expiry date ⇒ page 53
Rear spoiler hinges: lubricating ⇒ page 68
Windscreen/rear window washer system: checking spray pattern
and adjusting if necessary ⇒ page 69 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Wiper blades: checking for damage ⇒ pagewith

71respect to the correctness of information in this document. Copyright by AUDI AG.
Headlights: checking for correct adjustment ⇒ page 72

Headlight washer system: checking operation ⇒ page 71
Service interval display: resetting service ⇒ page 30
3. Maintenance 27
Seat belts: checking that retaining rivets are fitted, and checking
locking action of automatic belt retractor ⇒ page 77
Horn: checking operation ⇒ page 76
Stock vehicles: observing measures specified in Maintenance ta‐
ble for stock vehicles (see “Before handing vehicle over to cus‐
tomer”) ⇒ page 127
Dust and pollen filter: renewing ⇒ page 115
Dust and pollen filter: renewing preliminary filter ⇒ page 115
Transport mode: deactivating ⇒ page 30
Underbody: checking trim, wheel housing liners, side members
and pipes/wiring for damage, and checking that they are properly
secured ⇒ page 61
First-aid kit: checking and recording expiry date ⇒ page 78
Shipping mode: deactivating ⇒ page 31
Warning triangle: checking availability ⇒ page 78
Plenum chamber and water drains: checking for dirt
⇒ page 113
© satelettronica
Toothed belt for camshaft drive, and drive sprockets for camshaft,
crankshaft and high-pressure pump: renewing ⇒ page 129
Toothed belt for camshaft drive and tensioning roller: renewing
⇒ page 130
Toothed belt for camshaft drive: renewing ⇒ page 129
Spark plugs: renewing ⇒ page 93
3.1 Diesel particulate filter: reading out ash

deposit volume
Table of test values and procedure guidelines:
Engine Engine code Measured value designa‐ Maximum value for ash
tion for diagnostic tester deposit
4-cyl. diesel engine 2.0 ltr. All Particulate filter, oil ash de‐ Oil ash deposit volume:
TDI posit volume 175 ml
6-cyl. diesel engine 3.0 ltr. CVUA, CVUB
Protected by copyright. Particulate filter,
Copying for private oil ashpurposes,
or commercial de‐ Oilin ash
part ordeposit
in whole, isvolume:
not
TDI positby volume
permitted unless authorised 240 ml
AUDI AG. AUDI AG does not guarantee or accept any liability
CKVB, CKVC Particulate filter, oil ash de‐ Oil ash deposit volume:
posit volume 360 ml
CDUC, CDUD, CLAA, Particulate filter, oil ash de‐ Oil ash deposit volume:
CLAB posit volume 370 ml
CRTD, CRTE, CRTF, Particulate filter, oil ash de‐ Oil ash deposit volume:
CTCB, CTCC posit volume 380 ml
CGQB Particulate filter, oil ash de‐ Oil ash deposit volume:
posit volume 420 ml
Procedure:
– Connect vehicle diagnostic tester ⇒ page 23 .
– Select Diagnosis mode and begin diagnosis.
– Perform vehicle identification.
– De-select “Working with Guided Fault Finding” by removing
v and press Apply .
– Continue to follow instructions on screen.
28 3. Maintenance
– Switch to “Control units” tab.

– Select control unit “01 — Engine electronics” and carry out
following functions via right mouse button:
♦ Identify control unit
♦ Guided Functions
♦ 01 - Read measured values
– Select desired measured value (see table of test values and
procedure guidelines ⇒ page 28 ) by entering v and confirm‐
ing with OK .
– Evaluate measured value and follow further instructions on
screen.
– Perform the following measures according to the measured
value:
Result: Measure:
Measured value < critical Vehicle can be driven for a further 30,000 km (19,000 miles).
value
Measured value ≥ critical Renew diesel particulate filter and reset measured value to zero ⇒ Engine; Rep.
value gr. 26 ; Emission control system; Removing and installing particulate filter .
© satelettronica
3.2 Event memory: reading out and erasing
WARNING
expectedly!
on ⇒ page 13 .
Procedure:
– Select “Working with Guided Fault Finding” by entering v and
press Apply .
The control unit is then identified, and the event memory is inter‐
rogated. Observe notes and test conditions.
– Switch to “Control units” tab and call up “Event memory list”
for an overview of all entries stored in event memory.
– Correct relevant faults and erase event memory.
Note
The event memory is erased automatically if the Guided Fault

Finding is closed correctly.
3. Maintenance 29
3.3 Service interval display: resetting serv‐

ice
WARNING

expectedly!
on ⇒ page 13 .
Procedure:
v and press Apply .
© satelettronica
– Switch to “Special functions” tab.
– Select service setting to be reset (e.g. “17 — Inspection”).
– Start program by selecting Carry out check .
Note
Please refer to the relevant Maintenance table for information on

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

expectedly!
on ⇒ page 13 .
Procedure:
– Connect vehicle diagnostic tester ⇒ page
does not23 .
permitted unless authorised by AUDI AG. AUDI AG guarantee or accept any liability


v and press Apply .
– Switch to “Special functions” tab and select following program:

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

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

expectedly!
on ⇒ page 13 .
Procedure:
© satelettronica
–Protected
Perform vehicle
by copyright. identification.
Copying for private or commercial purposes, in part or in whole, is not
– with
De-select “Working
respect to the correctness with Guided
of information Fault
in this Finding”
document. Copyrightby removing
by AUDI AG.
v and press Apply .

♦ 34 - Activating / deactivating shipping mode
Note
Deactivating shipping mode may cause the height of the vehicle

to drop.
3.6 Battery: reading out status and sending

diagnostic log
WARNING

expectedly!
on ⇒ page 13 .
3. Maintenance 31
Battery -A- ⇒ page 32

Second battery -A1- ⇒ page 32
3.6.1 Battery -A-

Procedure:
press Apply .
♦ A - Battery check
– Start program by by
Protected selecting Carry
copyright. Copying out orcheck
for private . purposes, in part or in whole, is not
commercial
– Continue to follow instructions
with respect onofscreen.
to the correctness information in this document. Copyright by AUDI AG.
– Use results of test to determine following measures:

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

nostic log file online.
♦ After the diagnosis is complete, you will receive confirmation
that the test log was sent successfully.
Result on vehicle diagnostic test‐ Measure:

er:
“Battery OK” No further measures necessary.
“Charge battery” Charge battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging battery .
“Battery is no longer of the same Renew battery after consulting with customer ⇒ Electrical system; Rep. gr.
quality as when shipped” 27 ; Battery; Removing and installing battery .
3.6.2 Second battery -A1-

Only applies to hybrid vehicles
Procedure:
press Apply .
♦ A - second battery -A1-, check
32 3. Maintenance

er:
“Battery is no longer of the same Renew battery after consulting with customer ⇒ Electrical system; Rep. gr.
quality as when shipped” 27 ; Battery; Removing and installing battery .

– Send off diagnosis log online.
Note

© satelettronica
3.7 Battery: checking that battery and bat‐

tery cables are securely fitted
All models except A6 hybrid ⇒ page 33
A6 hybrid ⇒ page 34
3.7.1permitted All authorised
unless models except
by AUDI AG. AUDI A6AG does hybrid
not guarantee or accept any liability
WARNING
Risk of injury due to loose battery clamp on positive terminal.

♦ Disconnect battery clamp from negative terminal and then
tighten battery clamp on positive terminal.

♦ Torque wrench - V.A.G 1410- , measuring range 4 to 20 Nm
♦ Or: torque wrench - VAS 6583- , measuring range 3 to 60 Nm
Nut on battery clamp 4
Nut on accumulator 9
Bolt on retainer plate 18
The battery is located under the luggage compartment floor.

Requirements:
• Ignition switched off during test.
3. Maintenance 33
Removal steps:
– Lift luggage compartment floor and secure in position.
– Applies to vehicles with adaptive air suspension: Remove nuts
-arrows- and move accumulator to side (leave lines -1- and
solenoid valve block -2- connected).
– Take out tool kit box.
– Open battery terminal covers.
Procedure:
– Check by hand that battery terminal clamps are securely seat‐

ed. If necessary, tighten nuts -1- and -2- to specified torque
(see table of tightening torques for installation ⇒ page 33 ).
– Check by hand that battery is securely installed. If necessary,
tighten securing bolt -3- on retainer plate to specified torque
© satelettronica
3.7.2 A6 hybrid
DANGER!

⇒ page 11 .
WARNING
Risk of injury due to loose battery clamp on positive terminal.

♦ Disconnect battery clamp from negative terminal and then
tighten battery clamp on positive terminal.

Battery terminal clamp (battery -A-) 4
Battery terminal clamp (additional 4
battery -A1-)
34 3. Maintenance
Bolt on retainer plate (battery -A-) 9
Bolt on retainer plate (additional 18
battery -A1-)
Battery -A- and second battery -A1- are located under the luggage
compartment floor.
Requirements:
Removal steps:
– Remove luggage compartment floor covering ⇒ Trim, insula‐
tion; Rep. gr. 70 ; Removing and installing luggage compart‐
ment floor covering - Audi A6 hybrid .
– Move electrical wiring harness -1- clear.
© satelettronica
– Unscrew bolts -2-.
– Release retainers -1- on both sides and disconnect exhaust
air duct (front) -3- from battery cooling module.
– Lift air duct so that it is possible to check negative

with respect terminal of of information in this document. Copyright by AUDI AG.
to the correctness
battery, but do not remove it completely.
Step 1 - checking battery -A-:
3. Maintenance 35
– Check by hand that battery clamps -3- and -4- are securely
seated. If necessary, tighten nuts -2- and -5- to specified tor‐
que (see table of tightening torques for installation
⇒ page 34 ).
tighten securing bolt -7- on retainer plate -6- to specified torque
Step 2 - checking second battery -A1-:

– Check by hand that battery clamps -4- and -9- are securely
seated. If necessary, tighten nuts -2- and -5- to specified tor‐
© satelettronica
que (see table of tightening torques for installation
⇒ page 34 ).
tighten securing bolt -7- on retainer plate -8- to specified torque
Install in reverse sequence.
3.8 Battery: checking electrolyte level
Note
Batteries must not be opened.
Battery without magic eye ⇒ page 36

Battery with magic eye ⇒ page 37
3.8.1 Battery without magic eye

♦ Or: torque wrench - V.A.G 1783- , measuring range 2 to 10
Nm
36 3. Maintenance

Nm

Removal steps:
Procedure:
– Check battery housing for the following:
© satelettronica
♦ Battery terminals are not corroded or damaged
♦ Mechanical damage to battery housing and cover, indicated
by electrolyte leakage or crystals at the damaged area
– Damaged batteries must be renewed.
– Check electrolyte level of all battery cells using markings on
housing.
– If electrolyte level of one or more battery cells is below MIN
marking: Renew battery.
Note
♦ A bright hand-held light helps to better see the MIN and MAX
markings on the housing.
♦ If battery is difficult to see: Use a small mirror to check the
electrolyte level (shine a bright hand-held light at a right angle
onto the battery cells).
3.8.2 Battery with magic eye
WARNING
Risk of explosion if magic eye is colourless or light yellow!

♦ Do not attempt to jump-start vehicle.
♦ Do not check or charge battery. with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Renew battery.

3. Maintenance 37

Nm
Nm

Removal steps:
© satelettronica
Procedure:
– Before checking electrolyte level: Tap magic eye -arrow- care‐

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

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

Black or green Electrolyte level OK: No further measures necessary
Colourless or light yellow Electrolyte level too low: Battery must be renewed

38 3. Maintenance
Note
♦ The magic eye is also referred to as an ALI (acid level indica‐

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

tery charging unit for sustained charging
All models except A7 ⇒ page 39
A7 ⇒ page 41
3.9.1 All models except A7
DANGER! Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
© satelettronica
Risk of fatal injury if high-voltage components
with respect to the are damaged.
correctness of information in this document. Copyright by AUDI AG.

⇒ page 11 .
WARNING
Risk of injury if battery terminal clamps are connected incor‐

rectly.
♦ Connect positive battery terminal clamp first, then connect
negative battery terminal clamp.

♦ Battery charger - VAS 5906-
♦ Torque wrench - V.A.G. 1783- , measuring range 2 to 10 Nm

♦ Or: torque wrench - V.A.G. 1410- , measuring range 4 to 20
Nm
3. Maintenance 39

Nm
Tightening torques table:
Jump-start connection 9
Cap nut 9
Only applies to vehicles intended for display.

Requirements:
• Ignition switched off.
Removal steps:
– Take out spare wheel (where applicable).
– Applies to vehicles with air suspension: Detach pressure valve
© satelettronica
-illustration- from tool kit box (lines remain connected).
– Unscrew cap nut -illustration-.

– Screw in jump-start connectionProtected
- 4F0 by 972 501- and tighten to
copyright. Copying for private or commercial purposes, in part or in whole, is not
specified torque (see table of tightening torques for installation

⇒ page 40 ).
40 3. Maintenance
– Applies to vehicles without towing bracket: Remove rubber

grommet -illustration- from spare wheel well and store it in
glove box.
– Applies to vehicles with towing bracket: Loosen rubber grom‐
met -illustration- in spare wheel well along with wiring harness
and pull it slightly inwards into vehicle.
Procedure for connecting battery charger:

– Disconnect charger clamps from battery charger - VAS 5906- .
– Working from above, thread connector end of cable for charg‐
er clamps through hole in spare wheel well and down to
underside of vehicle.
– Open battery terminal cover (+).
– First connect charger clamp (+) to positive battery terminal

-A-.
– Then connect charger clamp (-) to earth point (-) -B- on body.
– Arrange wiring of battery charger - VAS 5906- neatly in spare
wheel well.
© satelettronica
– Place vehicle tool kit box in spare wheel well.
– Applies to vehicles with air suspension: Attach pressure valve
with lines connected.
– Fit luggage compartment floor cover.
– Under vehicle: Connect cable for charger clamps to unless
permitted battery
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
charger - VAS 5906- . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Switch on battery charger - VAS 5906- and adjust settings as

needed.
– Position battery charger - VAS 5906- under vehicle so that it
is hidden from view as well as possible, ensuring that ventila‐
tion grille of charger is unobstructed.
Procedure for disconnecting battery charger:

Remove in reverse sequence.
3.9.2 A7
WARNING

rectly.
3. Maintenance 41
Requirements:
Removal steps:
– Remove stopper from wheel housing on right side of vehicle
© satelettronica
and store it in glove box.
– Guide plug of charging cable from above through wheel hous‐
ing -arrow- and out from underside of vehicle.
– Open cover for jump start connection (+) -3- in direction of

-arrow-.
– First connect charger clamp (+) to jump start connection (+)
-2-, and ensure that charger clamp does not make contact with
bonnet when it is closed.
– Then connect charger clamp (-) to earth point (-) -1- on body,
and ensure that charger clamp does not make contact with
– Arrange wiring of battery charger - VAS 5906- neatly in engine
compartment.
needed.

42 3. Maintenance
3.10 Brake fluid: changing
WARNING
Risk of accident if the brake pedal has too much free play.
♦ Make sure that the brakes work properly before the vehicle
is driven on the road.
WARNING
Risk of injury due to caustic brake fluid.

♦ Avoid contact with skin.
Caution
Risk of damage due to improper handling of brake fluid.
© satelettronica
♦ Avoid contact with vehicle paint.
♦ Avoid contact with liquids containing mineral oils (oil, pet‐
rol, cleaning agents).

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

The value given in the table is for one brake caliper, i.e. if there
are two bleeder screws on one caliper, the sum of the quantities
3. Maintenance 43
discharged from both bleeder screws must equal the value given
in the table.
Sequence of opening bleeder screws: Quantity of brake fluid to discharge:
Brake calipers
Front axle on driver's side 1. 0.20 ltr.
Front axle on front passenger's side 2. 0.20 ltr.
Rear axle on driver's side 3. 0.30 ltr.
Rear axle on front passenger's side 4. 0.30 ltr.
Clutch slave cylinder 5. 0.15 ltr.
⇒ Total quantity, automatic gearbox 1.00 ltr.

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

– Unscrew filler cap -1- from brake fluid reservoir.
© satelettronica
– Use extraction hose included in brake fillingpermitted
and bleeding
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
equipment - VAS 5234- to extract brake fluid with from reservoir
(with strainer installed) until fluid is level with bottom edge of

strainer. Make sure that no more fluid flows back into reservoir
from strainer after extracting fluid.
44 3. Maintenance
– Screw adapter -1- onto brake fluid reservoir.

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

If there are two bleeder screws on each brake caliper, first bleed
the inner, then the outer bleeder screw.
– Raise vehicle ⇒ page 15 .
Front axle:
– Brake caliper (driver's side): Remove cap(s) -1- from bleeder

screw(s).
© satelettronica
– Fit bleeder hose -1- attached to collector container onto bleed‐
er screw from inside of rim.
– Open bleeder screw and allow brake fluid to discharge. Refer
to table for correct quantity of brake fluid to discharge
⇒ page 43 .
– Close bleeder screw.
– If there are two bleeder screws on each brake caliper: Repeat
procedure with second bleeder screw.
– Refit cap on bleeder screw(s).
– Repeat procedure on passenger's side.
Rear axle:

screw(s).
– Take reversible ratchet and appropriate socket from tool set
for brake bleeding - VASto the6564- and fit together.

with respect correctness of information in this document. Copyright by AUDI AG.
3. Maintenance 45
– Run bleeder hose -1- from inside of rim through reversible

ratchet -2- and socket -3- and fit onto bleeder screw.
– Open bleeder screw with ratchet -2- and allow brake fluid to
discharge. Refer to table for correct quantity of brake fluid to
discharge ⇒ page 43 .
© satelettronica
46 3. Maintenance
– If there are two bleeder screws on each brake caliper: Working

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

Only for vehicles with manual gearbox
– Remove components necessary for access; refer to ⇒ Manual
gearbox; Rep. gr. 30 ; Clutch mechanism; Bleeding clutch
mechanism .
– Fit bleeder hose attached to collector container -1- onto bleed‐
er screw of clutch slave cylinder.
– Open bleeder screw and allow correct amount of brake fluid
to flow out (see table of test values and procedure guidelines
⇒ page 43 ).
– Close bleeder screw and fit cap.
© satelettronica
Step 4 - final steps:
– Close filling lever of brake filling and bleeding equipment -
VAS 5234- .
– Detach filling hose from adapter.
– Unscrew adapter
permitted unless from
authorised brake
by AUDI fluidAG
AG. AUDI reservoir.
– Check brake fluid level and adjust if necessary (depending on
brake pad wear) ⇒ page 48 .
– Screw cap onto brake fluid reservoir.
– Operate clutch pedal several times.
– Check pedal pressure and free travel: No more than 1/3 of total
pedal travel.
– Make sure that the brakes work properly before the vehicle is
driven on the road.
– If free travel of brake pedal is greater than specified, or if brake
function is impaired: Check brake system for leaks and renew
brake fluid again.
Note
♦ The bleeder hose must fit tightly on the bleeder screw to pre‐
vent air from entering the brake system.
♦ In the case of certain wheel combinations, the wheels may
have to be removed.
♦ With the aid of the tool set for brake bleeding - VAS 6564- ,
the rear brakes or, depending on version, the front and rear
brakes can be bled without having to remove the wheels.
♦ Use genuine Audi brake fluid; see Electronic parts catalogue
(ETKA).
♦ Do not reuse brake fluid.
♦ Always observe the relevant environmental regulations for
disposal of brake fluid.
3. Maintenance 47
3.11 Brake fluid: checking fluid level

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

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

check:
© satelettronica
Fluid level: Evaluation/measure:

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

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

ponent.
– Check that caps are fitted and secured on bleeder screws of
all brake calipers.
– Renew any missing caps.
3.13 Brake pads: checking thickness

♦ Test pin - T40139- : Use the side with the thin probe (brake
symbol) to measure brake pad thickness.
© satelettronica
Axle Brake pad wear limit including backplate and damper plate
[mm]
Front axle: permitted unless9authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Rear axle: 8
Check only the thickness of the outer brake pads.

Procedure:
– Before you begin: Push sliding ring towards tip of test pin as
far as it will go.
– Bring tip of test pin into contact with brake disc.
– Slide test pin towards brake pad until test pin makes contact
with backplate of brake pad.
3. Maintenance 49
– Remove test pin and read off brake pad wear value -a- from
scale on tool.
– Repeat procedure for all wheels.
– If brake pad thickness has reached wear limit (see table of test
values and procedure guidelines ⇒ page 49 ): Renew brake
pads ⇒ Brake system; Rep. gr. 46 ; Removing and installing
brake pads .
Note
♦ When removing the test gauge, take care not to move the slid‐
ing ring. This would give an incorrect measurement.
♦ Note where the test gauge makes contact on the rear of the
brake pad and include the thickness of the damper plate in the
calculation if necessary.
♦ In the case of certain wheel combinations, the wheels must be
removed.
© satelettronica
3.14 Tyres: checking condition and wear pat‐
tern, and checking and recording tread
depth
Special Protected
tools and workshop equipment required
♦ Test pin - T40139- : Use the side with the thick probe and
shoulder (scale marked with tyre symbol) to measure tread

depth.

Country-specific regulations for minimum tread depth apply; for
countries not listed, evaluate values according to the country's
specifications.
Country Minimum tread depth [mm]
EU countries 1.61)
Brazil 1.6
China 1.6
India 1.6
Japan 1.6
Norway 1.61)
Russia 1.6
Switzerland 1.6
Turkey 1.6
50 3. Maintenance

Ukraine 1.61)
USA 1.6
1) Larger values for winter tyres where these are mandatory
Performing wheel alignment is a repair measure and should be

charged separately.
Step 1 - checking condition:
– Check for and remove anybyforeign
Protected copyright. bodies
Copying forin tyreortread.
private commercial purposes, in part or in whole, is not
– Check all tyres for following types of damages:

♦ Cuts, cracks, tears

♦ Scuffing or flattened areas on tyre tread
♦ Porous sidewalls
♦ Blisters on sidewalls
© satelettronica
– If damage is found: Renew tyres.
Step 2 - checking tyre wear pattern:
– Check tyre wear pattern of front wheels; check for the follow‐
ing:
♦ Feathering on tread indicating possible incorrect toe setting
♦ One-sided tread wear indicating possible incorrect camber
– If the above types of wear are found: Check wheel alignment
to determine the cause.
Step 3 - checking tread depth:
– Measure tread depth on all tyres (including spare tyre) at sev‐
eral points using test pin - T40139- . Uneven tread depth
indicates damage.
– Record average measurement for each tyre in Maintenance
table.
– If minimum tread depth has been reached (as specified for
your country; see table of test values and procedure guidelines
⇒ page 50 ): Renew tyre.
Note
Vehicles with four-wheel drive must be fitted with tyres with the
same tread pattern. Otherwise the centre differential may be
damaged.
3.15 Tyres: checking tyre pressures and ad‐

justing if necessary
Note
The tyre valves must be sealed with valve caps. Otherwise, dirt
could enter the valve, which will then become blocked and will no
longer seal properly.
3. Maintenance 51
Front and rear axles ⇒ page 52

Spare wheel and temporary spare wheel ⇒ page 52
3.15.1 Front and rear axle

The tyre pressure specifications are listed on the sticker on the
inside of the driver's door.
Tyre sizes not listed: See Wheel/tyre guide for tyre pressure
specification ⇒ Wheel/Tyre Guide; Rep. gr. 44 ; Wheels, tyres,
vehicle geometry; Tyre pressures .
Procedure:
– Check tyre pressure of all tyres.
– If necessary, adjust to correct tyre pressures.
Note
The tyre pressures listed only apply to cold tyres. When the tyres
are warm, the actual pressures will be higher, but must not be
reduced.
© satelettronica
3.15.2 Spare wheel and temporary spare
wheel
The following parameters apply to the tyre pressure specifica‐
tions:
• Spare wheel with standard-size tyre: Inflate to maximum tyre
pressure indicated on tyre pressure sticker.
• Temporary spare wheel: The correct tyre pressure is indicated
on the sidewall.
Procedure:
– Check tyre pressure of spare wheel/temporary spare wheel.
Noteto the correctness of information in this document. Copyright by AUDI AG.

with respect
Depending on equipment version, there may only be a tyre repair

kit supplied; see Maintenance table.
3.16 Tyre Pressure Loss Indicator: storing

changed tyre pressures
WARNING

expectedly!
on ⇒ page 13 .
The Tyre Pressure Loss Indicator must be initialised after every

time the tyre pressures are changed or the tyres are renewed.
52 3. Maintenance
Requirements:
• The inflation pressures of all tyres must be adjusted to the
correct values before the pressures are stored.
Procedure:
♦ Servicing & checks
♦ Tyre pressure monitoring
♦ Store tyre pressures
– Use MMI rotary pushbutton to select option to store tyre pres‐
sures.
3.17 Tyre repair kit: checking that set is com‐

plete, and checking and recording expi‐
ry date
© satelettronica
The tyre repair kit is located under the luggage compartment floor.
Procedure:
– Check that the following components of the tyre repair kit are
present:
♦ Compressor
♦ Tyre filler bottle incl. filler hose
– Take out the bottle and check the expiry date (printed on bottle
-arrow-).
– Record expiry date in Maintenance table.
– If expiry date has been exceeded or if bottle has already been
used: Protected
Renew tyre filler bottle.
3.18 Tool kit: checking that all components

necessary in the event of a breakdown
are present
The tool kit is located under the luggage compartment floor.
The vehicle jack is located under the luggage compartment floor.
Procedure:
– Check that jack (including crank handle) is present.
– Check that following components of tool kit are present:
♦ Wheel bolt spanner
♦ Adapter for anti-theft wheel bolts
♦ Puller
♦ Clip
3. Maintenance 53
♦ Towing hook
– Renew any missing components.
3.19 Wheel bolts: tightening to specified tor‐

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

included in the vehicle tool kit.
© satelettronica
Procedure:
– Tighten wheel bolts in a diagonal sequence to specified torque
(see table of test values and procedure guidelines
⇒ page 54 ).
– If adapter for anti-theft wheel bolts was usedunless
permitted from tool kit:
authorised Put AG. AUDI AG does not guarantee or accept any liability
by AUDI
adapter back in tool kit. with respect to the correctness of information in this document. Copyright by AUDI AG.
3.20 Suspension struts on front and rear axle:

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

mirror -arrow-.
♦ It is not necessary to remove the wheels to perform this oper‐
ation.
Suspension struts on front axle ⇒ page 54

Suspension struts on rear axle ⇒ page 55
Pressing in bump stop ⇒ page 56
3.20.1 Suspension struts on front axle

Requirements:
• Vehicle suspension extended
54 3. Maintenance
Procedure:
– Push all locking elements -A- off piston rod.
– When all locking elements have been removed from vehicle:
Remove tag on interior mirror.
– After road test: Check that all bump stops are firmly seated in
shock absorber mountings.
– If necessary, press any loose bump stops into shock absorber
mountings ⇒ page 56 .
Note
© satelettronica
The bump stops of the suspension struts are pressed into the
shock absorber mountings due to the compression movements
during the road test.
3.20.2 Suspension struts on rear axle

Requirements:
Procedure:
– Push all locking elements -1- off piston rod.
3. Maintenance 55
– After road test: Check that all bump stops are firmly seated in
shock absorber mountings.
– If necessary, press any loose bump stops into shock absorber
mountings ⇒ page 56 .
Note
The bump stops of the suspension struts are pressed into the
shock absorber mountings due to the compression movements
during the road test.
3.20.3 Pressing in bump stop
© satelettronica
♦ Soap-based lubricant, e.g. tyre assembly paste
Procedure:
– Remove coarse dirt from top edge of loose bump stop and coat
with tyre assembly paste.
– Press loose bump stop firmly into shock absorber mounting by
hand.
3.21 Components of front and rear axles:

checking play, secure attachment and
protective boots
The following applies to all components shown below:
• There must be no noticeable or visual play.
• As a rule you can identify damage to the boots/drive shaft
boots by emerging grease.
• Check that retaining rings and spring-type clips are seated
correctly.
56 3. Maintenance
Front axle ⇒ page 57

Rear axle ⇒ page 59
3.21.1 Front axle

Track control links, guide links and coupling rod:
– Check relative movement between wheel bearing housing and
track control link/guide link.
– Track control link and guide link: Check boots -arrows- of track
control link and guide link joints all around for damage and
© satelettronica
make sure they are seated correctly.
– Check swivel joints for play.
– Check all bonded rubber bushes of track control links and

guide links -arrows- for play.
– Check play at coupling rod -1-.
Track rod ball joint:
3. Maintenance 57
– Check boot -2- for track rod ball joint all around for damage
and make sure it is seated correctly.
– Check play at track rod ball joint.
Upper links:
– Upper links -2-: Check bushes of swivel joints all around for
damage and make sure they are seated correctly.
– Check bonded rubber bushes -3- and -4- of swivel joints (top)
for play.
Anti-roll bar:
© satelettronica
– Check anti-roll bar bush -3- for damage.
Drive shaft and steering rack: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– With steering turned: Check drive shaft boots -arrows- all

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

– If faults are found on any of the above components: Renew
relevant component.
58 3. Maintenance
3.21.2 Rear axle

Lower and upper transverse links:
both transverse links.
– Check all bonded rubber bushes -arrows- of lower transverse
link for play.
– Check all bonded rubber bushes of upper transverse link -3-

for play.
© satelettronica
Track rod:
– Check play at bonded rubber bushes of track rod -4-.
Coupling rod and anti-roll bar:
3. Maintenance 59
Drive shaft:
Only applies to vehicles with four-wheel drive.
– Check drive shaft boots -1- all around for damage and make
sure they are seated correctly.

relevant component.
© satelettronica
3.22 Engine, gearbox, final drive and steer‐
ing: checking for leaks and damage
DANGER!

♦ Observe permitted
warnings forauthorised
unless high-voltage system:
by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 11 .
Applies to vehicles up to and including model year 2014: For in‐

spection every 60,000 km (38,000 miles)/4 years, remove noise
insulation.
Applies to vehicles from model year 2015 onwards: Remove
noise insulation for every inspection.
Removal steps:
– If necessary, remove noise insulation ⇒ page 21 .
Procedure:
– Check engine and engine ancillaries from below for leaks and
damage.
– Check radiator and cooling circuit for leaks and damage.
– Check refrigerant circuit for damage (check air conditioner
compressor, condenser and refrigerant lines including con‐
nections).
– Check gearbox, final drive and steering for leaks and damage.
– If faults are found: repair or renew relevant component.
60 3. Maintenance
3.23 Underbody: checking trim, wheel hous‐

ing liners, side members and pipes/wir‐
ing for damage, and checking that they
are properly secured
Procedure:
– Check all underbody trim panels and wheel housing liners for
tears and cracks.
– Use your hands to check that all underbody trim panels and
wheel housing liners are secured correctly and check for miss‐
ing fasteners.
– Inspect side members for deformations.
– Check visible area of pipes/wiring and connections for dam‐
age and ensure they
permitted areauthorised
unless secured correctly.
– If faults are found: Renew missing fastener or damaged com‐
ponent.
3.24 Roof insert: checking operation
© satelettronica
WARNING

expectedly!
on ⇒ page 13 .
Only applies to equipment version with sliding/tilting sunroof.

Cleaning and lubricating the roof insert is a repair measure and
Procedure:
– Open and close roof system completely and check for unusual
noises and stiffness/sticking.
– If there is unusual noise or stiffness/sticking: Clean and lubri‐
cate roof insert ⇒ page 61 .
3.25 Roof insert - sliding/tilting sunroof:

cleaning and lubricating
WARNING

expectedly!
on ⇒ page 13 .

♦ Lubricating paste - G 060 751 A2-
♦ Krytox lubricating paste - G 052 141 A2-
♦ Cleaning solution - D 009 401 04-
3. Maintenance 61
♦ Industrial vacuum cleaner, e.g. wet/dry vacuum cleaner - VAS

5128-
♦ Commercially available paintbrush: approx. 15 mm wide and
bent by approx. 40°
♦ Fine-pored sponge (e.g. a piece of household sponge without
a scouring surface)

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

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

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

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

lubricating paste - G 060 751 A2- .
– Use a paintbrush to lubricate outside of guide rail -arrow- with

© satelettronica
– Use a paintbrush to lubricate side guide rail of sliding headliner
-arrow- with lubricating paste - G 060 751 A2- .
– Remove surplus lubricant on guide rails with a lint-free cloth.
– Repeat procedure on opposite side of vehicle.
– Open and close roof system completely and check again for
surplus lubricant.
3. Maintenance 63
3.26 Roof insert - panorama sunroof: clean‐

ing and lubricating
WARNING

expectedly!
on ⇒ page 13 .

♦ Krytox lubricating paste - G 052 141 A2-
♦ Grease stone - VAS 6764-
© satelettronica
♦ Hand-cartridge gun - V.A.G 1628-

5128-
♦ Measuring cup
bent by approx. 40° using workshop equipment
a scouring surface)
Cleaning
withand lubricating
respect theofroof
to the correctness insert
information is document.
in this a repairCopyright
measure by AUDIand
AG.
64 3. Maintenance
Step 1 - cleaning and lubricating guide rails:

– Open sunroof sun blind completely.
residue from guide rail.
– Insert grease stone - VAS 6764- in rear section of guide rail
-1- and turn 90° into contour of rail -2-.
– Then pull tool into centre of guide rail opening -3-, turn through
90° again -4- and remove -5-.
– Clean front section of guide rail as described in previous step.
To do so, insert grease stone in front section of guide rail (near
wind deflector) and move it to centre of guide rail.
– Repeat cleaning procedure several times as required.
– Remove grease and dirt deposits from guide rail with a lint-
free cloth.
© satelettronica
– Screw grease stone - VAS 6764- -1- onto thread of lubricant
cartridge -G 060 751 A2- -2- and insert into hand-cartridge gun
- V.A.G 1628- -3-.
3. Maintenance 65
– Insert grease stone attached to hand-cartridge gun at front end

of guide rail -1- and turn 90° into contour of rails -2-.
– Pull hand-cartridge gun evenly towards rear -3-, operating lev‐
er continuously to apply lubricating paste - G 060 751 A2- to
guide rail.
– Turn hand-cartridge gun through 90°-4- and remove in vicinity
of open glass panel -5-.
– Repeat lubrication procedure on opposite side of vehicle.
Step 2 - cleaning and lubricating
permitted slottedbyguide
unless authorised for
AUDI AG. glass
AUDI panel:
– Remove grease and dirt from slotted guide for glass panel with
a lint-free cloth.
– Open and close sunroof and open glass panel again com‐
pletely. Opening and closing the sunroof distributes the lubri‐
cant along the guide rails. Any deposits of excess lubricant can
be used to grease the slotted guide.
– Use a paintbrush to lubricate slotted guide for glass panel
© satelettronica
– Remove excess lubricant from slotted guide and guide rail with
a lint-free cloth.
Step 3 - cleaning and lubricating locking hook for sunroof mech‐

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

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

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

– Remove grease and dirt from seal for roof frame using clean‐
ing solution - D 009 401 04- and a lint-free cloth.
– Use a fine-pored sponge to lubricate roof frame seal

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

– Clean screen and frame

Protected of wind
by copyright. deflector
Copying for private-1- using a purposes,
or commercial spongein part or in whole, is not
and soap solution.
– Use an industrial vacuum cleaner to remove any loose residue
from wind deflector slot -arrows-.
Step 7 - checking water drains for dirt:

3. Maintenance 67
– Use a measuring cup -1- to pour water into guide rail close to
open glass panel -arrow-. Work carefully to ensure that the
water does not overflow into the vehicle interior. Make sure
that water is distributed in both directions so that both water
drains can be checked.
– At underside of vehicle, check that water flows out in the area
of both the front and rear wheel housings.
– If water does not flow out of the appropriate drainage points,
clean water drain ⇒ General body repairs, exterior; Rep. gr.
60 ; Water drain hoses; Cleaning water drain hoses .
3.27 Rear spoiler hinges: lubricating
© satelettronica
♦ Lubricant - G 052 172 A1-
Requirements:
• The vehicle must be at least at room temperature.
Procedure:
– Switch on ignition and extend rear spoiler.
– First clean all lubricating points with a lint-free cloth.
– Apply lubricant - G 052 172 A1- to points marked on all rear
spoiler hinge joints -arrows-.
– Extend and retract rear spoiler at least five times so that lubri‐
cant is able to penetrate.
– Remove surplus lubricant with cloth.
– Repeat procedure on opposite side.
– Retract rear spoiler.
3.28 Bonnet arrester hook: lubricating

♦ Universal spray oil - G 000 115 A2-
Requirements:
Procedure:
68 3. Maintenance
– Lubricate arrester hook with universal spray oil - G 000 115

A2- at points marked -arrows-.
– Operate moving parts several times so that the lubricant is
able to penetrate.
3.29 Windscreen/rear window washer sys‐

tem: checking spray pattern and adjust‐
© satelettronica
ing if necessary
Checking windscreen spray pattern: triple washer jets
⇒ page 69
Checking windscreen spray pattern: hybrid jets ⇒ page 70
Checking spray pattern on rear window ⇒ page 70
Setting windscreen spray pattern, triple washer jets ⇒ page 70
Setting windscreen spray pattern: hybrid jets ⇒ page 71
Adjusting rear window washer jets ⇒ page 71
3.29.1 Checking windscreen spray pattern: tri‐

ple washer jets
The spray pattern must meet the following specifications:
• Evenly distributed, symmetrical spray pattern
• Uniform, precise jets of water
• Jet unit (passenger's side): Water from all washer jets makes
contact within upper third of wiper area -illustration-
• Jet unit (driver's side): Spray pattern symmetrically opposite
that of jet unit on passenger's side
Procedure:
– Operate windscreen washer system and check spray pattern.
– If spray pattern is not as specified, adjust windscreen washer
jetsunless
⇒ page 70 .by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted authorised
3. Maintenance 69
3.29.2 Checking windscreen spray pattern: hy‐

brid jets
• Jet unit (passenger's side): Upper concentrated jet should
make contact near upper edge of wiper area -1-.
• Jet unit (driver's side): Upper concentrated jet should make
contact -2- at same level as jet unit (passenger's side).
Procedure:
jets ⇒ page 71 .
3.29.3 Checking spray pattern on rear window

© satelettronica
• Water from both spray jets makes contact just above wiper
blade
• Uniform, precise Protected
jets of by
water
• Water from inner spray jet makes contact within approx. first
quarter of wiper blade length -illustration-

• Water from outer spray jet makes contact approx. at or just
beyond centre of wiper blade length -illustration- (third quarter)
Procedure:
– Operate rear window washer system and check spray pattern.
– If spray pattern is not as specified, adjust rear window washer
jets. ⇒ page 71
3.29.4 Setting windscreen spray pattern: triple

washer jets
♦ Commercially available adjusting tool (e.g. adjusting tool -
T10127- ) or suitable needle
Procedure:
– Use adjusting tool to align washer jets as required according
to specification.
– If the spray pattern still does not correspond to the specifica‐
tion, clean washer jets ⇒ Vehicle electrics; Rep. gr. 92 ;
Windscreen wash/wipe system; Adjusting and cleaning wash‐
er jets .
70 3. Maintenance
3.29.5 Setting windscreen spray pattern, hybrid

jets
Procedure:
– Using adjuster screw -2-, set jet unit being adjusted according
to specified pattern (use a tool with size 9 external Torx -3-).
tion, clean appropriate washer jets ⇒ Electrical system; Rep.
gr. 92 ; Windscreen wiper system; Adjusting washer jets .
Note
Only the height of the jets of water of each jet unit can be adjusted,
and all jets must be adjusted together via an adjuster screw. The
jets cannot be adjusted individually or laterally.
© satelettronica
3.29.6 Adjusting rear window washer jets
Procedure:
to specification.
tion, clean washer jets ⇒ Electrical system; Rep. gr. 92 ; Rear
window wiper system; Adjusting washer jets .
3.30 Wiper blades: checking for damage

Step 1 - service position:
– Switch off ignition. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press windscreen wiper lever downwards briefly.

Step 2 - checking:
– Lift windscreen wipers and check each wiper blade for tears,
cuts, abraded areas or other damage.
– Repeat check on rear window.
– If you find damage: Renew relevant wiper blade. Windscreen
wiper system ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing wiper blade ; rear win‐
dow wiper system ⇒ Electrical system; Rep. gr. 92 ; Rear
window wiper system; Removing and installing wiper blade
3.31 Headlight washer system: checking op‐

eration
Not all vehicles are equipped with a headlight washer system
(depending on equipment version).
3. Maintenance 71
Procedure:
– Operate headlight washer system and check function.
– If water jet does not contact headlight: Renew relevant washer
jets ⇒ Electrical system; Rep. gr. 92 ; Headlight washer sys‐
tem; Removing and installing washer jets .
Note
The headlight washer jets are set by the manufacturer and there‐
fore cannot be adjusted.
3.32 Headlights: checking for correct adjust‐

ment
♦ Headlight adjustment unit - VAS 5209B-
© satelettronica
♦ Or: headlight adjustment unit - VAS 621 001-
Performed as part of an inspection, this check is merely an ab‐

breviated form of the headlight adjustment check required, for
example, after a repair, and does not take the place of a full head‐
light adjustment check.
Do not adjust the vehicle load or the tyre pressures for this pro‐
cedure.
Do not adjust the headlights to their basic setting using the vehicle
diagnostic tester.
Checking and adjusting the headlights according to the instruc‐
tions in the Workshop Manual is a repair measure and must be
charged separately.
Procedure:
– For vehicles with manually adjustable headlight range control:
Use manual adjuster to set to basic setting.
– Activate dipped headlights.
72 3. Maintenance
– Align headlight adjustment unit parallel to vehicle and position

it centrally in front of headlight at a distance of 30 to 70 cm
-distance a-; deviation from centre of light emission surface
must not exceed 3 cm -distance b-.
– Adjust dip setting of headlight adjustment unit so that beam of

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

lights, number plate lights, turn signals,
hazard warning lights: checking opera‐
tion
WARNING

expectedly!
on ⇒ page 13 .
Check the lights/signals listed below from the outside to ensure

they function properly.
Procedure:
– Activate side lights and check that the following exterior lights
function properly:
♦ Side lights (front) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Side lights (rear) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ If applicable: additional tail light under open rear lid

– Check operation of daytime running lights (front).
– Operate right turn signal, left turn signal and hazard warning
lights, and check that corresponding turn signal lamps at front,
rear and side function properly.
3. Maintenance 73
– Activate dipped headlights and check that the following exte‐

rior lights function properly:
♦ Dipped headlights
♦ Taillights
♦ Number plate lights
– Use appropriate switch to activate fog lights and check that
– Check that main beam headlights function properly.
– Operate brakes and check function of all brake lights.
– Engage reverse gear and check that all reversing lights func‐
tion properly. This model is fitted with two reversing lights.
– Use appropriate switch to activate rear fog lights and check
that they function properly. This model is fitted with two rear
fog lights.
– Renew any defective bulbs.
Note
© satelettronica
It is possible to deactivate the daytime running lights intentionally
via the appropriate MMI setup menu.
3.34 Luggage compartment lighting: check‐

ing operation
A6 Avant ⇒ page 74
A6 Saloon ⇒ page 75
A7 ⇒ page 75
3.34.1 A6 Avant
Procedure:
– Check that luggage compartment lights shown -arrows- func‐
tion properly.
74 3. Maintenance
3.34.2 A6 Saloon
Procedure:
– Check that luggage compartment light shown -arrows- func‐
tions properly.
3.34.3 A7
Procedure:
tion properly.
© satelettronica
3.35 Glove box light, interior lighting and

reading light: checking operation
WARNING

expectedly!
on ⇒ page 13 .
Procedure:
– Open glove box and check that glove box light functions prop‐
erly.
– Use the appropriate switches to activate the following interior
lights and check that the lights function properly:
♦ Interior lights in headliner at front
♦ Interior lights in headliner at rear
Note
Checking the ambient lighting is NOT part of the inspection.
3. Maintenance 75
3.36 Horn: checking operation
WARNING

expectedly!
on ⇒ page 13 .
Procedure:
– Operate horn and check proper function of treble horn and
bass horn.
Note
Perform this check outdoors, e.g. when driving the vehicle to the
© satelettronica
workshop or during a road test.
3.37 Front passenger's airbag: checking key

switch on / off and setting to "on"
WARNING

expectedly!

on ⇒ page 13 .
76 3. Maintenance
Switch for “Airbag ON/OFF” is located in glove box -arrow-.

Procedure:
– Turn switch to “AIRBAG OFF” position.
– Switch ignition on and wait for vehicle to complete initial sys‐
tem check.
– Check that “PASSENGER AIRBAG OFF” display lights up in
instrument cluster.
– Switch off ignition.
– Turn switch to “AIRBAG ON” position.
tem check.
– Check that “PASSENGER AIRBAG OFF” disappears.
Note
The amount of time needed for the vehicle system check varies
© satelettronica
depending on the model and equipment.
3.38 Seat belts: checking that retaining rivets

are fitted, and checking locking action of

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

lamps
Reading out the event memory is a repair measure and should
be charged separately.
Procedure:
– Start engine and wait for vehicle to complete initial system
check.
– Check whether warning lamps light up in instrument cluster.
– Switch off engine.
– If relevant warning lamps light up: Read out event memory
⇒ page 29 .
3. Maintenance 77
Note
3.40 Warning triangle: checking availability

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

piry date
The first-aid kit is locatedwithinrespect

the centre armrest of the rearin thisseat
to the correctness of information document. Copyright by AUDI AG.
bench.
Procedure:
– Take out first-aid kit and check expiry date printed on kit.
– If expiry date has passed: Renew first-aid kit.
© satelettronica
3.42 Vehicle keys: checking operation and
recording number of keys given to cus‐
tomer
Procedure:
– Open key ring to check each key individually.
– Start engine with each key individually.
– Record number of keys which have been matched and handed
over in Maintenance table.
– If a vehicle key has not been matched: Re-match all keys to
vehicle using Guided Function of vehicle diagnostic tester via
online tool GeKo.
– If there is reason to suspect improper use (e.g. missing key):
See current notices from AUDI AG under “Technical informa‐
tion ► Anti-theft protection” on ServiceNet.
Note
♦ Only the key being checked may be inside the vehicle. Place
all other keys out of transmission range.
♦ If the key has not been matched, the engine will turn off after
a few seconds. In addition, the warning lamp for the immobil‐
iser or the display “SAFE” will appear in the instrument cluster,
depending on the vehicle equipment.
78 3. Maintenance
3.43 Engine oil: draining
Note
♦ Oil should always be changed when engine is warm.

disposal.
♦ Keep components clean.


♦ Used oil collection and extraction unit - V.A.S 6622 A-
© satelettronica

Oil drain plug on sump 20
Oil drain plug on oil filter cover 4
Removal steps: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove noisepermitted
insulation ⇒ page 21 .
Procedure:
– Place oil drip tray under engine sump.
3. Maintenance 79
– Unscrew oil drain plugs -arrows- of sump and in oil filter cover
-1-.
– Drain engine oil from oil filter housing and sump.
– Renew seals of both oil drain plugs.
– Re-install both oil drain plugs and tighten to specified torque

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

Removal steps:
– Remove noise insulation ⇒ page 21 .
Procedure:
80 3. Maintenance
– Unscrew oil drain plug of sump -arrow-.

– Drain engine oil from sump.
– Renew seal for oil drain plug.
– Screw oil drain plug into sump and tighten to specified torque
Continue installation in reverse sequence.
3.44 Engine oil: extracting

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

disposal.
3. Maintenance 81
3.45 Engine oil: renewing oil filter

⇒ page 82

DANGER!

© satelettronica
⇒ page 11 .

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

Nm

Oil filter cartridge 22
Removal steps:
– Remove engine cover panel ⇒ page 17 .
82 3. Maintenance
Procedure:
– Use Hazet strap wrench - 2171-1- or oil filter tool - 3417- to
slacken oil filter cartridge -arrow- and then remove it.
– Clean sealing surface for oil filter at engine.
– Lubricate rubber seal on new oil filter cartridge with engine oil.
– Fit new oil filter cartridge on engine and tighten to specified
torque (see table of tightening torques for installation
⇒ page 82 ).

© satelettronica
Nm
Sealing cap 25
Removal steps:
Procedure:
– Loosen sealing cap -arrow- of oil filter using socket (36 mm) .
This causes a valve to open.
– Wait a few minutes to allow engine oil to drain from filter hous‐
ing into crankcase.
– Completely remove sealing cap -arrow- of oil filter. Make sure
that no engine oil drips onto engine.
3. Maintenance 83
– Pull oil filter element and seal -2- out of sealing cap -1-.
– Clean sealing surface -B- of sealing cap -1-.
– Lightly lubricate new seal -2- with engine oil and insert into
sealing cap. Note position of service tab -A- on seal. Flat side
of seal profile must face outwards.
– Remove O-ring -2- on oil filter housing -1-.

– Lightly lubricate new O-ring -2- with engine oil and insert into
groove -arrow-.
– Fit new oil filter element in sealing cap.
– Screw sealing cap into oil filter housing and tighten it to speci‐
fied torque using socket (36 mm) (see table of tightening
torques for installation ⇒ page 83 ).
© satelettronica

Nm

Sealing cap 25
Removal steps:
84 3. Maintenance
Procedure:
– Loosen sealing cap of oil filter using socket (36 mm) . This
causes a valve to open.
ing into crankcase.
– Pull oil filter

Protected element
by copyright. and
Copying seal or
for private -2-commercial
out of sealing
purposes, incap
part or-1-.
in whole, is not
– Clean
with sealing surface
respect to the -B-
correctness of sealing
of information cap
in this -1-. Copyright by AUDI AG.
document.
© satelettronica
groove -arrow-.

Nm
Sealing cap on oil filter 25
Requirements:
• Engine oil drained.
3. Maintenance 85
Procedure:
– Loosen sealing cap using socket (32 mm) and remove it.
– Pull oil filter element -5- and O-ring -4- out of sealing cap -3-.
– Clean sealing surfaces of sealing cap.
– Lightly lubricate new O-rings -4- and -6- with engine oil and
insert into grooves.
– Fit new oil filter element -5- in sealing cap -3-.
– Fit sealing cap -3- on engine and tighten to appropriate torque
using socket (32 mm) (see table of tightening torques for in‐
stallation ⇒ page 85 ).
© satelettronica
1)
Nm
Sealing cap 25
Removal steps: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove engine cover panel ⇒ page 17 . with respect to the correctness of information in this document. Copyright by AUDI AG.
Procedure:
– Loosen sealing cap -1- of oil filter using socket (32 mm) . This
ing into crankcase.
– Completely remove sealing cap. Make sure that no engine oil
drips onto engine.
86 3. Maintenance
– Lightly lubricate new O-rings -2-, -3- and -4- with engine oil and
insert O-rings.
– Fit new oil filter element -3- in sealing cap.
Note
There is more than one version of the oil filter for the 4-cylinder
2.0 ltr. TDI diesel engine ⇒ page 87 .

2)
© satelettronica
Nm
Sealing cap 25
Removal steps:
Procedure:
ing into crankcase.
drips onto engine.
3. Maintenance 87
– Clean sealing surfaces of sealing cap -5-.
– Lightly lubricate new O-ring -4- with engine oil and insert O-
ring.
– Screw sealing cap -5- into oil filter housing -2- and tighten it to
specified torque using socket (32 mm) (see table of tightening
Note
2.0 ltr. TDI diesel engine ⇒ page 86 .

© satelettronica
Nm
Table of tightening torques
permitted unless forbyinstallation:
authorised AUDI AG. AUDI AG does not guarantee or accept any liability
Sealing cap 35
Removal steps:
Procedure:
– Loosen sealing cap -arrow- using socket (32 mm) . This cau‐
ses a valve to open.
ing into crankcase.
drips onto engine.
88 3. Maintenance
ring.
3.46 Engine oil: filling up
© satelettronica
Caution
Risk of engine damage if the engine is revved too soon after

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

♦ Oil filler funnel - VAS 6842-
Refer to ELSA maintenance table for engine-specific oil capaci‐

ties and oil grades.
Procedure:
– Fill up engine oil using oil filler funnel - VAS 6842- .
– Then check oilProtected
level and adjust if necessary ⇒ page 90 .
3. Maintenance 89
– For all 4-cylinder petrol engines 1.8 ltr./2.0 ltr. TFSI with oil filler
neck on timing chain cover: Clean sealing surface -arrow- on
inside of oil filler neck with a lint-free cloth before screwing on
filler cap.
3.47 Engine oil: checking oil level and cor‐

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

high!
© satelettronica
♦ Drain engine oil until level meets specification.
Requirements for all engines except V6 diesel engines and V8
petrol engines:
• Engine oil temperature at least 60 ℃.
• Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.
• Vehicle must be level (horizontal).
Requirements for V6 diesel engines:
• The engine must be at operating temperature (90 °C oil tem‐
perature).
• Wait approx. two minutes after switching off the engine to allow
the oil to drain back into the sump.
Requirements for V8 petrol engines:
perature).
• Allow engine to run at idling speed for approx. one minute.
• Switch off engine and wait approx. five minutes (to allow oil to
flow back slowly).
• Check engine oil level within one minute.
Checking oil level with dipstick ⇒ page 90
Checking oil level on MMI ⇒ page 91
3.47.1 Checking oil level with dipstick

Procedure:
– Pull out dipstick and wipe it off with a clean cloth.
– Re-insert dipstick into guide tube as far as it will go.
90 3. Maintenance
– Pull oil dipstick out again and read off oil level on marked area.
– Evaluate oil level and determine any necessary measures ac‐

cordingly:
Oil level: Evaluation/measure:

Marked area -arrow- Optimum oil level.
Area A Oil must not be topped up.
Area B Oil can be topped up.
Area C Oil must be topped up.
© satelettronica
Note
Some engines are not fitted with an oil dipstick; if this is the case,
use the oil level display in the MMI system ⇒ page 91 .
3.47.2 Checking oil level on MMI

Procedure:
– If necessary, close bonnet.
– Under »Car systems«, navigate through following menu struc‐
ture:
♦ Oil level
– Read off and evaluate oil level on display.
– If necessary, correct oil level:
Oil level Evaluation/measure

At “max” Drain engine oil until level meets optimum level.
Just under “max” Optimum oil level.
Significantly under “max” Fill up engine oil to optimum level (close bonnet to refresh oil level display).
3. Maintenance 91
Note
♦ The oil level display on the MMI is not refreshed when the
bonnet is open.
♦ A warning lamp in the driver information system indicates that
the level is too low.
3.48 Poly V-belts for ancillaries: checking

Caution
Risk of engine damage if camshaft drive slips.

♦ Turn crankshaft only in normal direction of engine rotation.
This maintenance item only applies to certain countries: Note

specification in Maintenance table.
© satelettronica
Removal steps:
– Remove poly V-belt ⇒ ; Rep. gr. 13 ; Cylinder block (pulley
end); Removing and installing poly V-belt .
Procedure:
– Check poly V-belt (removed from vehicle) along entire length,
as well as pulleys on engine that are within view. Look for the
following types of damage:
♦ Cracks or tears in belt profile and on reverse side (cracks, core
fractures, cross-sectional fractures)
♦ Layer separation (top layer, cord strands)
♦ Fraying of cord strands
♦ Foreign objects in belt profile and reverse side
♦ Excessive traces of oil and grease on rollers and pulleys
♦ Flank wear on pulleys (material wear, frayed flanks, surface
cracks); see -illustration-
– Applies to vehicles with power steering pump: Check alterna‐
tor freewheel.
– If damage is found: Renew damaged component.

Note
The example given here shows possible damage to a pulley. The

appearance of other types of material wear on the load-bearing
flanks of the ribbing can be different.
92 3. Maintenance
3.49 Spark plugs: renewing

⇒ page 93
6-cyl. petrol engine 2.5 ltr. FSI/2.8 ltr. FSI/3.0 ltr. TFSI
⇒ page 95

Special tools and workshop equipment required Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Spark plug socket and extension - 3122B- with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
♦ Puller - T40039-

Spark plugs 30
Securing bolts for connector rail 5
Removal steps:
3. Maintenance 93
Step 1 - removing spark plugs:

– Release and unplug electrical connectors -arrows- from ac‐
tuators for camshaft adjustment.
– Unscrew bolts for connector rail.
– Release connectors -arrows- and pull all connectors simulta‐

neously off ignition coils.
– Place connector rail slightly to one side. Make sure that wiring
is not kinked or damaged.
© satelettronica
– Position puller - T40039- on thick rib at top of ignition coils and
detach all ignition coils from spark plugs one after the other in
direction of -arrow-.
94 3. Maintenance
– Unscrew spark plugs from cylinder head using spark plug

socket - VAS 3122B- .
Step 2 - installing spark plugs:

– Install new spark plugs using spark plug socket and extension
- VAS 3122B- and tighten to specified torque (table
⇒ page 93 ).
– Fit all ignition coils loosely into spark plug apertures and align
with connectors of connector rail.
– Push ignition coils evenly onto spark plugs by hand (do not
attempt to knock in coils with any kind of tool).
– Align connector rail and plug all connectors simultaneously
onto ignition coils so that they engage.
– Plug electrical connectors into actuators for camshaft adjust‐
ment so that they engage.
– Install connector rail, screwing in securing bolts to specified

⇒ page 93 ).
© satelettronica
3.49.2 6-cyl. petrol engine 2.5 ltr. FSI/2.8 ltr.

FSI/3.0 ltr. TFSI
♦ Spark plug socket and extension - 3122B-
♦ Puller - T40039-
3. Maintenance 95

Spark plugs 30
Removal steps:
Step 1 - removing spark plugs, cylinder bank (right-side):
– Move fuel line -1- and hose -2- leading to activated charcoal
filter clear at air pipe.
– Detach vacuum hose -3- from connection on air pipe.
– Loosen hose clips -arrows- and detach air pipe.
– Remove air cleaner housing ⇒ Rep. gr. 24 ; Removing and
installing air cleaner housing .
© satelettronica
– Release and unplug electrical connectors -2-, -3-, -4-, -5-, -6-,
-7-, -8- and -9- from actuators for camshaft adjustment.
– Unplug electrical connector -1- at Hall sender 3 - G300- .
– Release connectors for ignition coils -arrows- and unplug all
connectors from ignition coils at the same time.

Step 2 - removing spark plugs, cylinder bank (left-side):
96 3. Maintenance
– Unplug electrical connector -1- for coolant shortage indicator

switch - F66- .
– Unscrew bolt -2- on coolant expansion tank.
– Place coolant expansion tank to one side with coolant hoses
-arrows- attached.
© satelettronica
– Unplug electrical connector -1- at Hall sender 3 - G163- .

direction of -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew spark plugs from cylinder headtousing
with respect sparkofplug
the correctness information in this document. Copyright by AUDI AG.

⇒ page 96 ).
⇒ page 96 ).
3. Maintenance 97

♦ Spark plug socket and extension - 3122B-
♦ Puller - T10530-
© satelettronica

Spark plugs 30
Bolts for ignition coils 9
Removal steps:
98 3. Maintenance
– Unplug the following electrical connectors and move electrical

wiring harness clear:
1 - For ignition coils -N70- , -N127- , -N291- , -N292-
2 - For Hall sender - G40-
4 - For inlet/exhaust cam actuators -F456- , -F457- , -F458- and
-F459-
5 - For intake air temperature sender - G42-
-F455-
– Disconnect vacuum hoses -3- and -7-.
– Unscrew bolts -arrows- for connector rail.
– Push ignition coil connector towards ignition coil, release re‐
tainer and detach connector from ignition coil.
– Unscrew bolts -arrows- for ignition coils.
© satelettronica
– Insert puller - T10530- into hole -1- of ignition coil and turn
knurled nut -2- clockwise until puller is secured in place.
3. Maintenance 99
– Carefully pull ignition coil out upwards using puller - T10530- .

– Repeat removal procedure with all other ignition coils.
– Unscrew spark plugs using spark plug socket and extension -
VAS 3122B- .
– Release retaining clips -1- and -4- and disconnect coolant ho‐
ses.
© satelettronica
– Move coolant hose -arrow- clear.
switch - F66- .
– Lift coolant expansion tank out of bracket and place to one
side.
– Move clear coolant hoses -3- and air pipe -1- at wiring guide
-2-.
– Take electrical connectors -1- out of bracket -2-, unplug con‐

nectors and move wiring clear.
– Lift off bracket -2-.
100 3. Maintenance
– Unplug electrical connectors -arrows- and move wiring clear.

-F467-
4 - For fuel metering valve 2 - N402-
5 - For fuel pressure sender for low pressure - G410-
6 - For Hall sender 4 - G301-
© satelettronica
-F479-
– Remove bolts -2-, -9- and centre hex stud -arrow- and move
earth wire clear.
3. Maintenance 101

VAS 3122B- .
© satelettronica
⇒ page 98 ).
– Tighten bolts -arrow- for ignition coils tospecified torque
with respect (see
table of tightening torques for installation ⇒ page 98 ).
– Plug in connector on each ignition coil until it engages.
3.50 Cooling system: checking anti-freeze

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

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

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

with respecttank
to the (this is of information in this document. Copyright by AUDI AG.
correctness
by technical design). Do NOT extract coolant.
Checking coolant level and anti-freeze ⇒ page 103

Filling up coolant ⇒ page 105
3.50.1 Checking coolant level and anti-freeze

♦ Refractometer - T10007 A-

Type of service: Coolant level specification:
Delivery Inspection Coolant at level of MAX marking.
Inspection Coolant level between MIN and MAX markings.
Checking the coolant system for leaks is a repair measure and

Requirements:
• Anti-freeze protection must be guaranteed to -25 °C (in coun‐
tries with an arctic climate to -36 ℃); note specification in
Maintenance table.
3. Maintenance 103
• The proportion of coolant additive must not exceed 55 %

(gives anti-freeze protection down to -48 °C); beyond this con‐
centration the frost protection and the cooling efficiency are
reduced again.
• The vehicle must be parked on a level surface.
Step 1 - checking coolant level:
– Check coolant level (according to marking -illustration-) in
coolant expansion tank with engine cold.
– If coolant level is too low: Add required amount (using correct
mixture ratio) ⇒ page 105 .
– If fluid losses are greater than can be reasonably expected:
First use a leak test to determine the cause ⇒ Engine; Rep.
gr. 19 ; Cooling system/coolant; Checking cooling system for
leaks .
Step 2 - checking anti-freeze:

– Use a pipette to place a drop of coolant on glass of refractom‐
eter - T10007 A- . Light-dark border will now be clearly visible
through refractometer.
© satelettronica
– Check level of anti-freeze protection using corresponding
scale on refractometer; to do so, read off value on light-dark
border.
– If anti-freeze protection level does not meet specification in
Maintenance table: Perform following
Protected measures:
Anti-freeze protection level: Evaluation/measure:
> Specification Depending on deviation from specification, remove a small amount of coolant
and replace it with distilled water. Repeat procedure until coolant mixture meets
correct specification.
< Specification Depending on deviation from specification, remove a small amount of coolant
and replace it with coolant additive. Repeat procedure until coolant mixture
meets correct specification.
– Check coolant additive concentration once more following

road test.
104 3. Maintenance
Note
♦ The refractometer - T10007 A- must be used to determine the

current anti-freeze concentration.
♦ Scale -1- on the refractometer applies to coolant additives
G11, G12, G12+ and G12++.
♦ Scale -2- refers only to coolant additive G13.
♦ If more than one type of coolant additive has been used: Al‐
ways use the scale for G13 to determine the anti-freeze pro‐
tection.
♦ The temperature indicated on the refractometer - T10007 A-
corresponds to the temperature at which the first ice crystals
can form in the coolant.
♦ It is essential that anti-freeze be used in the cooling system all
year round. In the correct concentration, coolant additives pre‐
vent scaling and frost and corrosion damage, and also raise
the boiling point of the coolant.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads in countries with tropical climates.
© satelettronica
3.50.2 Filling up coolant
Frost protection to: Coolant additive: Water:
-25 °C approx. 40 % approx. 60 %
-36 ℃ approx. 50 % approx. 50 %
Procedure:
– Add required amount (using mixture ratio according to anti-
freeze protection specification in Maintenance table). Use the
table as a reference for the coolant mixture ratio.
Note
Small quantities of coolant can simply be topped up. Use the

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

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

♦ Secure all hose connections with hose clips
AG.(same
AUDI AGas original
permitted unless authorised by AUDI does not guarantee or accept any liability
equipment); see Electronic parts
with respect to catalogue
the correctness (ETKA).
of information in this document. Copyright by AUDI AG.
3. Maintenance 105
Air cleaner housing: cleaning ⇒ page 113

⇒ page 106

Removal steps:
Step 1 - removing air filter element:
– Release hose clip -3- and detach air pipe.
– Unplug electrical connector -2- for air mass meter - G70- .
© satelettronica
– Release retainer -1-.

– Turn filter element in anti-clockwise direction -arrow A- and
remove it.
Step 2 - installing air filter element:
– Check for dirt in housing and water drains -arrow- and clean if
necessary ⇒ page 113 .
106 3. Maintenance
– Insert new filter element -1- centrally in housing cover -2-. En‐
sure that filter element is installed in correct direction and that
all centring lugs engage in housing cover.
– Fit housing cover (with filter element attached) centrally into

mounting in air cleaner housing and turn it in clockwise direc‐
tion -arrow B- until it engages -1-.
– Attach air pipe to air cleaner (top section) and fit hose clip.
– Plug electrical connector for air mass meter - G70- back in.
© satelettronica
Removal steps:
– Disengage fuel line -1- and hose -2- from retainer on air pipe.
– Disconnect vacuum hose -3- from air pipe.

remove it.
3. Maintenance 107
© satelettronica

Removal steps:
108 3. Maintenance

remove it.
© satelettronica

3. Maintenance 109

– Release hose clips -2- and detach air pipe.
– Turn housing cover in anti-clockwise direction -arrow B- and
remove filter element.
– Fit new filter element centrally in housing cover, ensuring that
it is installed in correct direction.
© satelettronica
tion -arrow A- until it engages -3-.

Removal steps:
110 3. Maintenance

– Release retainer -1- on housing cover.

– Turn housing cover with filter element in anti-clockwise direc‐
tion -arrow A- and remove it.
Step 2 - installing air filter element: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
© satelettronica
– Fit housing cover (with filter element attached) into mounting
of air cleaner housing so that it is centred. When fitting, hold
onto filter element as you insert it through opening for housing
cover; ensure that it does not slip off centring lugs and become
tilted when it is installed.
3. Maintenance 111
– Turn housing cover in clockwise direction -arrow B- until you

feel it engage -1-.
Note
If the housing cover does not engage easily, this may indicate that
the air filter element is not aligned properly or is tilted.

Removal steps:
– Release hose clips -arrows- and detach air pipe -1-.
© satelettronica
remove it.
– Check for dirt in housing and water drains -arrow- andProtected

clean by if copyright. Copying for private or commercial purposes, in part or in whole, is not
necessary ⇒ page 113 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
112 3. Maintenance

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

er air mass meter with a clean cloth.
♦ On vehicles for cold countries, the snow screen in the intake
section must also be cleaned; see specification in ELSA Main‐
tenance table.
3.52 Plenum chamber and water drains:

checking for dirt
DANGER!

♦ Handling high-voltagepermitted
wiresunless
⇒ page 12 by
authorised . AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 11 .
3. Maintenance 113
Checking plenum chamber and water drains for dirt

⇒ page 114
Cleaning plenum chamber and water drain valves ⇒ page 115
3.52.1 Checking plenum chamber and water

drains for dirt
Nm
Nm
Bolts for washer fluid reservoir 8
© satelettronica
Cleaning the plenum chamber, as well as the removal procedures
required, are a repair measure and should be charged separately.
Removal steps:
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Remove bolts -arrows- for washer fluid reservoir -1-.
– Carefully lift filler neck, but do not remove completely.
Step 1 - checking plenum chamber and water drains (driver's

side):
– Check for dirt in water drain grommet -1- and bottom of plenum
chamber using a hand-held light.
– If no dirt was found: Carefully pour a small amount of water
into plenum chamber and check that water drains quickly and
fully.
– If necessary, clean plenum chamber and water drains
⇒ page 115 .
Step 2 - checking plenum chamber and water drains (passenger's

side):
114 3. Maintenance
– Check for dirt in water drain grommet -1- and water drains
-arrows- using a hand-held light.
⇒ page 115 .

Note
If the water you have poured in does not drain out or drains out
very slowly, this is a sign that the water drains -arrows- are fully
or partly blocked.
3.52.2 Cleaning plenum chamber and water

drains
© satelettronica
♦ Suction feed spray-gun - VAG 1538-
♦ Nylon probe - VAG 1538/2-
♦ Flexible picking tool
Procedure: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove coarse dirt from plenum chamber and water drain
grommets with a flexible picking tool.
– Remove fine dirt using suction-feed spray gun - V.A.G 1538-
and nylon probe - V.A.G 1538/2- or a thin water hose.
3.53 Dust and pollen filter: renewing

Preliminary filter ⇒ page 115
Main filter ⇒ page 116
3.53.1 Preliminary filter

Equipment version for certain countries: Note specification in
Maintenance table.
The preliminary filter is fitted in the vehicle plenum chamber.
Removal steps:
chamber cover .
3. Maintenance 115
Step 1 - removing filter element:

– Take out filter element -2- under retainers -3- in direction of
-arrow-.
Step 2 - installing filter element:
– Clean surrounding area (e.g. with a vacuum cleaner) after re‐
moving filter element.
– Fit new filter element -2- so that arrows indicating direction of
flow point downwards.
3.53.2 Main filter

The dust and pollen filter is fitted under the glove box.
Removal steps:
– On vehicles with special equipment used by driving schools:
Remove pedal cluster if necessary; see installation instruc‐
© satelettronica
tions for equipment for driving schools.
– Cover footwell beneath dust and pollen filter with paper.
– Release quick-release fastener -2- with screwdriver -1-.
– Disengage cover -3- at retainer -4- and detach.
116 3. Maintenance
– Release retaining tab -B-, swivel cover -A- for aperture down
and detach.
– Pull filter element -D- out of aperture -E- in direction of
-arrow-.

– Clean aperture -E- with a vacuum cleaner before fitting new
filter element.
– Fit new filter element -D- correctly: angled side faces fresh air
blower.
– Position aperture cover -A- in tab -C- and engage on opposite
side -B-.
3.54 Fuel filter: draining
© satelettronica
WARNING
Fuel is hot and under pressure - risk of injuries!

♦ Wear protective gloves.
♦ Wear
Protectedsafety goggles.
♦ Loosen draining
with respect valve carefully.

Nm
♦ Diesel-resistant hose with appropriate diameter: must not slip
off draining valve under system pressure
♦ Container for collecting fluid
Fastener Tightening torque
[Nm]
Water drain plug -5- 10
The fuel filter is located on the underbody at the rear of the vehicle.
3. Maintenance 117
Procedure:
– Attach hose to water drain plug -5- on cover of filter housing.
Place opposite end of hose in appropriate container.
– Start the engine. System pressure is necessary for draining
fuel filter.
– Open water drain plug slowly until water begins to drain.
– When diesel fuel begins to drain: Screw water drain plug back
in.
– Turn off engine and disconnect hose from water drain plug.
– Tighten water drain plug -5- to specified torque (see table of
3.55 Fuel filter: renewing
© satelettronica
WARNING

♦ Wear protective gloves.
♦ Wear safety goggles.
♦ Allow connections of fuel lines to cool down.
♦ Place cloths around connections and loosen them care‐
fully.
Fuel filter without water separator ⇒permitted

pageunless
118 authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Fuel filter with water separator ⇒ page 119

3.55.1 Fuel filter without water separator

♦ Hose clip pliers - VAS 6362-

♦ Container for collecting fluid
118 3. Maintenance

[Nm]
Nuts on bracket 2
The fuel filter is located on the underbody.

Removal steps:
– Remove underbody trim (right-side) ⇒ Rep. gr. 66 ; Under‐
body trim; Removing and installing underbody trim .
Step 1 - removing:
– Observe the safety precautions when working on the fuel sys‐
tem ⇒ Fuel supply system, diesel engines; Rep. gr. 00 ; Safety
precautions; Safety precautions when working on the fuel sys‐
tem .
– Unscrew nuts -2-.
© satelettronica
– Swivel bracket downwards, disengage it from mounting points
-arrows- and detach it.
– Place drip tray under fuel filter.
– Use hose clip pliers to disconnect fuel supply hoses -1- and
-3- and detach fuel filter -2-.
Step 2 - installing:
Flow direction is indicated by arrows on filter housing.
– Then bleed fuel system ⇒ Engine; Rep. gr. 23 ; Injection sys‐
tem; Filling/bleeding fuel system . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3.55.2 Fuel filter with water separator

3. Maintenance 119
♦ Diesel extractor - VAS 5226-
♦ Hose clamps, up to Ø 25 mm - 3094-
© satelettronica
Nm
[Nm]
Bolts for filter housing -8- 9
120 3. Maintenance
Step 1 - removing:
– Clamp off supply hose for underbody hose -14- with hose
clamps, up to Ø 25 mm - 3094- .
– Fit hose of diesel extractor - VAS 5226- together with suitable
adapter onto water drain plug -5-.
– Open water drain plug -5-.
– Operate diesel extractor - VAS 5226- until no more diesel
emerges.
– Unscrew bolts -8- and detach filter housing.
– Remove filter element -4- and seal -3- from filter housing -9-.
– Use diesel extractor - VAS 5226- to draw off remaining diesel
fuel.
– Clean filter housing -9-.
© satelettronica
– Insert new filter element in filter housing so that it is centred.
– Fit new seal.
– Insert and align filter housing. Make sure that filter housing is
screwed on in correct position.
– Fit bolts for filter housing -8- and tighten to specified torque
– Remove hose clamps, up to Ø 25 mm - 3094- from supply hose
for underbody hose.
– Finally, bleed fuel system ⇒ Rep. gr. 23 ; Injection system;
Filling/bleeding fuel system .
3.56 Fuel tank: adding fuel additive

♦ Multi-purpose additive for petrol fuels - G 001 770 A2-
♦ Or: Multi-purpose additive for petrol fuel - G 001 780 M3-

China Russia India
VW 507 53 B: Applies to all petrol VWpermitted
507 53 B: Applies to all petrol VW 507 53 B: Applies to all petrol
engines engines engines
VW 507 53 A: Applies to all petrol VW 507 53 A: Applies to all petrol
engines except g-tron and E85 flex‐ engines except g-tron and E85 flex‐
ible fuel ible fuel
Multi-purpose additive for petrol Multi-purpose additive for petrol Multi-purpose additive for petrol
fuels - G 001 780 M3- fuels - G 001 780 M3- fuels - G 001 780 M3-
Multi-purpose additive for petrol Multi-purpose additive for petrol
fuels - G 001 770 A2- fuels - G 001 770 A2-

3. Maintenance 121
Procedure:
– Follow measuring guidelines on fuel additive container and
add fuel additive to fuel tank according to current fuel tank
level.
Note
♦ Use only fuel additives that correspond to the standard VW

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

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

♦ Do not kink lines of filling device.
© satelettronica
♦ If you come into contact with this liquid: Rinse it off imme‐
diately with plenty of water and contact a medical profes‐
sional.
Caution
Risk of damage to trim and body components due to contact

with reducing agent!
♦ Do not kink lines of filling device.
♦ Clean the affected areas with clean water and a cotton
cloth.
♦ Remove anyProtected
crystallised reducing agent using warm wa‐
ter and a sponge.


♦ Filling device for AdBlue - VAS 6542-
122 3. Maintenance
♦ Engine and gearbox jack - VAS 6931-
♦ Mounting plate - V.A.G 1383A/1-
© satelettronica
Components of filling device -VAS 6542-
3. Maintenance 123
1 - Breather connection for re‐

ducing agent container
2 - Union nut for reducing
agent container
3 - Cut-off valve for breather
line
4 - Quick-release coupling on
breather line
5 - Filler line
6 - Cut-off valve for filler line
7 - Union nut for tank filler neck
8 - Breather line
© satelettronica
Procedure:
– Open tank flap and unscrew filler cap for reducing agent tank.
– Clean filler neck of tank for reducing agent with a lint-free cot‐
ton cloth soaked with water.
– Close cut-off valves of breather and filler lines of filling device
for AdBlue - VAS 6542- .
– Apply filling device for AdBlue - VAS 6542- to reducing agent
container (see Electronic parts catalogue, ETKA) and screw it
on as far as stop.
124 3. Maintenance
– Position reducing agent container on engine and gearbox jack

- VAS 6931- with mounting plate - V.A.G 1383A/1- . Difference
in height of reducing agent container and filler neck of tank for
reducing agent must be between 60 - 80 cm -dimension A-.
© satelettronica
3. Maintenance 125
– Position filling device for AdBlue - VAS 6542- on filler neck on

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

♦ The reducing agent is used for the after-treatment of exhaust
gases of diesel-engined vehicles, i.e. to reduce the level of
nitrogen oxides.
♦ The reducing agent is not a diesel additive and must not be
filled into the diesel fuel tank.
♦ Do not add any additives to the reducing agent, and do not
dilute it with water.
♦ Only use the reducing agent as supplied in its original con‐
tainer.
♦ In addition, please observe the reducing agent manufacturer's
notices on usage and storage.
3.58 Body: checking vehicle paintwork

Protected for for private or commercial purposes, in part or in whole, is not
by copyright. Copying
damage and corrosion with fromrespectbelow andof information in this document. Copyright by AUDI AG.
to the correctness
with bonnet, rear lid and doors open
Procedure:
– Open all vehicle doors, bonnet and rear lid.
– Check vehicle paintwork on inside and outside of body for
damage and corrosion.
– Rectify defects of any kind (repair measure).
3.59 Road test

Procedure:
– The following points must be checked during the road test:
♦ Engine: performance, misfiring, idling speed, acceleration,
starting behaviour (engine cold and warm), engine noise
126 3. Maintenance
♦ Clutch: pulling away, pedal pressure, odours, noise due to

load change
♦ Manual gearbox: ease of operation, gear lever position, gear‐
box noise
♦ Automatic gearbox: selector lever position, shift lock / ignition
key lock, gearbox noise, kickdown, shift behaviour, instrument
cluster display
♦ Brake pedal and handbrake: operation, travel and effective‐
ness, pulling to one side, response (delayed braking), judder‐
ing, squeal
♦ ABS function: pulsing must be felt at the brake pedal when
performing ABS-controlled braking.
♦ Steering: operation, steering free play, steering wheel central‐
ised when wheels are in straight-ahead position, moving off
line when travelling straight
♦ Imbalance: wheels, drive shafts
♦ Wheel bearings: noises
♦ Roof insert: unusual noise during operation
© satelettronica
♦ Horn: checking
♦ Hybrid vehicles: check electrical operation by pressing EV
button, charging function in overrun phases
Note
To what extent all of these can be checked depends on vehicle

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

specified in Maintenance table for stock
vehicles (see “Before handing vehicle
over to customer”)
This maintenance item only applies to stock vehicles.
Procedure:
– Before handing vehicle over to customer: Check whether the
following three measures for stock vehicles (as specified in the
Maintenance table) are due, and carry them out as necessary:
♦ For vehicles older than 12 months (from date of manufacture):
Renew brake fluid ⇒ page 43 .
♦ For vehicles with a defective battery: Renew battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Removing and installing
battery; Removing and installing battery, vehicles without
high-voltage system . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Check brake discs for surface rust; if necessary, operate
brakes to remove rust according to manufacturer's instruc‐
tions.
– Record measures performed in maintenance table for stock
vehicles.
3.61 Rear final drive: changing gear oil

Procedure:
– Change gear oil according to Workshop Manual ⇒ Rep. gr.
39 ; Gear oil; Draining and filling gear oil .
3. Maintenance 127
3.62 Rear final drive: changing ATF

Procedure:
– Change ATF according to Workshop Manual ⇒ Rep. gr. 39 ;
ATF; Draining and filling ATF .
3.63 Display instruments: setting language,

time and date
Procedure:
– Change settings of display instruments: Refer to Operating
Manual for radio/sound system/MMI system.
3.64 Automatic gearbox (multitronic): chang‐

ing ATF
Procedure:
– Change ATF according to Workshop Manual
by AUDI⇒AG. ; Rep. gr.does37not; guarantee or accept any liability
permitted unless authorised AUDI AG
ATF; Draining and filling
withATF . to the correctness of information in this document. Copyright by AUDI AG.
respect
3.65 Automatic gearbox (tiptronic): changing
© satelettronica
ATF fluid
Procedure:
– Change ATF fluid according to Workshop Manual ⇒ ; Rep. gr.
37 ; ATF; Draining and filling ATF .
3.66 Dual clutch gearbox (S tronic): changing

ATF

ATF and renewing exchangeable ATF
filter
Procedure:
– Change exchangeable ATF filter according to Workshop Man‐
ual ⇒ ; Rep. gr. 34 ; ATF circuit; Removing and installing ATF
filter .
3.68 Interior mirror: calibrating compass
WARNING

expectedly!
on ⇒ page 13 .
Procedure:
– Calibrate compass according to Workshop Manual ⇒ General
body repairs, interior; Rep. gr. 68 ; Interior mirror; Calibrating
digital compass .
128 3. Maintenance
3.69 Poly V-belt for supercharger with charge

air coolers: renewing
Procedure:
– Renew poly V-belt for supercharger with charge air coolers
according to specifications in Workshop Manual ⇒ ; Rep. gr.
13 ; Cylinder block (pulley end); Removing and installing poly
V-belt .
3.70 Poly V-belts for ancillaries: renewing

Procedure:
– Renew poly V-belt for ancillaries according to specifications in
Workshop Manual ⇒ ; Rep. gr. 13 ; Cylinder block (pulley
3.71 Poly V-belts for ancillaries and pulleys

for coolant pump and power steering
pump: renewing
Procedure:
© satelettronica
– Renew pulleys according to Workshop Manual ⇒ ; Rep. gr.
13 ; Cylinder block (pulley end); Exploded view - cylinder block
(pulley end) .
3.72 Instrument cluster: resetting driver infor‐

mation system
Procedure:
– Reset single
Protectedjourney memory
by copyright. Copying forand total
private journeypurposes,
or commercial memory in partof
or in whole, is not
driver information
permitted unlesssystem; refer
authorised by AUDIto AG.vehicle Owner's
AUDI AG does Manual.
3.73 Toothed belt for camshaft drive: renew‐

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

drive sprockets for camshaft, crankshaft
and high-pressure pump: renewing
Procedure:
– Renew drive sprockets for camshaft, crankshaft and high-
pressure pump according to Workshop Manual ⇒ ; Rep. gr.
15 ; Toothed belt drive; Exploded view - toothed belt .
3. Maintenance 129
3.75 Toothed belt for camshaft drive and ten‐

sioning roller: renewing
Procedure:
– Renew tensioning roller according to Workshop Manual ⇒ ;
Rep. gr. 15 ; Toothed belt drive; Exploded view - toothed belt .
3.76 Poly V-belts for ancillaries and pulley for

power steering pump: renewing
Procedure:
– Renew pulley for power steering pump according to Workshop
Manual ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hy‐
draulic power steering; Exploded view - power steering pump .
© satelettronica
130 3. Maintenance
Service
Maintenance
Audi A6 2011 ➤
Edition 12.2018
© satelettronica

Service
Maintenance
Heading
1. General information
2. Preparations
3. Maintenance
4. Exhaust emissions test
© satelettronica

Copyright © 2019 Audi AG, Ingolstadt D4B806E4CA7

Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 --- Change history --- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Warnings for high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Vehicle: raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Engine cover panel: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Noise insulation: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Window regulators: activating automatic open/close function . . . . . . . . . . . . . . . . . . . . . . 17
2.5 Vehicle diagnostic tester: connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 Diesel particulate filter: reading out ash deposit volume . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 ERA-GLONASS: checking emergency call function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Event memory: reading out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Service interval display: resetting service event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
© satelettronica
3.5 Diagnostic work: performing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Transport mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7 Transport mode: checking activation and activating if necessary . . . . . . . . . . . . . . . . . . . . 27
3.8 Vehicle: cleaning interior and exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.9 Shipping mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.10 Battery: reading out status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.11 Connecting vehicle diagnostic tester and sending diagnostic log . . . . . . . . . . . . . . . . . . . . 30
3.12 Battery: checking electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.13 Battery: connecting stationary battery charging unit (min. 30A, charging voltage max. 14.8 V
on IV characteristic curve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.14 Battery: determining and recording state of charge (SOC) . . . . . . . . . . . . . . . . . . . . . . . . 37
3.15 Mirror hanger indicating defective battery: renewing battery on affected vehicles . . . . . . . . 40
3.16 Data sheet for Radio Equipment Directive: printing and placing in glove compartment . . . . 40
3.17 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.18 Brake fluid (vehicles older than 12 months): changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.19 Brake fluid: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.20 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder
screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.21 Brake pads: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.22 Brake discs: checking for surface rust and operating brakes to clean if necessary . . . . . . 47
3.23 Parking brake: releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.24 Tyres: checking condition and wear pattern, and checking and recording tread depth . . . . 48
3.25 Tyres: checking tyre pressures and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . 49
3.26 Tyres (except spare wheel): checking tyre pressures and adjusting to 3.5 bar if necessary
........................................................................ 51
3.27 Tyre Pressure Loss Indicator: storing changed tyre pressures . . . . . . . . . . . . . . . . . . . . . . 51
3.28 Tyre repair kit: checking that set is complete, and checking and recording expiry date . . 51
3.29 Wheel bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.30 Suspension struts on front and rear axle: removing locking elements and correctly fitting
bump stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.31 Axles (front and rear): checking components for play, secure attachment and damage, and
checking protective boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.32 Engine, gearbox, final drive and steering: checking for leaks and damage . . . . . . . . . . . . 59
3.33 Steering boots and inner hose clips: checking secure seating . . . . . . . . . . . . . . . . . . . . . . 60
3.34 Vehicle (from below): checking for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.35 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage,
and checking that they are properly secured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.36 Roof insert: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contents i
3.37 Roof insert - sliding/tilting sunroof: cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . 61

3.38 Roof insert - panorama sunroof: checking, cleaning and lubricating . . . . . . . . . . . . . . . . . . 63
3.39 Water drains - sliding panoramic sunroof: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.40 Rear spoiler hinges: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.41 Door hinges with separate door arrester: cleaning and lubricating . . . . . . . . . . . . . . . . . . 68
3.42 Front lid arrester hook: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.43 Windscreen/rear window washer system: checking spray pattern and adjusting if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.44 Wiper blades: checking for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.45 Headlight washer system: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.46 Headlights: checking for correct adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.47 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning
lights: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.48 Luggage compartment lighting: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.49 Luggage compartment: removing protective film and felt pieces . . . . . . . . . . . . . . . . . . . . 77
3.50 Glove box light, interior lighting and reading light: checking operation . . . . . . . . . . . . . . . . 77
3.51 Horn: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.52 Passenger airbag: checking key switch on/off and setting to "on" . . . . . . . . . . . . . . . . . . . . 78
3.53 Owner's literature: checking that all documents are present . . . . . . . . . . . . . . . . . . . . . . . . 78
3.54 Service wallet: affixing vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
© satelettronica
3.55 Service Schedule: entering Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.56 Seat belts: checking fixing device for latch plate, and checking locking action of automatic
belt retractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.57 Vehicle interior: removing protective covers for seats and carpet . . . . . . . . . . . . . . . . . . . . 79
3.58 Vehicle interior: checking that it is clean and cleaning if necessary . . . . . . . . . . . . . . . . . . 80
3.59 Vehicle interior: removing any objects other than those protecting interior surfaces . . . . . . 80
3.60 Vehicle interior and exterior: checking for and documenting any damage . . . . . . . . . . . . . . 80
3.61 Instrument cluster: checking warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.62 Warning triangle: checking availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.63 First-aid kit: checking and recording expiry date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.64 Vehicle keys: checking operation and recording number of keys given to customer . . . . . . 81
3.65 Vehicle key: removing from ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.66 Vehicle key(s), wheel covers and owner's literature: checking availability and recording
number present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.67 Sun visors: checking that they are folded up and folding up if necessary . . . . . . . . . . . . . . 82
3.68 Luggage compartment cover and sun blind: checking that they are rolled up and rolling up if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.69 Engine oil: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.70 Engine oil: extracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.71 Engine oil: renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.72 Engine oil: filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.73 Engine oil: checking oil level and correcting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.74 Poly V-belts for ancillaries: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.75 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.76 Coolant level: checking (coolant level must reach at least top marking on coolant expansion
tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.77 Air cleaner: renewing filter element and cleaning housing . . . . . . . . . . . . . . . . . . . . . . . . 110
3.78 Plenum chamber and water drains: checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.79 Dust and pollen filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.80 Fuel filter: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.81 Fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.82 Fuel tank: adding fuel additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.83 Reducing agent (AdBlue®): filling up tank completely . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.84 Vehicle doors: removing edge protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.85 Vehicle exterior: checking unprotected areas for dirt, and cleaning if necessary . . . . . . . . 131
3.86 Vehicle exterior: removing protective film, if present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.87 Vehicle cover: checking position and correcting if necessary . . . . . . . . . . . . . . . . . . . . . . 132
ii Contents
3.88 Vehicle cover: removing according to manufacturer's instructions . . . . . . . . . . . . . . . . . . 132

3.89 Paintwork, trims, side windows and wiper blades: checking cleanliness . . . . . . . . . . . . . . 132
3.90 Body: checking vehicle paintwork for damage and corrosion from below and with bonnet, rear
lid and doors open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.91 Vehicles parked outdoors: locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.92 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.93 Stock vehicles: observing measures specified in Maintenance table for stock vehicles (see
“Before handing vehicle over to customer”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.94 Accessories: installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.95 Protective display films: removing if present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.96 “TQS – Documentation of the vehicle care” checklist: checking that list is present . . . . . . 134
3.97 “Stock vehicle maintenance” checklist: signing and placing in vehicle wallet . . . . . . . . . . 134
3.98 Cleaning and care: checking that required measures have been carried out on time . . . . 134
3.99 Stock vehicle care management: deciding and recording date of next check . . . . . . . . . . 134
3.100 Rear final drive: changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.101 Rear final drive: changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.102 Display instruments: setting time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.103 Manual gearbox/automatic gearbox: selecting 1st gear/park . . . . . . . . . . . . . . . . . . . . . . . . 135
3.104 Automatic gearbox (multitronic): changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.105 Automatic gearbox (tiptronic): changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
© satelettronica
3.106 Dual clutch gearbox (S tronic): changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.107 Dual clutch gearbox (S tronic): changing ATF and renewing exchangeable ATF filter . . . . 135
3.108 Interior mirror: calibrating compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.109 Poly V-belt for supercharger with charge air coolers: renewing . . . . . . . . . . . . . . . . . . . . . . 136
3.110 Poly V-belt for ancillaries, belt tensioner, idler rollers and pulley for coolant pump:
renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.111 Poly V-belt for ancillaries: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.112 Poly V-belt for ancillaries and pulleys for coolant pump and power steering pump:
renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.113 Instrument cluster: resetting driver information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.114 Toothed belt for camshaft drive: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.115 Toothed belt for camshaft drive, and drive sprockets for camshaft, crankshaft and high-
pressure pump: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.116 Toothed belt for camshaft drive and tensioning roller: renewing . . . . . . . . . . . . . . . . . . . . 137
3.117 Poly V-belt for ancillaries and pulley for power steering pump: renewing . . . . . . . . . . . . . . 137
4 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.1 Petrol engines: performing exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.2 Diesel engines: performing exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Contents iii
© satelettronica
iv Contents
1 General information
(AIGG000992; Edition 12.2018)
Change history ⇒ page 1
Engine number ⇒ page 1
Vehicle identification number ⇒ page 4
Vehicle data sticker ⇒ page 4
Warnings for high-voltage vehicles ⇒ page 5
1.1 --- Change history ---

N Date Chapter Changes made
o.
1 15.05.20 Steering boots and inner hose clips: checking secure Chapter added for Chinese market
2 19 seating ⇒ page 60
1 03.05.20 Diagnostic work: performing ⇒ page 26 New chapter
1 18
Water drains - sliding panoramic sunroof: checking New chapter
⇒ page 67
© satelettronica
1 06.11.20 Various chapters on stock vehicle management Chapter modified
0 17
Note
For greater clarity, only the last three updates to the document
are listed.
1.2 Engine number
Note
The engine number consists of the engine code letters (3 or 4

characters) and the serial number.
4-cyl. petrol engine 1.8/2.0 TFSI/2.0 TFSI hybrid ⇒ page 2

6-cyl. petrol engine 2.5 FSI/2.8 FSI ⇒ page 2
6-cyl. petrol engine 3.0 TFSI ⇒ page 3
4-cyl. diesel engine 2.0 TDI ⇒ page 3
1.2.1 4-cyl. petrol engine 1.8/2.0 TFSI/2.0

TFSI hybrid
DANGER
⇒ page 6 .
© satelettronica
cover (top).
1.2.2 6-cyl. petrol engine 2.5 FSI/2.8 FSI

cover (top).
1.2.3 6-cyl. petrol engine 3.0 TFSI

cover (top).

cover (top) -arrow A-.
© satelettronica
1.2.5 4-cyl. diesel engine 2.0 TDI

cover (top).

cover (top).
1.3 Vehicle identification number

Depending on the equipment and country-specific version, the
vehicle identification number is located:
♦ Optional: In the MMI under »Car systems«
♦ At the bottom left edge of the windscreen
♦ On the right side of the engine compartment under a cover
♦ On the bulkhead of the engine compartment
♦ On the vehicle data sticker ⇒ page 4
The vehicle identification number consists of the following:

WAU ZZZ 4G Z B A/N 000 234
Manufacturer Filler charac‐ Type Filler charac‐ Model year Production lo‐ Serial number
code ters ters cation
1.4 Vehicle data sticker
© satelettronica
The vehicle data sticker is located:
♦ In the Service Schedule or service wallet
♦ In the area of the spare wheel well under the floor covering
-arrow-
The vehicle data sticker contains the following vehicle data:

1 - Vehicle identification number
2 - Vehicle model, manufacturer's code, engine type and power
output, production month and year
3 - Engine and gearbox code letters (not specified on some export
models)
4 - Paint number, interior equipment number
5 - Numbers for optional extras
6 - Fuel consumption: urban, extra urban, combined, CO2 (not
specified on some export models)
1.5 Warnings for high-voltage vehicles

Overview of high-voltage components and wires ⇒ page 5
Working in the vicinity of high-voltage components ⇒ page 6
Handling high-voltage wires ⇒ page 7
Work that must be performed with the ignition switched on
⇒ page 8
Work that must be performed with the ignition switched off
⇒ page 8
1.5.1 Overview of high-voltage components

and wires
The high-voltage system of the Audi A6 is comprised of the fol‐
lowing components:
1 - Combustion engine
2 - High-voltage wire for elec‐
trical air conditioner compres‐
sor - P3-
© satelettronica
3 - Power and control electron‐
ics for electric drive - JX1-
❑ Electric drive control
unit - J841-
❑ Voltage converter - A19-
❑ DC/AC converter for
drive motor - A37-
connections
4 - Drive battery - A2-
❑ Maintenance connector
for high-voltage system
- TW-
❑ Red warning label and
battery warning label
connections
5 - Air duct for cooling drive
battery - A2-
6 - Cooling module for drive
battery - A2-
7 - High-voltage system wiring
junction - TV1-
8 - Air supply duct for cooling
drive battery - A2-
9 - High-voltage wire for hybrid
battery - PX1-
❑ High-voltage wiring harness for high-voltage battery, positive terminal - P1- (red coloured ring)
❑ High-voltage wiring harness for hybrid battery, negative terminal - P2- (brown coloured ring)
❑ Coding of high-voltage connections to drive battery - A2-
10 - High-voltage wiring harness for drive motor - PX2-

❑ High-voltage wire 1 for drive motor - P4- (U) blue coloured ring/coding lug on right side
❑ High-voltage wire 1 for drive motor - P5- (V) green coloured ring/coding lug on left side
❑ High-voltage wire 1 for drive motor - P6- (W) violet coloured ring/two coding lugs
❑ Coding of high-voltage connections to electric drive motor - V141-
11 - Electric drive motor - V141-
❑ Coded high-voltage connections
12 - Electrical air conditioner compressor - V470-
❑ Coding of high-voltage connection: red coloured ring
1.5.2 Working in the vicinity of high-voltage

components
DANGER
© satelettronica
Observe the following when working in the vicinity of high-volt‐
age components or wiring:
♦ It is not permitted to use cutting or forming tools, other sharp-
edged tools or heat sources such as welding, brazing, sol‐
dering, hot air or thermal bonding equipment.
♦ Before starting work, visually inspect the high-voltage com‐
ponents in the areas involved.
♦ Before working in the engine compartment, visually inspect
the power and control electronics for electric drive - JX1- ,
electric drive motor - V141- , air conditioner compressor -
V470- and high-voltage wiring.
♦ Before working on the vehicle underbody, visually inspect
the high-voltage wiring and covers.
♦ Before working on the rear section of the vehicle, visually
inspect the high-voltage wiring and the electronics box with
the maintenance connector for high-voltage system - TW- .
♦ Visually inspect all potential equalisation lines.
Check the following when making the visual inspection:
♦ There must be no external damage on any component.
♦ The insulation of the high-voltage wiring and potential equal‐
isation lines must not be damaged.
♦ There must be no unusual deformation of the high-voltage
wiring.
♦ All high-voltage components must be identified by a red
warning sticker.
Note

personnel .
1.5.3 Handling high-voltage wires

DANGER
Working on vehicles with high-voltage wiring:
• Do not support yourself or tools on high-voltage wiring or
associated components --> this can damage the insulation.
© satelettronica
• High-voltage wiring must not be excessively bent or kinked
--> this can damage the insulation.
• The round high-voltage connectors are colour-coded with an
external coloured ring and are provided with mechanical
coding or guide lugs. It is important to observe this coding
when joining up the round high-voltage connectors; other‐
wise the connectors can be damaged.
Note

personnel .

ignition switched on
DANGER
When working on a vehicle with the ignition switched on or while
the drive system is active, the engine can start unexpectedly
and exhaust fumes can cause a health hazard in closed rooms.
Moving parts can trap or draw in parts of the body and/or cloth‐
ing (safety hazard).
Before switching on the ignition, perform the following steps:
♦ Move selector lever to position P
♦ Activate parking brake
♦ Switch off ignition
♦ Open bonnet
♦ Connect battery charger (e.g. battery charger - VAS
5095A- ) to jump-start connections of 12 V electrical system
♦ Switching on ignition
© satelettronica
Note

personnel .

ignition switched off
WARNING
Safety hazard: the engine can start unexpectedly.
Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.
Note

personnel .
2 Preparations
Vehicle: raising ⇒ page 9
Engine cover panel: removing and installing ⇒ page 11
Noise insulation: removing and installing ⇒ page 15
Window regulators: activating automatic open/close function
⇒ page 17
Vehicle diagnostic tester: connecting ⇒ page 17
2.1 Vehicle: raising

CAUTION
Risk of damage to vehicle due to incorrect use of lifting platform.
♦ Do not exceed the permissible lifting capacity of the lifting
platform.
♦ The vehicle should be lifted only at the points shown in the
illustration.
♦ Position support plates so that they are aligned centrally be‐
© satelettronica
low the lifting points.
♦ Ensure sufficient clearance between low-mounted vehicle
components and the lifting platform.
Procedure:
– For vehicles with adaptive air suspension: Activate jacking
mode before lifting vehicle ⇒ page 10 .
– Applies to RS models: Pull side member extension covers
downwards -arrow- and remove.
2. Preparations 9
– Front: Position support plates of lifting platform under plastic

– Rear: Position support plates of lifting platform under plastic

© satelettronica
Note
The location of the lifting points is indicated by markings stamped

on the side member trim.
2.1.1 Activating jacking mode

WARNING
Risk of injury as engine of high-voltage vehicle can start unex‐
pectedly!
on ⇒ page 8 .
Procedure:
♦ adaptive air suspension
♦ SETUP
10 2. Preparations
– Use MMI rotary pushbutton to select “Jacking mode” and set

to “on”.
Note
♦ Jacking mode is switched off again automatically once a

speed higher than 15 km/h is reached.
♦ If jacking mode is activated for a longer period of time, the
pressure in the suspension struts may dissipate, thereby low‐
ering the vehicle. If necessary, start the engine briefly to
reactivate jacking mode.
2.2 Engine cover panel: removing and in‐

stalling
4-cyl. petrol engine 1.8 TFSI/2.0 TFSI (version 1) ⇒ page 11
4-cyl. petrol engine 2.0 TFSI/2.0 TFSI hybrid (version 2)
⇒ page 12
6-cyl. petrol engine 2.5 FSI/2.8 FSI/3.0 TFSI (version 1)
⇒ page 12
© satelettronica
6-cyl. petrol engine 2.5 FSI/2.8 FSI (version 2) ⇒ page 13
6-cyl. petrol engine 3.0 TFSI (version 2) ⇒ page 13
6-cyl. diesel engine 3.0 TDI (version 1) ⇒ page 14
2.2.1 4-cyl. petrol engine 1.8 TFSI/2.0 TFSI

(version 1)
another -arrows-.
Note
4-cylinder 2.0 TFSI petrol engine ⇒ page 12 .
2. Preparations 11
2.2.2 4-cyl. petrol engine 2.0 TFSI/2.0 TFSI

hybrid (version 2)
another -arrows-.
Note
2.2.3 6-cyl. petrol engine 2.5 FSI/2.8 FSI/3.0

TFSI (version 1)
© satelettronica
another -arrows-.
Note
the 6-cylinder 2.5 FSI/2.8 FSI petrol engine ⇒ page 13 .
the 6-cylinder 3.0 TFSI petrol engine ⇒ page 13 .
12 2. Preparations
2.2.4 6-cyl. petrol engine 2.5 FSI/2.8 FSI (ver‐

sion 2)
– Carefully pull engine cover panels off retaining pins one after
another -arrows-.
Note
6-cylinder 2.5 FSI/2.8 FSI petrol engine ⇒ page 12 .
© satelettronica
2.2.5 6-cyl. petrol engine 3.0 TFSI (version 2)
– Carefully pull engine cover panels -1- and -2- off retaining pins
one after another.
Note
2. Preparations 13

– Carefully pull engine cover panel off rear retaining pins -1-.
– Carefully pull engine cover panel off front retaining pins -2-.

another -arrows-.
© satelettronica
2.2.8 6-cyl. diesel engine 3.0 TDI (version 1)

another -arrows-.
Note
6-cylinder 3.0 TDI diesel engine ⇒ page 15 .
14 2. Preparations

another -arrows-.
Note

© satelettronica
another -arrows-.
Note
2.3 Noise insulation: removing and installing

DANGER
⇒ page 7 .
Noise insulation (front) ⇒ page 15

Noise insulation (rear) ⇒ page 16
2.3.1 Noise insulation (front)

Bolt M8 -2- 20
Bolt M6 -3- 3.5
2. Preparations 15

– Pull noise insulation -5- towards rear out of bottom section of
bumper cover and detach.
Installation is carried out in reverse sequence. Note tightening
torques (see table of tightening torques for installation
⇒ page 15 ).
Note
♦ Ensure that you feel the quick-release fasteners engage when

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

♦ Torque screwdriver - V.A.G 1624- , measuring range 1 to 5
Nm
Bolt M6 -1- 3.6
16 2. Preparations

– Remove bolts -1- at connection to noise insulation (front).
– Pull noise insulation -3- towards rear out of noise insulation
(front) and detach.
Installation is carried out in reverse sequence. Note tightening
torques (see table of tightening torques for installation
⇒ page 16 ).
Note
Ensure that you feel the quick-release fasteners engage when

installing.
2.4 Window regulators: activating automatic

open/close function
© satelettronica
WARNING
pectedly!
on ⇒ page 8 .
If the vehicle battery was disconnected, the automatic open/close

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

WARNING
pectedly!
on ⇒ page 8 .
2. Preparations 17
♦ Diagnosis system - VAS 6160 A-
♦ Remote diagnosis head - VAS 5054A-

♦ Or: diagnosis interface - VAS 5055-
Procedure:
– Plug connector for remote diagnosis head - VAS 5054A- into
diagnostic connection in vehicle.
© satelettronica
– Switch on diagnostic system - VAS 6160 A- .
– Follow the menu on the screen to start the desired functions.
18 2. Preparations
© satelettronica
3. Maintenance 19
3 Maintenance
Rear final drive: changing gear oil ⇒ page 134
Rear final drive: changing ATF ⇒ page 134
Display instruments: setting time and date ⇒ page 135
Automatic gearbox (multitronic): changing ATF ⇒ page 135
Automatic gearbox (tiptronic): changing ATF ⇒ page 135
Battery: determining and recording state of charge (SOC)
⇒ page 37
Battery: checking electrolyte level ⇒ page 31
Battery: connecting stationary battery charging unit (min. 30A,
charging voltage max. 14.8 V on IV characteristic curve)
⇒ page 34
Battery: reading out status ⇒ page 29
Axles (front and rear): checking components for play, secure at‐
tachment and damage, and checking protective boots
⇒ page 55
© satelettronica
Passenger airbag: checking key switch on/off and setting to "on"
⇒ page 78
Tyres (except spare wheel): checking tyre pressures and adjust‐
ing to 3.5 bar if necessary ⇒ page 51
Tyres: checking tyre pressures and adjusting if necessary
⇒ page 49
Tyres: checking condition and wear pattern, and checking and
recording tread depth ⇒ page 48
Service wallet: affixing vehicle data sticker ⇒ page 78
Owner's literature: checking that all documents are present
⇒ page 78
Brake fluid (vehicles older than 12 months): changing
⇒ page 45
Brake system: checking condition of brake hoses, and checking
that caps are fitted on bleeder screws ⇒ page 45
Brake pads: checking thickness ⇒ page 46
Brake fluid (vehicles older than 12 months): changing
⇒ page 45
Brake fluid: checking fluid level ⇒ page 45
Brake fluid: changing ⇒ page 40
Brake discs: checking for surface rust and operating brakes to
clean if necessary ⇒ page 47
“TQS – Documentation of the vehicle care” checklist: checking
that list is present ⇒ page 134
“Stock vehicle maintenance” checklist: signing and placing in ve‐
hicle wallet ⇒ page 134
Roof insert - panorama sunroof: checking, cleaning and lubricat‐
ing ⇒ page 63
Roof insert - sliding/tilting sunroof: cleaning and lubricating
⇒ page 61
Data sheet for Radio Equipment Directive: printing and placing in
glove compartment ⇒ page 40
20 3. Maintenance
Diagnostic work: performing ⇒ page 26

Diesel particulate filter: reading out ash deposit volume
⇒ page 23
Protective display films: removing if present ⇒ page 134
Dual clutch gearbox (S tronic): changing ATF ⇒ page 135
Dual clutch gearbox (S tronic): changing ATF and renewing ex‐
changeable ATF filter ⇒ page 135
ERA-GLONASS: checking emergency call function ⇒ page 24
Event memory: reading out ⇒ page 25
Headlights and reversing lights, side lights, number plate lights,
turn signals, hazard warning lights: checking operation
⇒ page 75
Vehicle: cleaning interior and exterior ⇒ page 28
Connecting vehicle diagnostic tester and sending diagnostic log
⇒ page 30
Mirror hanger indicating defective battery: renewing battery on
affected vehicles ⇒ page 40
© satelettronica
Vehicle exterior: checking unprotected areas for dirt, and cleaning
if necessary ⇒ page 131
Vehicle exterior: removing protective film, if present
⇒ page 131
Vehicle key(s): checking operation and recording number of keys
given to customer ⇒ page 81
Vehicle interior and exterior: checking for and documenting any
damage ⇒ page 80
Vehicle interior: checking that it is clean and cleaning if necessary
⇒ page 80
Vehicle interior: removing any objects other than those protecting
interior surfaces ⇒ page 80
Vehicle interior: removing protective covers for seats and carpet
⇒ page 79
Vehicle (from below): checking for damage ⇒ page 60
Vehicle key(s), wheel covers and owner's literature: checking
availability and recording number present ⇒ page 81
Vehicle key: removing from ignition lock ⇒ page 81
Vehicle doors: removing edge protection ⇒ page 131
Vehicle cover: checking position and correcting if necessary
⇒ page 132
Vehicle cover: removing according to manufacturer's instructions
⇒ page 132
Cleaning and care: checking that required measures have been
carried out on time ⇒ page 134
Bonnet arrester hook: lubricating ⇒ page 69
Suspension struts on front and rear axle: removing locking ele‐
ments and correctly fitting bump stops ⇒ page 53
Luggage compartment cover and sun blind: checking that they
are rolled up and rolling up if necessary ⇒ page 82
Glove box light, interior lighting and reading light: checking oper‐
ation ⇒ page 77
3. Maintenance 21
Interior mirror: calibrating compass ⇒ page 135

Vehicles parked outdoors: locking ⇒ page 132
Body: checking vehicle paintwork for damage and corrosion from
below and with bonnet, rear lid and doors open ⇒ page 132
Poly V-belt for supercharger with charge air coolers: renewing
⇒ page 136
Poly V-belt for ancillaries, belt tensioner, idler rollers and pulley
for coolant pump: renewing ⇒ page 136
Poly V-belts for ancillaries and for pulleys for coolant pump and
power steering pump: renewing ⇒ page 136
Poly V-belt for ancillaries and pulley for power steering pump: re‐
newing ⇒ page 137
Poly V-belt for ancillaries: renewing ⇒ page 136
Poly V-belts for ancillaries: checking ⇒ page 96
Luggage compartment lighting: checking operation ⇒ page 76
Luggage compartment: removing protective film and felt pieces
⇒ page 77
© satelettronica
Instrument cluster: resetting driver information system
⇒ page 136
Instrument cluster: checking warning lamps ⇒ page 80
Fuel tank: adding fuel additive ⇒ page 126
Fuel filter: draining ⇒ page 122
Fuel filter: renewing ⇒ page 123
Coolant level: checking (coolant level must reach at least top
marking on coolant expansion tank) ⇒ page 107
Paintwork, trims, side windows and wiper blades: checking clean‐
liness ⇒ page 132
Steering boots and inner hose clips: checking secure seating
⇒ page 60
Air cleaner: renewing filter element and cleaning housing
⇒ page 110
Engine, gearbox, final drive and steering: checking for leaks and
damage ⇒ page 59
Engine oil: draining ⇒ page 82
Engine oil: extracting ⇒ page 84
Engine oil: renewing oil filter ⇒ page 85
Engine oil: filling up ⇒ page 93
Engine oil: checking oil level and correcting if necessary
⇒ page 94
Parking brake: releasing ⇒ page 48
Road test ⇒ page 132
Wheel bolts: tightening to specified torque ⇒ page 52
Reducing agent (AdBlue®): filling up tank completely
⇒ page 127
Tyre Pressure Loss Indicator: storing changed tyre pressures
⇒ page 51
Tyre repair kit: checking that set is complete, and checking and
recording expiry date ⇒ page 51
22 3. Maintenance
Manual gearbox/automatic gearbox: selecting 1st gear/park

⇒ page 135
Rear spoiler hinges: lubricating ⇒ page 68
Windscreen washer system: checking spray pattern and adjust‐
ing if necessary ⇒ page 70
Wiper blades: checking for damage ⇒ page 72
Headlights: checking for correct adjustment ⇒ page 73
Headlight washer system: checking operation ⇒ page 73
Service interval display: resetting service event ⇒ page 26
Service Schedule: entering Delivery Inspection ⇒ page 79
Seat belts: checking fixing device for latch plate, and checking
locking action of automatic belt retractor ⇒ page 79
Horn: checking operation ⇒ page 77
Sun visors: checking that they are folded up and folding up if nec‐
essary ⇒ page 82
Stock vehicles: observing measures specified in Maintenance ta‐
ble for stock vehicles (see “Before handing vehicle over to cus‐
© satelettronica
tomer”) ⇒ page 133
Dust and pollen filter: renewing ⇒ page 120
Dust and pollen filter: renewing preliminary filter ⇒ page 120
Stock vehicle care management: deciding and recording date of
next check ⇒ page 134
Transport mode: checking activation and activating if necessary
⇒ page 27
Transport mode: deactivating ⇒ page 27
Door hinges with separate door arrester: cleaning and lubricating
⇒ page 68
Underbody: checking trim, wheel housing liners, side members
and pipes/wiring for damage, and checking that they are properly
secured ⇒ page 60
First-aid kit: checking and recording expiry date ⇒ page 81
Shipping mode: deactivating ⇒ page 28
Warning triangle: checking availability ⇒ page 80
Water drains - sliding panoramic sunroof: checking ⇒ page 67
Plenum chamber and water drains: checking for dirt
⇒ page 118
Toothed belt for camshaft drive, and drive sprockets for camshaft,
crankshaft and high-pressure pump: renewing ⇒ page 137
Toothed belt for camshaft drive and tensioning roller: renewing
⇒ page 137
Toothed belt for camshaft drive: renewing ⇒ page 136
Accessories: installing ⇒ page 133
Spark plugs: renewing ⇒ page 97
3.1 Diesel particulate filter: reading out ash

deposit volume
3. Maintenance 23
Engine Engine code Measured value designa‐ Maximum value for ash
tion for diagnostic tester deposit
4-cyl. diesel engine 2.0 All Particulate filter, oil ash de‐ Oil ash deposit volume:
6-cyl. diesel engine 3.0 CVUA, CVUB Particulate filter, oil ash de‐ Oil ash deposit volume:
CDUC, CDUD, CLAA, Particulate filter, oil ash de‐ Oil ash deposit volume:
CLAB posit volume 370 ml
CRTD, CRTE, CRTF, Particulate filter, oil ash de‐ Oil ash deposit volume:
CTCB, CTCC, CZVA, posit volume 380 ml
CKVB, CKVC
CGQB Particulate filter, oil ash de‐ Oil ash deposit volume:
posit volume 420 ml
Procedure:
© satelettronica
v and press Apply .

– Switch to “Control units” tab.
– Select control unit “01 — Engine electronics” and carry out
following functions via right mouse button:
♦ Identify control unit
♦ Guided Functions
♦ 01 - Read measured values
– Select desired measured value (see table of test values and
procedure guidelines ⇒ page 23 ) by entering v and confirm‐
ing with OK .
– Evaluate measured value and follow further instructions on
screen.
– Perform the following measures according to the measured
value:
Result: Measure:
Measured value < critical Vehicle can be driven for a further 30,000 km (19,000 miles).
value
Measured value ≥ critical Renew diesel particulate filter and reset measured value to zero ⇒ Engine; Rep.
value gr. 26 ; Emission control system; Removing and installing particulate filter .
3.2 ERA-GLONASS: checking emergency

call function
Requirements:
• Applies to: vehicles with ERA-GLONASS emergency call func‐
tion (depends on market).
• The services can only used if there is sufficient mobile network
coverage.
• Transport mode deactivated.
24 3. Maintenance
• The system is designed to allow up to 15 minutes between

deactivating the transport mode and checking the emergency
call function.
• Ensure adequate mobile reception; move vehicle outside if
necessary.
Procedure:
– Check if LED -2- is lit in green.
– Run ERA-GLONASS test mode:
– Use a pointed object to press and hold test button (behind
cover -1- in roof module, in corner next to emergency call but‐
ton) for three seconds and follow the voice prompts to perform
the test.
– Once the test is completed, press the emergency call button
to initiate a test call.
Note
© satelettronica
♦ If the LED lights up in red or if it is not possible to activate the
test mode, connect vehicle diagnostic tester ⇒ page 17 and
perform Guided Fault Finding “75 - Emergency Call Module,
functions, Commissioning ERA-GLONASS”.
♦ Due to applicable legislation in certain countries, the vehicle
must not be delivered unless the ERA-GLONASS emergency
call function (red LED) has been successfully activated.
3.3 Event memory: reading out

WARNING
pectedly!
on ⇒ page 8 .
Procedure:
press Apply .
The control unit is then identified, and the event memory is inter‐
rogated. Observe notes and test conditions.
– Switch to “Control units” tab and call up “Event memory list”
for an overview of all entries stored in event memory.
– Select “Test plan” tab and carry out test plans according to
instructions.
3. Maintenance 25
3.4 Service interval display: resetting serv‐

ice event
WARNING
pectedly!
on ⇒ page 8 .
Procedure:
v and press Apply .
– Switch to “Special functions” tab.
© satelettronica
– Reset service event via ODIS (select corresponding service
event).
Note
The distance until the next oil service is calculated on the basis
of the customer’s driving profile. When the service interval display
is reset, the distance until the next oil service is recalculated on
the basis of this driving profile. Frequent cold starts or short jour‐
neys make high demands on the engine oil. This can cause the
information about the distance until the next oil service to vary,
depending on the driving profile.
3.5 Diagnostic work: performing

Procedure:
– Connect vehicle diagnostic tester. ⇒ page 17
– Untick Working with Guided Fault Finding .
– Switch to Special functions tab and select following pro‐
gram:
♦ Predelivery inspection total
– Continue to follow instructions on screen and complete the
process.
– Switch to the Control units tab, press the Guided Fault
Finding button and launch Guided Fault Finding as far as the
test plan.
– Carry out test programs on the events read out of the event
memory.
26 3. Maintenance
3.6 Transport mode: deactivating

WARNING
pectedly!
on ⇒ page 8 .
Procedure:
v and press Apply .

© satelettronica
Note

start.
3.7 Transport mode: checking activation

and activating if necessary
Checking transport mode ⇒ page 27
Activating transport mode ⇒ page 27
3.7.1 Checking transport mode

Procedure:
– Check whether »Transport mode on« is shown in instrument
cluster.
– If necessary, activate transport mode ⇒ page 27 .
3.7.2 Activating transport mode

Procedure:
v and press Apply .
3. Maintenance 27

Note

start.
3.8 Vehicle: cleaning interior and exterior

Procedure:
– Wash vehicle exterior.
– Clean vehicle interior.
3.9 Shipping mode: deactivating
© satelettronica
WARNING
pectedly!
on ⇒ page 8 .
Procedure:
v and press Apply .

♦ 34 - Activating / deactivating shipping mode
Note
Deactivating shipping mode may cause the height of the vehicle

to drop.
28 3. Maintenance
3.10 Battery: reading out status

WARNING
pectedly!
on ⇒ page 8 .
Note
The test program Predelivery inspection total may also be

used for the Delivery Inspection.
Battery -A- ⇒ page 29

Second battery -A1- ⇒ page 30
3.10.1 Battery -A-
© satelettronica
Procedure:
press Apply .
♦ A - Battery, Testing
– Send off diagnostic log online.
Note


er:
“Battery is no longer of the same Renew battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
quality as when shipped” installing battery .
3. Maintenance 29
3.10.2 Second battery -A1-

Only applies to hybrid vehicles
Procedure:
press Apply .
♦ A - second battery -A1-, check
er:
© satelettronica
“Battery is no longer of the same Renew battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
quality as when shipped” installing battery .
Note
A working network connection is necessary to send the diagnostic

log file online.
3.11 Connecting vehicle diagnostic tester

and sending diagnostic log
– Carry out test programs according to test plan.
– Send off diagnostic log online.
Note
♦ The event memory is erased automatically when you exit Gui‐

ded Fault Finding.
♦ The diagnostic log is sent automatically when you exit Guided
Fault Finding.
♦ If no network connection is available, the diagnostic log will be
cached for a few days. Complete the online data transfer as
soon as possible.
30 3. Maintenance
3.12 Battery: checking electrolyte level
Note
Batteries must not be opened.
Battery without magic eye ⇒ page 31

Battery with magic eye ⇒ page 32
3.12.1 Battery without magic eye

Nm
© satelettronica
Nm

Removal steps:
3. Maintenance 31

Procedure:
– Check electrolyte level of all battery cells using markings on
housing.
– If electrolyte level of one or more battery cells is below MIN
marking: Renew battery.
© satelettronica
Note
♦ A bright hand-held light helps to better see the MIN and MAX
markings on the housing.
♦ If battery is difficult to see: Use a small mirror to check the
electrolyte level (shine a bright hand-held light at a right angle
onto the battery cells).
3.12.2 Battery with magic eye

WARNING
Risk of explosion if magic eye is colourless or light yellow!
♦ Do not attempt to jump-start vehicle.
♦ Do not check or charge battery.
♦ Renew battery.

Nm
Nm
32 3. Maintenance
Removal steps:
Procedure:
– Before checking electrolyte level: Tap magic eye -arrow- care‐

fully with handle of a screwdriver.
© satelettronica
– Read off battery electrolyte level according to colour display.
Two different results are possible:
Colour of magic eye: Measure:

Black or green Electrolyte level OK: No further measures necessary
Colourless or light yellow Electrolyte level too low: Battery must be renewed

Note
♦ The magic eye is also referred to as an ALI (acid level indica‐

tor).
♦ The magic eye is only for use in determining the electrolyte
level.
♦ During battery charging or vehicle operation, air bubbles can
form underneath the magic eye which could falsify the colour
display. Tap magic eye lightly to release any bubbles.
3. Maintenance 33
3.13 Battery: connecting stationary battery

charging unit (min. 30A, charging volt‐
age max. 14.8 V on IV characteristic
curve)
All models except A7 ⇒ page 34
A7 ⇒ page 36
3.13.1 All models except A7

DANGER
⇒ page 6 .
WARNING
© satelettronica
rectly.

♦ Torque wrench - V.A.G. 1783- , measuring range 2 to 10 Nm

Nm
Nm
Tightening torques table:
Jump-start connection 9
Cap nut 9
34 3. Maintenance

Requirements:
Removal steps:
– Take out spare wheel (where applicable).
– Applies to vehicles with air suspension: Detach pressure valve
-illustration- from tool kit box (lines remain connected).
© satelettronica
– Unscrew cap nut -illustration-.
– Screw in jump-start connection - 4F0 972 501- and tighten to
specified torque (see table of tightening torques for installation
⇒ page 34 ).
– Applies to vehicles without towing bracket: Remove rubber

grommet -illustration- from spare wheel well and store it in
glove box.
– Applies to vehicles with towing bracket: Loosen rubber grom‐
met -illustration- in spare wheel well along with wiring harness
and pull it slightly inwards into vehicle.

– Disconnect charger clamps from battery charger - VAS 5906- .
– Working from above, thread connector end of cable for charg‐
er clamps through hole in spare wheel well and down to
underside of vehicle.
– Open battery terminal cover (+).
3. Maintenance 35
– First connect charger clamp (+) to positive battery terminal

-A-.
– Then connect charger clamp (-) to earth point (-) -B- on body.
– Arrange wiring of battery charger - VAS 5906- neatly in spare
wheel well.
– Place vehicle tool kit box in spare wheel well.
– Applies to vehicles with air suspension: Attach pressure valve
with lines connected.
– Fit luggage compartment floor cover.
– Under vehicle: Connect cable for charger clamps to battery
charger - VAS 5906- .
needed.
© satelettronica
3.13.2 A7
WARNING
rectly.


Requirements:
Removal steps:
– Remove stopper from wheel housing on right side of vehicle
and store it in glove box.
36 3. Maintenance

– Guide plug of charging cable from above through wheel hous‐
ing -arrow- and out from underside of vehicle.
– Open cover for jump start connection (+) -3- in direction of

-arrow-.
– First connect charger clamp (+) to jump start connection (+)
-2-, and ensure that charger clamp does not make contact with
– Then connect charger clamp (-) to earth point (-) -1- on body,
and ensure that charger clamp does not make contact with
© satelettronica
front lid when it is closed.
– Arrange wiring of battery charger - VAS 5906- neatly in engine
compartment.
needed.

3.14 Battery: determining and recording state

of charge (SOC)
Vehicles with transport mode ON ⇒ page 37
Vehicles with transport mode OFF ⇒ page 38
3.14.1 Vehicles with transport mode ON

Procedure:
– Read off battery charge level on instrument cluster.
State of charge Measure:
(SOC):
“≥ 80% (12.5 V)” No further measures necessary.
“SOC < 80% (12.5 Charge battery ⇒ Rep. gr. 27 ; Battery;
V) and SOC ≥ 10% Charging battery .
(11.6 V)”
“< 10% (11.6 V)” Charge battery ⇒ Rep. gr. 27 ; Battery;
Charging battery , and attach mirror hanger
for “Battery defective”.
– Record charge level in maintenance table.
3. Maintenance 37
Note
If if is not possible to read off the state of charge in the instrument

cluster, measure the battery's no load voltage ⇒ page 39 .
3.14.2 Vehicles with transport mode OFF

♦ Battery tester - VAS 6161-
Removal steps:
Vehicles without high-voltage system:
– Take hold of grip to lift luggage compartment floor covering
and fold it towards front.
– If fitted, remove accumulator and place it to one side with lines
connected ⇒ Rep. gr. 43 ; Air suspension; Removing and
installing air supply unit .
– Take out tool kit.
© satelettronica
– Remove battery terminal covers.
Vehicles with high-voltage system:
– Remove second battery ⇒ Rep. gr. 27 ; Battery; Removing
and installing battery .
– Remove battery terminal cover.
Procedure:
– Switch on battery tester - VAS 6161- and select “QC check,
new vehicles”.
– Use battery tester - VAS 6161- to measure voltage between
battery clamps.
Battery Measure:
tester
shows:
“Battery No further measures necessary.
good”
“Charge Charge battery ⇒ Rep. gr. 27 ; Battery; Charging
fully now” battery .
“Battery Charge battery ⇒ Rep. gr. 27 ; Battery; Charging
Faulty” battery , and attach mirror hanger for “Battery de‐
fective”.
– Record charge level in maintenance table.
Note
♦ When using battery tester - VAS 6161- , ensure that the soft‐
ware is up to date.
♦ If if is not possible to measure the state of charge with battery
tester - VAS 6161- , measure the battery's no load voltage
⇒ page 39 .
38 3. Maintenance
3.14.3 Measuring no load voltage of battery

♦ Hand-held multimeter - V.A.G. 1526 C-
♦ Or: digital multimeter - V.A.G. 1715-
Requirements:
© satelettronica
• Battery must not be placed under load from connected elec‐
trical equipment for at least 2 hours before test.
• Battery must not have been charged for at least 2 hours before
test.
• Engine must remain off for at least 2 hours before test.
Removal steps:
Vehicles without high-voltage system:
– Take hold of grip to lift luggage compartment floor covering
and fold it towards front.
– If fitted, remove accumulator and place it to one side with lines
connected ⇒ Rep. gr. 43 ; Air suspension; Removing and
installing air supply unit .
– Take out tool kit.
– Remove battery terminal covers.
Vehicles with high-voltage system:
– Remove second battery ⇒ Rep. gr. 27 ; Battery; Removing
and installing battery .
– Remove battery terminal cover.
Procedure:
– Use hand-held multimeter - V.A.G. 1526 C- to measure volt‐
age between battery clamps -2- and -3-.
3. Maintenance 39
State of charge Measure:

(SOC):
“≥ 12.5 V” No further measures necessary.
“SOC < 12.5 V and Charge battery ⇒ Rep. gr. 27 ; Battery; Charging battery .
SOC ≥ 11.6 V”
“< 11.6 V” Charge battery ⇒ Rep. gr. 27 ; Battery; Charging battery , and attach mirror hanger
for “Battery defective”.
3.15 Mirror hanger indicating defective bat‐

tery: renewing battery on affected vehi‐
cles
Only for vehicles with mirror hanger for “Battery defective”.
Procedure:
– Wait until shortly before vehicle delivery, then renew battery
according to instructions in workshop manual ⇒ Rep. gr. 27 ;
Battery; Removing and installing battery .
© satelettronica
3.16 Data sheet for Radio Equipment Direc‐
tive: printing and placing in glove com‐
partment
As part of the European Union’s Radio Equipment Directive (RED
2014/53/EU), legislation requires that a data sheet be provided
containing information regarding which radio frequencies are
used.
The Radio Equipment Directive data sheet can be downloaded at
www.audi.com/generalinfo.
– Print out data sheet (same language as owner's literature) and

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

♦ The data sheet applies to all vehicles across Europe; it can
therefore be printed out in advance and kept at hand.
3.17 Brake fluid: changing

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

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

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

⇒ Total quantity, manual gearbox 1.15 ltr.
3. Maintenance 41
Step 1 - connecting brake filling and bleeding equipment:

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

equipment - VAS 5234- to extract brake fluid from reservoir
(with strainer installed) until fluid is level with bottom edge of
strainer. Make sure that no more fluid flows back into reservoir
from strainer after extracting fluid.
© satelettronica
– Screw adapter -1- onto brake fluid reservoir.
– Connect filling hose -2- included with brake filling and bleeding
equipment - VAS 5234- to adapter.
– Set pressure on brake filling and bleeding equipment -
VAS 5234- (see operating instructions).
Step 2 - bleeding and filling brake system:

If there are two bleeder screws on each brake caliper, first bleed
the inner, then the outer bleeder screw.
– Raise vehicle ⇒ page 9 .
Front axle:
42 3. Maintenance

screw(s).
– Fit bleeder hose -1- attached to collector container onto bleed‐

er screw from inside of rim.
– Open bleeder screw and allow brake fluid to discharge. Refer
to table for correct quantity of brake fluid to discharge
⇒ page 41 .
– If there are two bleeder screws on each brake caliper: Repeat
procedure with second bleeder screw.
© satelettronica
– Refit cap on bleeder screw(s).
Rear axle:

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

ratchet -2- and socket -3- and fit onto bleeder screw.
– Open bleeder screw with ratchet -2- and allow brake fluid to
discharge. Refer to table for correct quantity of brake fluid to
discharge ⇒ page 41 .
3. Maintenance 43
– If there are two bleeder screws on each brake caliper: Working

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

Only for vehicles with manual gearbox
– Remove components necessary for access; refer to ⇒ Manual
gearbox; Rep. gr. 30 ; Clutch mechanism; Bleeding clutch
mechanism .
– Fit bleeder hose attached to collector container -1- onto bleed‐
er screw of clutch slave cylinder.
– Open bleeder screw and allow correct amount of brake fluid
to flow out (see table of test values and procedure guidelines
⇒ page 41 ).
– Close bleeder screw and fit cap.
© satelettronica
Step 4 - final steps:
– Close filling lever of brake filling and bleeding equipment -
VAS 5234- .
– Detach filling hose from adapter.
– Unscrew adapter from brake fluid reservoir.
– Check brake fluid level and adjust if necessary (depending on
brake pad wear) ⇒ page 45 .
– Screw cap onto brake fluid reservoir.
– Operate clutch pedal several times.
– Check pedal pressure and free travel: No more than 1/3 of total
pedal travel.
– Make sure that the brakes work properly before the vehicle is
driven on the road.
– If free travel of brake pedal is greater than specified, or if brake
function is impaired: Check brake system for leaks and renew
brake fluid again.
Note
♦ The bleeder hose must fit tightly on the bleeder screw to pre‐
vent air from entering the brake system.
♦ In the case of certain wheel combinations, the wheels may
have to be removed.
♦ With the aid of the tool set for brake bleeding - VAS 6564- ,
the rear brakes or, depending on version, the front and rear
brakes can be bled without having to remove the wheels.
♦ Use genuine Audi brake fluid; see Electronic parts catalogue
(ETKA).
♦ Do not reuse brake fluid.
disposal of brake fluid.
44 3. Maintenance
3.18 Brake fluid (vehicles older than 12

months): changing
Only applies to vehicles older than 12 months (from date of man‐
ufacture).
Procedure:
– Change brake fluid ⇒ page 40 .
3.19 Brake fluid: checking fluid level

Type of service: Fluid level specification:
Delivery Inspection Fluid level must be at MAX marking.
Brake fluid change Fluid level must be between MAX marking and MIN marking according to wear
level of brake pads.
Checking the brake system for leaks is a repair measure and
© satelettronica
Procedure:
– Evaluate brake fluid level according to markings -arrows- on
brake fluid reservoir.
– Perform the following measures according to the results of the

check:

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

brake hoses, and checking that caps are
fitted on bleeder screws
Requirements:
• Brake hoses must not touch any components when steering
is on full lock.
• Brake hoses must not be twisted.
3. Maintenance 45
Procedure:
– Check that all brake hoses are secured properly; when doing
so, ensure that the conditions listed are met:
– Check all brake hoses for abrasion, porosity, blistering and
cracking.
– Check that brake connections are seated correctly, and check
for corrosion and leaks.
– If faults are found on brake hoses: Repair/renew relevant com‐
ponent.
– Check that caps are fitted and secured on bleeder screws of
all brake calipers.
– Renew any missing caps.
3.21 Brake pads: checking thickness

♦ Test pin - T40139- / test pin - T40139A- : Use the side with the
thin probe (brake symbol) to measure brake pad thickness.
© satelettronica
Axle Brake pad wear limit including backplate and damper plate
[mm]
Front axle: 9
Rear axle: 8
Check only the thickness of the outer brake pads.

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

and operating brakes to clean if neces‐
sary
Checking brake discs ⇒ page 47
Operating brakes to clean brake discs ⇒ page 47
3.22.1 Checking brake discs

Procedure:
– Check outside of all brake discs for surface rust.
– If necessary, operate brakes to clean brake discs
⇒ page 47 .
Note
The brake discs can be damaged irreparably if surface rust is not

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

Procedure:
– Accelerate vehicle to 40 km/h, then brake gently to 10 km/h
(do this five times).
– Accelerate vehicle to 40 km/h, then brake sharply to a stand‐
still (do this five times).
Note
The wheels should not spin or lock during acceleration and brak‐
ing.
3. Maintenance 47
3.23 Parking brake: releasing

Mechanical parking brake ⇒ page 48
Electromechanical parking brake ⇒ page 48
3.23.1 Mechanical parking brake

Procedure:
– Release parking brake.
3.23.2 Electromechanical parking brake

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

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

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

charged separately.
Step 1 - checking condition:
– Check for and remove any foreign bodies in tyre tread.
– Check all tyres for following types of damages:
♦ Cuts, cracks, tears
♦ Scuffing or flattened areas on tyre tread
♦ Porous sidewalls
♦ Blisters on sidewalls
– If damage is found: Renew tyres.
Step 2 - checking tyre wear pattern:
– Check tyre wear pattern of front wheels; check for the follow‐
ing:
♦ Feathering on tread indicating possible incorrect toe setting
♦ One-sided tread wear indicating possible incorrect camber
© satelettronica
– If the above types of wear are found: Check wheel alignment
to determine the cause.
Step 3 - checking tread depth:
– Measure tread depth on all tyres (including spare tyre) at sev‐
eral points using test pin - T40139- . Uneven tread depth
indicates damage.
– Record average measurement for each tyre in Maintenance
table.
– If minimum tread depth has been reached (as specified for
your country; see table of test values and procedure guidelines
⇒ page 48 ): Renew tyre.
Note
Vehicles with four-wheel drive must be fitted with tyres with the
same tread pattern. Otherwise the centre differential may be
damaged.
3.25 Tyres: checking tyre pressures and ad‐

justing if necessary
Note
3. Maintenance 49
Front and rear axles ⇒ page 50

Spare wheel and temporary spare wheel ⇒ page 50
3.25.1 Front and rear axle

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

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

kit supplied; see Maintenance table.
50 3. Maintenance
3.26 Tyres (except spare wheel): checking

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

changed tyre pressures
WARNING
© satelettronica
pectedly!
on ⇒ page 8 .
The Tyre Pressure Loss Indicator must be initialised at every in‐

spection (after the tyre pressures have been checked or
changed).
Requirements:
• The inflation pressures of all tyres must be adjusted to the
correct values before the pressures are stored.
Procedure:
♦ Tyre pressure monitoring
♦ Store tyre pressures
– Use MMI rotary pushbutton to select option to store tyre pres‐
sures.
3.28 Tyre repair kit: checking that set is com‐

plete, and checking and recording expi‐
ry date
The tyre repair kit is located under the luggage compartment floor.
Procedure:
– Check that the following components of the tyre repair kit are
present:
♦ Compressor
3. Maintenance 51
♦ Tyre filler bottle incl. filler hose

– Take out the bottle and check the expiry date (printed on bottle
-arrow-).
– If expiry date has been exceeded or if bottle has already been
used: Renew tyre filler bottle.
3.29 Wheel bolts: tightening to specified tor‐

que
© satelettronica
Nm
♦ Tool to secure wheel nut caps 8Z0.012.287
Fastener Tightening torque [Nm]
Wheel bolts 120
The adapter for loosening and tightening anti-theft wheel bolts is

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

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

mirror -arrow-.
♦ It is not necessary to remove the wheels to perform this oper‐
ation.
Suspension struts on front axle ⇒ page 53

Suspension struts on rear axle ⇒ page 54
Pressing in bump stop ⇒ page 54
3.30.1 Suspension struts on front axle

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

into shock absorber mountings.
3. Maintenance 53
3.30.2 Suspension struts on rear axle

Requirements:
Procedure:
– Push all locking elements -1- off piston rod.
– Press bump stops all the way into shock absorber mountings
(make sure they are straight).
© satelettronica
Note
With vehicle suspension extended, check that all bump stops are
firmly seated in shock absorber mountings.
– If necessary, use a suitable tool to press any loose bump stops

into shock absorber mountings.
3.30.3 Pressing in bump stop

♦ T40401 Lever for mounting bump stops
♦ Soap-based lubricant, e.g. tyre assembly paste
54 3. Maintenance
Procedure:
– Remove coarse dirt from top edge of loose bump stop and coat
with tyre assembly paste.
– Press bump stop firmly into shock absorber mounting by hand
or using lever - T40401- .
Note
Lever - T40401- can only be used on the rear axle.
© satelettronica
3.31 Axles (front and rear): checking compo‐
nents for play, secure attachment and
damage, and checking protective boots
The following applies to all components shown below:
• There must be no noticeable or visual play.
• As a rule you can identify damage to the boots/drive shaft
boots by emerging grease.
• Check that retaining rings and spring-type clips are seated
correctly.
Front axle ⇒ page 55
Rear axle ⇒ page 57
3.31.1 Front axle

Track control links, guide links and coupling rod:
track control link/guide link.
3. Maintenance 55
– Track control link and guide link: Check boots -arrows- of track
control link and guide link joints all around for damage and
make sure they are seated correctly.
– Check all bonded rubber bushes of track control links and

guide links -arrows- for play.
Track rod ball joint:
© satelettronica
– Check boot -2- for track rod ball joint all around for damage
and make sure it is seated correctly.
– Check play at track rod ball joint.
Upper links:
56 3. Maintenance
– Upper links -2-: Check bushes of swivel joints all around for
damage and make sure they are seated correctly.
– Check bonded rubber bushes -3- and -4- of swivel joints (top)
for play.
Anti-roll bar:
© satelettronica
Drive shaft and steering rack:
– With steering turned: Check drive shaft boots -arrows- all

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

relevant component.
3.31.2 Rear axle

Lower and upper transverse links:
both transverse links.
3. Maintenance 57
– Check all bonded rubber bushes -arrows- of lower transverse

link for play.
– Check all bonded rubber bushes of upper transverse link -3-

for play.
Track rod:
© satelettronica
– Check play at bonded rubber bushes of track rod -4-.
Coupling rod and anti-roll bar:
58 3. Maintenance
Drive shaft:
Only applies to vehicles with four-wheel drive.
– Check drive shaft boots -1- all around for damage and make
sure they are seated correctly.

relevant component.
© satelettronica
3.32 Engine, gearbox, final drive and steer‐
ing: checking for leaks and damage
DANGER
⇒ page 6 .
Applies to vehicles up to and including model year 2014: For in‐

spection every 60,000 km (38,000 miles)/4 years, remove noise
insulation.
Applies to vehicles from model year 2015 onwards: Remove
noise insulation for every inspection.
Removal steps:
Procedure:
– Check engine and engine ancillaries from below for leaks and
damage.
– Check visible area of belt drives for damage.
– Check radiator and cooling circuit for leaks and damage.
– Check refrigerant circuit for damage (check air conditioner
compressor, condenser and refrigerant lines including con‐
nections).
– Check gearbox, final drive and steering for leaks and damage.
– If faults are found: repair or renew relevant component.
3. Maintenance 59
3.33 Steering boots and inner hose clips:

checking secure seating
Note
Only applies to vehicles with electromechanical power steering in

the Chinese market.
Removal steps:
Procedure:
– Check that steering boot -2- and inner hose clip -1- are seated
securely.
– If steering boot and/or hose clip is loose, fit components cor‐
rectly and tighten them to correct torque ⇒ Running gear,
front-wheel drive and four-wheel drive; Rep. gr. 48 ; Steering
rack; Removing and installing boot .
© satelettronica
3.34 Vehicle (from below): checking for dam‐
age
Procedure:
– Check underbody carefully and thoroughly for damage and
loose fasteners.
ponent.
3.35 Underbody: checking trim, wheel hous‐

ing liners, side members and pipes/wir‐
ing for damage, and checking that they
are properly secured
Procedure:
– Check all underbody trim panels and wheel housing liners for
tears and cracks.
– Use your hands to check that all underbody trim panels and
wheel housing liners are secured correctly and check for miss‐
ing fasteners.
– Inspect side members for deformations.
– Check visible area of pipes/wiring and connections for dam‐
age and ensure they are secured correctly.
ponent.
60 3. Maintenance
3.36 Roof insert: checking operation

WARNING
pectedly!
on ⇒ page 8 .
Only applies to equipment version with sliding/tilting sunroof.

Procedure:
– Open and close roof system completely and check for unusual
noises and stiffness/sticking.
– If there is unusual noise or stiffness/sticking: Clean and lubri‐
cate roof insert ⇒ page 61 .
3.37 Roof insert - sliding/tilting sunroof:
© satelettronica
WARNING
pectedly!
on ⇒ page 8 .

5128-
bent by approx. 40°
a scouring surface)

Step 1 - cleaning and lubricating glass panel seal:
– Tilt open glass panel at rear.
– Remove all accessible grease and dirt residue from glass pan‐
el seal using cleaning solution - D 009 401 04- and a lint-free
cloth.
3. Maintenance 61
– Use a fine-pored sponge -1- to lubricate sides and rear of glass

panel seal -arrows- with lubricating paste - G 052 141 A2- .
Make sure that no coarse residue remains visible after apply‐
ing lubricant.

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

seal -arrow- with lubricating paste - G 052 141 A2- . Make sure
© satelettronica
that no coarse residue remains visible after applying lubricant.
Step 2 - cleaning and lubricating guide rail:

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

62 3. Maintenance
– Use a paintbrush to lubricate outside of guide rail -arrow- with

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

© satelettronica
– Remove surplus lubricant on guide rails with a lint-free cloth.
surplus lubricant.
3.38 Roof insert - panorama sunroof: check‐

ing, cleaning and lubricating
WARNING
pectedly!
on ⇒ page 8 .

3. Maintenance 63
♦ Grease stone - VAS 6764-
♦ Hand-cartridge gun - V.A.G 1628-
© satelettronica
5128-
♦ Measuring cup
bent by approx. 40° using workshop equipment
a scouring surface)
Note
First carry out a visual check to determine which type of sunroof

is fitted on the vehicle.

– Carry out a visual check to determine which type of grease has
been used in area of guide rails.
♦ White/grey grease G 060 751 A2: Clean and lubricate accord‐
ing to method used to date (description below)
♦ Transparent grease (special lubricant): Perform functional
check only; proceed as follows:
Procedure:
– Open and close sunroof completely.
This must not produce any vibrations or noises (rattling, squeak‐
ing, clicking) other than those of normal operation.
64 3. Maintenance
Note
Please refer to TPI if normal operating sounds are accompanied

by other noises or vibrations on a sunroof version with new spray-
on grease.

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

cartridge -G 060 751 A2- -2- and insert into hand-cartridge gun
- V.A.G 1628- -3-.
3. Maintenance 65
– Insert grease stone attached to hand-cartridge gun at front end

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

– Remove grease and dirt from slotted guide for glass panel with
a lint-free cloth.
– Open and close sunroof and open glass panel again com‐
pletely. Opening and closing the sunroof distributes the lubri‐
cant along the guide rails. Any deposits of excess lubricant can
be used to grease the slotted guide.
– Use a paintbrush to lubricate slotted guide for glass panel
© satelettronica
– Remove excess lubricant from slotted guide and guide rail with
a lint-free cloth.
Step 3 - cleaning and lubricating locking hook for sunroof mech‐

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

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

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

– Remove grease and dirt from seal for roof frame using clean‐
ing solution - D 009 401 04- and a lint-free cloth.
– Use a fine-pored sponge to lubricate roof frame seal

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

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

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

roof: checking
♦ Measuring cup
♦ Lint-free cloth
3. Maintenance 67
♦ Industrial vacuum cleaner

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

♦ Lubricant - G 052 172 A1-
Requirements:
Procedure:
– Switch on ignition and extend rear spoiler.
– Apply lubricant - G 052 172 A1- to points marked on all rear
spoiler hinge joints -arrows-.
– Extend and retract rear spoiler at least five times so that lubri‐
cant is able to penetrate.
– Retract rear spoiler.
3.41 Door hinges with separate door arrester:

68 3. Maintenance
♦ Universal spray oil - G 000 115 A2- for door arresters and
hinges
Requirements:
Procedure:
– Lubricate door hinge (top and bottom) at points marked
-arrows- as well as separate door arrester -arrows- with uni‐
versal oil spray - G 000 115 A2- .
Door hinge:
© satelettronica
Door arrester:
– Move door several times so that the universal spray oil is able
to penetrate.
– Use cloth to remove surplus lubricant from all door hinges.
– Repeat cleaning and lubricating procedure on all remaining
doors of vehicle.
3.42 Front lid arrester hook: lubricating

♦ Universal spray oil - G 000 115 A2-
Requirements:
Procedure:
3. Maintenance 69
– Lubricate arrester hook with universal spray oil - G 000 115

A2- at points marked -arrows-.
– Operate moving parts several times so that the lubricant is
able to penetrate.
3.43 Windscreen/rear window washer sys‐

tem: checking spray pattern and adjust‐
© satelettronica
ing if necessary
Checking windscreen spray pattern: triple washer jets
⇒ page 70
Checking windscreen spray pattern: hybrid jets ⇒ page 71
Checking spray pattern on rear window ⇒ page 71
Setting windscreen spray pattern, triple washer jets ⇒ page 71
Setting windscreen spray pattern: hybrid jets ⇒ page 72
Adjusting rear window washer jets ⇒ page 72
3.43.1 Checking windscreen spray pattern: tri‐

ple washer jets
• Jet unit (passenger's side): Water from all washer jets makes
contact within upper third of wiper area -illustration-
• Jet unit (driver's side): Spray pattern symmetrically opposite
that of jet unit on passenger's side
Procedure:
jets ⇒ page 71 .
70 3. Maintenance
3.43.2 Checking windscreen spray pattern: hy‐

brid jets
• Jet unit (passenger's side): Upper concentrated jet should
make contact near upper edge of wiper area -1-.
• Jet unit (driver's side): Upper concentrated jet should make
contact -2- at same level as jet unit (passenger's side).
Procedure:
jets ⇒ page 72 .
3.43.3 Checking spray pattern on rear window

© satelettronica
• Water from both spray jets makes contact just above wiper
blade
• Water from inner spray jet makes contact within approx. first
quarter of wiper blade length -illustration-
• Water from outer spray jet makes contact approx. at or just
beyond centre of wiper blade length -illustration- (third quarter)
Procedure:
– Operate rear window washer system and check spray pattern.
– If spray pattern is not as specified, adjust rear window washer
jets. ⇒ page 72
3.43.4 Setting windscreen spray pattern: triple

washer jets
Procedure:
to specification.
tion, clean washer jets ⇒ Vehicle electrics; Rep. gr. 92 ;
Windscreen wash/wipe system; Adjusting and cleaning wash‐
er jets .
3. Maintenance 71
3.43.5 Adjusting windscreen spray pattern: hy‐

brid jets
Procedure:
– Using adjuster screw -2-, set jet unit being adjusted according
to specified pattern (use a tool with size 9 external Torx -3-).
tion, clean appropriate washer jets ⇒ Electrical system; Rep.
gr. 92 ; Windscreen wiper system; Adjusting washer jets .
Note
Only the height of the jets of water of each jet unit can be adjusted,
and all jets must be adjusted together via an adjuster screw. The
jets cannot be adjusted individually or laterally.
© satelettronica
3.43.6 Adjusting rear window washer jets
Procedure:
to specification.
tion, clean washer jets ⇒ Electrical system; Rep. gr. 92 ; Rear
window wiper system; Adjusting washer jets .
3.44 Wiper blades: checking for damage

Wiper blades: checking for damage (version 1) ⇒ page 72
Wiper blades: checking for damage (version 2) ⇒ page 73
3.44.1 Wiper blades: checking for damage

(version 1)
– Press windscreen wiper lever downwards briefly.
Step 2 - checking:
72 3. Maintenance
Note
There are other methods of setting the service position

⇒ page 73 .
3.44.2 Wiper blades: checking for damage

(version 2)
– Under »Systems«/»Car systems«, navigate through following
menu structure:
♦ Wiper change pos.
– Use MMI rotary pushbutton to activate service position for
windscreen wipers.
© satelettronica
Step 2 - checking:
Note
There are other methods of setting the service position

⇒ page 72 .
3.45 Headlight washer system: checking op‐

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

ment
3. Maintenance 73
♦ Headlight adjustment unit - VAS 5209B-
♦ Or: headlight adjustment unit - VAS 621 001-
Note
Other headlight adjustment units (e.g. VAS 5208A, VAS 621 005,
VAS 5046A and VAS 5047A) can also be used to check the
headlight adjustment (except for matrix LED headlights). Check‐
ing matrix LED headlights requires adjustment unit VAS 5209B
© satelettronica
or VAS 621 001.
Performed as part of an inspection, this check is merely an ab‐

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

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

lights, number plate lights, turn signals,
hazard warning lights: checking opera‐
tion
WARNING
© satelettronica
pectedly!
on ⇒ page 8 .
Check the lights/signals listed below from the outside to ensure

Procedure:
– Activate side lights and check that the following exterior lights
function properly:
♦ Side lights (front)
♦ Side lights (rear)
♦ If applicable: additional tail light under open rear lid
– Check operation of daytime running lights (front).
– Operate right turn signal, left turn signal and hazard warning
lights, and check that corresponding turn signal lamps at front,
rear and side function properly.
– Activate dipped headlights and check that the following exte‐
rior lights function properly:
♦ Dipped headlights
♦ Tail lights
♦ Number plate lights
– Use appropriate switch to activate fog lights and check that
– Check that main beam headlights function properly.
– Operate brakes and check function of all brake lights.
– Engage reverse gear and check that all reversing lights func‐
tion properly. This model is fitted with two reversing lights.
3. Maintenance 75
– Use appropriate switch to activate rear fog lights and check

that they function properly. This model is fitted with two rear
fog lights.
– Renew any defective bulbs.
Note
It is possible to deactivate the daytime running lights intentionally

via the appropriate MMI setup menu.
3.48 Luggage compartment lighting: check‐

ing operation
A6 Avant ⇒ page 76
A6 Saloon ⇒ page 76
A7 ⇒ page 77
3.48.1 A6 Avant
Procedure:
© satelettronica
tion properly.
3.48.2 A6 Saloon
Procedure:
– Check that luggage compartment light shown -arrows- func‐
tions properly.
76 3. Maintenance
3.48.3 A7
Procedure:
tion properly.
3.49 Luggage compartment: removing pro‐

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

reading light: checking operation
WARNING
pectedly!
on ⇒ page 8 .
Procedure:
– Open glove box and check that glove box light functions prop‐
erly.
– Use the appropriate switches to activate the following interior
lights and check that the lights function properly:
♦ Interior lights in headliner at front
♦ Interior lights in headliner at rear
Note
Checking the background lighting is NOT part of the inspection.
3.51 Horn: checking operation

WARNING
pectedly!
on ⇒ page 8 .
3. Maintenance 77
Procedure:
– Operate horn and check proper function of treble horn and
bass horn.
Note
Perform this check outdoors, e.g. when driving the vehicle to the
workshop or during a road test.
3.52 Passenger airbag: checking key switch

on/off and setting to "on"
WARNING
pectedly!
© satelettronica
on ⇒ page 8 .
Switch for “Airbag ON/OFF” is located in glove box -arrow-.

Procedure:
– Turn switch to “AIRBAG OFF” position.
tem check.
– Check that “PASSENGER AIRBAG OFF” display lights up in
instrument cluster.
– Turn switch to “AIRBAG ON” position.
tem check.
– Check that “PASSENGER AIRBAG OFF” disappears.
Note
3.53 Owner's literature: checking that all

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

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

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

latch plate, and checking locking action
of automatic belt retractor
Procedure:
For all seat belts installed:
– Check that retaining rivets/clips/loop sewn to belt for fixing
latch plate in place are present.
– Check locking action of automatic belt retractors when belt is
unrolled abruptly.
Note
♦ The fixing devices on the seat belts in the vehicle may vary
depending on the model (e.g. loop sewn on belt for front belts
and retaining rivets for rear belts). There may also be two rivets
per belt (centre rear). If a retaining rivet/loop is missing, this
can be detected by damage on the belt.
♦ If the seat belt is securing an object (e.g. child seat), do not
release the seat belt. Only check the locking action when the
belt is buckled; it is not necessary to check the retaining rivet/
clip in this case.
3.57 Vehicle interior: removing protective

covers for seats and carpet
Procedure:
– Remove protective covers for seats and carpet carefully and
completely from vehicle interior.
3. Maintenance 79
3.58 Vehicle interior: checking that it is clean

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

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

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

lamps
Reading out the event memory is a repair measure and should
be charged separately.
Procedure:
– Start engine and wait for vehicle to complete initial system
check.
– Check whether warning lamps light up in instrument cluster.
– Switch off engine.
– If relevant warning lamps light up: Read out event memory
⇒ page 25 .
Note
3.62 Warning triangle: checking availability

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

piry date
The first-aid kit is located in the centre armrest of the rear seat
bench.
Procedure:
– Take out first-aid kit and check expiry date printed on kit.
– If expiry date has passed: Renew first-aid kit.
3.64 Vehicle keys: checking operation and

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

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

er's literature: checking availability and
recording number present
Procedure:
– Check whether there are keys for the vehicle and record num‐
ber of keys in maintenance table.
– Check whether there are wheel covers for the vehicle and re‐
cord number of wheel covers in maintenance table.
– Check whether owner's literature is in place and record num‐
ber of copies in maintenance table.
– Wait until shortly before vehicle delivery to renew any missing
components.
3. Maintenance 81
3.67 Sun visors: checking that they are folded

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

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




Oil drain plug on oil filter cover 4
82 3. Maintenance
Requirements:
• Engine oil temperature at least 90 °C
Removal steps:
Procedure:
– Unscrew oil drain plugs -arrows- of sump and in oil filter cover
-1-.
– Drain engine oil from oil filter housing and sump.
– Renew seals of both oil drain plugs.
– Re-install both oil drain plugs and tighten to specified torque
© satelettronica

Nm

Removal steps:
Procedure:
3. Maintenance 83
– Unscrew oil drain plug of sump -arrow-.

– Drain engine oil from sump.
– Renew seal for oil drain plug.
– Screw oil drain plug into sump and tighten to specified torque
3.70 Engine oil: extracting

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

disposal.
84 3. Maintenance
3.71 Engine oil: renewing oil filter

4-cyl. petrol engine 1.8 TFSI/2.0 TFSI/2.0 TFSI hybrid (version 1)
⇒ page 85
4-cyl. petrol engine 2.0 TFSI (version 2) ⇒ page 86
3.71.1 4-cyl. petrol engine 1.8 TFSI/2.0 TFSI/

2.0 TFSI hybrid (version 1)
DANGER
© satelettronica
⇒ page 6 .

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

Nm

Oil filter cartridge 22
Removal steps:
3. Maintenance 85
Procedure:
– Use Hazet strap wrench - 2171-1- or oil filter tool - 3417- to
slacken oil filter cartridge -arrow- and then remove it.
– Clean sealing surface for oil filter at engine.
– Lubricate rubber seal on new oil filter cartridge with engine oil.
– Fit new oil filter cartridge on engine and tighten to specified
⇒ page 85 ).
Note
There is an additional oil filter version for the 2.0 TFSI engine.
3.71.2 4-cyl. petrol engine 2.0 TFSI (version 2)

© satelettronica
Nm

Sealing cap 25
Removal steps:
– Remove engine cover panel.
Procedure:
ing into crankcase.
– Fully unscrew sealing cap -arrow- and pull it off straight up‐
wards. Make sure that no engine oil drips onto engine.
86 3. Maintenance
– Pull oil drain connection -6- out fully and check for damage.
ring.
– Fit oil drain connection in new oil filter element.
Note
There is an additional oil filter version for the 2.0 TFSI engine.
© satelettronica
Nm
Sealing cap 25
Removal steps:
Procedure:
ing into crankcase.
3. Maintenance 87

groove -arrow-.
© satelettronica

Nm

Sealing cap 25
Removal steps:
88 3. Maintenance
Procedure:
ing into crankcase.
© satelettronica
groove -arrow-.

Nm
Sealing cap on oil filter 25
Requirements:
• Engine oil drained.
3. Maintenance 89
Procedure:
– Loosen sealing cap using socket (32 mm) and remove it.
– Lightly lubricate new O-rings -4- and -6- with engine oil and
insert into grooves.
– Fit new oil filter element -5- in sealing cap -3-.
– Fit sealing cap -3- on engine and tighten to appropriate torque
using socket (24 mm) (see table of tightening torques for in‐
stallation ⇒ page 89 ).
© satelettronica
Nm
Sealing cap 25
Removal steps:
Procedure:
– Loosen sealing cap -1- of oil filter using socket (32 mm) . This
ing into crankcase.
drips onto engine.
90 3. Maintenance
– Lightly lubricate new O-rings -2-, -3- and -4- with engine oil and
insert O-rings.
Note
2.0 TDI diesel engine ⇒ page 91 .

© satelettronica
Nm
Sealing cap 25
Removal steps:
Procedure:
ing into crankcase.
drips onto engine.
3. Maintenance 91
ring.
Note
2.0 TDI diesel engine ⇒ page 90 .

© satelettronica
Nm
Sealing cap 35
Removal steps:
Procedure:
– Loosen sealing cap -arrow- using socket (32 mm) . This cau‐
ses a valve to open.
ing into crankcase.
drips onto engine.
92 3. Maintenance
ring.
3.72 Engine oil: filling up
© satelettronica
CAUTION
Risk of engine damage if the engine is revved too soon after
changing the oil!
♦ The engine must only run at idling speed as long as the oil
pressure warning lamp in the instrument cluster is on.
♦ Increase the engine speed only after the warning lamp has
gone out.

♦ Oil filler funnel - VAS 6842-
Refer to ELSA maintenance table for engine-specific oil capaci‐

ties and oil grades.
Procedure:
– Fill up engine oil using oil filler funnel - VAS 6842- .
– Then check oil level and adjust if necessary ⇒ page 94 .
3. Maintenance 93
– For all 4-cylinder petrol engines 1.8/2.0 TFSI with oil filler neck
on timing chain cover: Clean sealing surface -arrow- on inside
of oil filler neck with a lint-free cloth before screwing on filler
cap.
Note
The quantity of oil specified in the maintenance table refers to the

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

recting if necessary
CAUTION
Risk of damage to catalytic converter if engine oil level is too
high!
♦ Drain engine oil until level meets specification.
© satelettronica
Requirements for all engines except V6 diesel engines and V8
petrol engines:
• Engine oil temperature at least 60 °C
• Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.
Requirements for V6 diesel engines:
perature).
• Wait approx. two minutes after switching off the engine to allow
the oil to drain back into the sump.
Requirements for V8 petrol engines:
perature).
• Allow engine to run at idling speed for approx. one minute.
• Switch off engine and wait approx. five minutes (to allow oil to
flow back slowly).
• Check engine oil level within one minute.
Checking oil level with dipstick ⇒ page 94
Checking oil level on MMI ⇒ page 95
3.73.1 Checking oil level with dipstick

Procedure:
– Pull out dipstick and wipe it off with a clean cloth.
– Re-insert dipstick into guide tube as far as it will go.
94 3. Maintenance
– Pull oil dipstick out again and read off oil level on marked area.
– Evaluate oil level and determine any necessary measures ac‐

cordingly:

Marked area -arrow- Optimum oil level.
Area A Oil must not be topped up.
Area B Oil can be topped up.
Area C Oil must be topped up.
© satelettronica
Note
Some engines are not fitted with an oil dipstick; if this is the case,
use the oil level display in the MMI system ⇒ page 95 .
3.73.2 Checking oil level on MMI

Procedure:
– If necessary, close bonnet.
– Under »Car systems«, navigate through following menu struc‐
ture:
♦ Fluid level
– Read off and evaluate oil level on display.
– If necessary, correct oil level:
Fluid level Evaluation/measure

At or just under “max” Optimum oil level.
Significantly under “max” Fill up engine oil to optimum level (close bonnet to refresh oil level display).
3. Maintenance 95
Note
♦ The oil level display on the MMI is not refreshed when the
bonnet is open.
♦ A warning lamp in the driver information system indicates that
the level is too low.
3.74 Poly V-belts for ancillaries: checking

CAUTION
Risk of engine damage if camshaft drive slips.
♦ Only turn crankshaft in direction of engine rotation.

Removal steps:
© satelettronica
– Remove poly V-belt ⇒ ; Rep. gr. 13 ; Cylinder block (pulley
Procedure:
– Check poly V-belt (removed from vehicle) along entire length,
as well as pulleys on engine that are within view. Look for the
following types of damage:
♦ Cracks or tears in belt profile and on reverse side (cracks, core
fractures, cross-sectional fractures)
♦ Layer separation (top layer, cord strands)
♦ Fraying of cord strands
♦ Foreign objects in belt profile and reverse side
♦ Excessive traces of oil and grease on rollers and pulleys
♦ Flank wear on pulleys (material wear, frayed flanks, surface
cracks); see -illustration-
– Applies to vehicles with power steering pump: Check alterna‐
tor freewheel.
– If damage is found: Renew damaged component.

Note
The example given here shows possible damage to a pulley. The

appearance of other types of material wear on the load-bearing
flanks of the ribbing can be different.
96 3. Maintenance
3.75 Spark plugs: renewing

6-cyl. petrol engine 2.5 FSI/2.8 FSI/3.0 TFSI ⇒ page 99
Lubricating ignition coils ⇒ page 106

TFSI hybrid
♦ Spark plug spanner - 3122B-
© satelettronica
♦ Puller - T40039-

Spark plugs with M12 thread 20+5
Removal steps:
3. Maintenance 97
Step 1 - removing spark plugs:

– Release and unplug electrical connectors -arrows- from ac‐
tuators for camshaft adjustment.
– Release connectors -arrows- and pull all connectors simulta‐

neously off ignition coils.
© satelettronica
98 3. Maintenance


⇒ page 97 ).
– Lubricate ignition coils ⇒ page 106 .
© satelettronica
⇒ page 97 ).
3.75.2 6-cyl. petrol engine 2.5 FSI/2.8 FSI/3.0

TFSI
♦ Puller - T40039-
3. Maintenance 99

Removal steps:
– Move fuel line -1- and hose -2- leading to activated charcoal
filter clear at air pipe.
© satelettronica
– Unplug electrical connectors -1- at Hall sender 3 - G300- .

100 3. Maintenance

switch - F66- .
– Place coolant expansion tank to one side with coolant hoses
-arrows- attached.
© satelettronica
– Unplug electrical connectors -1- at Hall sender 3 - G163- .


⇒ page 100 ).
⇒ page 100 ).
3. Maintenance 101

♦ Puller - T10530-
© satelettronica

Bolts for ignition coils 9
Removal steps:
102 3. Maintenance

-F459-
5 - For intake air temperature sender - G42-
-F455-
– Unscrew bolts -arrows- for connector rail.
© satelettronica
3. Maintenance 103

VAS 3122B- .
– Release retaining clips -1- and -4- and disconnect coolant ho‐
ses.
© satelettronica
– Move coolant hose -arrow- clear.
switch - F66- .
– Lift coolant expansion tank out of bracket and place to one
side.
– Move clear coolant hoses -3- and air pipe -1- at wiring guide
-2-.
– Take electrical connectors -1- out of bracket -2-, unplug con‐

nectors and move wiring clear.
– Lift off bracket -2-.
104 3. Maintenance
– Unplug electrical connectors -arrows- and move wiring clear.

-F467-
4 - For fuel metering valve 2 - N402-
5 - For fuel pressure sender for low pressure - G410-
© satelettronica
-F479-
– Remove bolts -2-, -9- and centre hex stud -arrow- and move
earth wire clear.
3. Maintenance 105

VAS 3122B- .
© satelettronica
⇒ page 102 ).
– Tighten bolts -arrow- for ignition coils to specified torque (see

table of tightening torques for installation ⇒ page 102 ).
– Plug in connector on each ignition coil until it engages.
3.75.4 Lubricating pencil-type ignition coils

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

catalogue (ETKA).
♦ New ignition coils are already lubricated when they are deliv‐
ered; it is not necessary to lubricate them again when instal‐
ling.
CAUTION
Ignition coils can be damaged irreparably if the wrong lubricant
is used.
– Use only the approved silicone paste.
© satelettronica
3.76 Coolant level: checking (coolant level
must reach at least top marking on cool‐
ant expansion tank)
WARNING
Coolant expansion tank under pressure - risk of injuries!
♦ Only open coolant expansion tank when engine is cold.
CAUTION
Incorrect coolant additives can cause serious damage to vehi‐
cle components.
The coolant additive G12EVO is not approved for engines
based on EA288 (A6 2.0 TDI).
3. Maintenance 107
Note
♦ Specification for coolant level is top marking on coolant ex‐

pansion tank.
♦ Coolant additives may only be mixed with distilled water, as
the effectiveness of the coolant and the corrosion protection it
provides are greatly influenced by the quality of the water with
which the coolant is mixed. To ensure an adequate water
quality, the coolant additive should be mixed with distilled wa‐
ter.
♦ Only use approved coolant additives; refer to Electronic parts
catalogue (ETKA).
♦ Coolant additives G12EVO, G13 and G12++ may be mixed
together.
♦ G12EVO, G13 and G12++ may be mixed with coolant addi‐
tives G11, G12 and G12+.
♦ G12 and G11 must NOT be mixed together.
© satelettronica
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
♦ It is permissible to operate the vehicle if the coolant level is
above the MAX marking on the coolant expansion tank (this is
by technical design). Do NOT extract coolant.
♦ The vehicle must not be driven if the coolant level is below the
top marking.
Checking coolant level and anti-freeze ⇒ page 108

Filling up coolant ⇒ page 110
3.76.1 Checking coolant level and anti-freeze


Type of service: Coolant level specification:
Delivery Inspection Coolant at least at level of MAX marking.
Inspection Coolant at level of MAX marking.
Checking the cooling system for leaks is a repair measure and

108 3. Maintenance
Requirements:
• Anti-freeze protection must be guaranteed to -25 °C (in coun‐
tries with an arctic climate to -36 ℃); note specification in
Maintenance table.
• The proportion of coolant additive must not exceed 55 %
(gives anti-freeze protection down to -48 °C); beyond this con‐
centration the frost protection and the cooling efficiency are
reduced again.
• The vehicle must be parked on a level surface.
Step 1 - checking coolant level:
– Check coolant level (according to marking -illustration-) in
coolant expansion tank with engine cold.
– If coolant level is too low: Add required amount (using correct
mixture ratio) ⇒ page 110 .
– If fluid losses are greater than can be reasonably expected:
First use a leak test to determine the cause ⇒ Engine; Rep.
gr. 19 ; Cooling system/coolant; Checking cooling system for
leaks .
© satelettronica
Step 2 - checking anti-freeze:
– Use a pipette to place a drop of coolant on glass of refractom‐
eter - T10007 A- . Light-dark border will now be clearly visible
through refractometer.
– Check level of anti-freeze protection using corresponding
scale on refractometer; to do so, read off value on light-dark
border.
– If anti-freeze protection level does not meet specification in
Maintenance table: Perform following measures:
Anti-freeze protection level: Evaluation/measure:

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

road test.
3. Maintenance 109
Note
♦ The refractometer - T10007 A- must be used to determine the

current anti-freeze concentration.
♦ Scale -1- on the refractometer applies to coolant additives
G11, G12, G12+ and G12++.
♦ Scale -2- refers only to coolant additive G13.
tection.
♦ The temperature indicated on the refractometer - T10007 A-
♦ It is essential that anti-freeze be used in the cooling system all
year round. In the correct concentration, coolant additives pre‐
vent scaling and frost and corrosion damage, and also raise
the boiling point of the coolant.
reliability under heavy loads in countries with tropical climates.
© satelettronica
3.76.2 Filling cooling system
Frost protection to: Coolant additive: Water:
Procedure:
– Add required amount (using mixture ratio according to anti-
freeze protection specification in Maintenance table). Use the
table as a reference for the coolant mixture ratio.
Note
Small quantities of coolant can simply be topped up. Use the

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

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

♦ Secure all hose connections with hose clips (same as original
equipment); see Electronic parts catalogue (ETKA).
110 3. Maintenance
Air cleaner housing: cleaning ⇒ page 118


TFSI hybrid
Removal steps:
© satelettronica
remove it.
3. Maintenance 111

© satelettronica
Removal steps:

remove it.
112 3. Maintenance
© satelettronica

Removal steps:
3. Maintenance 113

remove it.
© satelettronica

114 3. Maintenance

– Release hose clips -2- and detach air pipe.
– Turn housing cover in anti-clockwise direction -arrow B- and
remove filter element.
– Fit new filter element centrally in housing cover, ensuring that
it is installed in correct direction.
© satelettronica
tion -arrow A- until it engages -3-.

Removal steps:
3. Maintenance 115

– Release retainer -1- on housing cover.

– Turn housing cover with filter element in anti-clockwise direc‐
tion -arrow A- and remove it.
© satelettronica
– Fit housing cover (with filter element attached) into mounting
of air cleaner housing so that it is centred. When fitting, hold
onto filter element as you insert it through opening for housing
cover; ensure that it does not slip off centring lugs and become
tilted when it is installed.
116 3. Maintenance
– Turn housing cover in clockwise direction -arrow B- until you

feel it engage -1-.
Note
If the housing cover does not engage easily, this may indicate that
the air filter element is not aligned properly or is tilted.

Removal steps:
© satelettronica
remove it.
3. Maintenance 117

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

er air mass meter with a clean cloth.
♦ On vehicles for cold countries, the snow screen in the intake
section must also be cleaned; see specification in ELSA Main‐
tenance table.
3.78 Plenum chamber and water drains:

checking for dirt
DANGER
⇒ page 6 .
118 3. Maintenance
Checking plenum chamber and water drains for dirt

⇒ page 119
Cleaning plenum chamber and water drain valves ⇒ page 120
3.78.1 Checking plenum chamber and water

drains for dirt
Nm
Nm
Bolts for washer fluid reservoir 8
© satelettronica
Removal steps:
chamber cover .
– Remove bolts -arrows- for washer fluid reservoir -1-.
– Carefully lift filler neck, but do not remove completely.
Step 1 - checking plenum chamber and water drains (driver's

side):
– Check for dirt in water drain grommet -1- and bottom of plenum
chamber using a hand-held light.
– If no dirt was found: Carefully pour a small amount of water
into plenum chamber and check that water drains quickly and
fully.
⇒ page 120 .
Step 2 - checking plenum chamber and water drains (passenger's

side):
3. Maintenance 119
– Check for dirt in water drain grommet -1- and water drains
-arrows- using a hand-held light.
⇒ page 120 .

Note
If the water you have poured in does not drain out or drains out
very slowly, this is a sign that the water drains -arrows- are fully
or partly blocked.
3.78.2 Cleaning plenum chamber and water

drains
© satelettronica
♦ Suction feed spray-gun - VAG 1538-
♦ Nylon probe - VAG 1538/2-
♦ Flexible picking tool
Procedure:
– Remove coarse dirt from plenum chamber and water drain
grommets with a flexible picking tool.
– Remove fine dirt using suction-feed spray gun - V.A.G 1538-
and nylon probe - V.A.G 1538/2- or a thin water hose.
3.79 Dust and pollen filter: renewing

Preliminary filter ⇒ page 120
Main filter ⇒ page 121
3.79.1 Preliminary filter

Equipment version for certain countries: Note specification in
Maintenance table.
The preliminary filter is fitted in the vehicle plenum chamber.
Removal steps:
chamber cover .
120 3. Maintenance

– Take out filter element -2- under retainers -3- in direction of
-arrow-.
– Clean surrounding area (e.g. with a vacuum cleaner) after re‐
moving filter element.
– Fit new filter element -2- so that arrows indicating direction of
flow point downwards.
3.79.2 Main filter

The dust and pollen filter is fitted under the glove box.
Removal steps:
– On vehicles with special equipment used by driving schools:
Remove pedal cluster if necessary; see installation instruc‐
© satelettronica
tions for equipment for driving schools.
– Cover footwell beneath dust and pollen filter with paper.
– Unfasten quick-release fastener -2- with screwdriver -1-.
– Disengage cover -3- at retainer -4- and detach.
3. Maintenance 121
– Release retaining tab -B-, swivel cover -A- for aperture down
and detach.
– Pull filter element -D- out of aperture -E- in direction of
-arrow-.

– Clean aperture -E- with a vacuum cleaner before fitting new
filter element.
– Fit new filter element -D- correctly: angled side faces fresh air
blower.
– Position aperture cover -A- in tab -C- and engage on opposite
side -B-.
3.80 Fuel filter: draining
© satelettronica
WARNING
♦ Put on protective gloves.
♦ Put on safety goggles.
♦ Loosen draining valve carefully.

Nm
♦ Diesel-resistant hose with appropriate diameter: must not slip
off draining valve under system pressure
♦ Reservoir
[Nm]
The fuel filter is located on the underbody at the rear of the vehicle.
122 3. Maintenance
Procedure:
– Attach hose to water drain plug -5- on cover of filter housing.
Place opposite end of hose in appropriate container.
– Start engine. System pressure is necessary for draining fuel
filter.
– Open water drain plug slowly until water begins to drain.
– When diesel fuel begins to drain: Screw water drain plug back
in.
– Turn off engine and disconnect hose from water drain plug.
3.81 Fuel filter: renewing
© satelettronica
WARNING
♦ Allow connections of fuel lines to cool down.
♦ Place cloths around connections and loosen them carefully.
Fuel filter without water separator ⇒ page 123

Fuel filter with water separator ⇒ page 124
3.81.1 Fuel filter without water separator


♦ Reservoir
3. Maintenance 123

[Nm]
Nuts on bracket 2
The fuel filter is located on the underbody.

Removal steps:
– Remove underbody trim (right-side) ⇒ Rep. gr. 66 ; Under‐
body trim; Removing and installing underbody trim .
Step 1 - removing:
– Observe the safety precautions when working on the fuel sys‐
tem ⇒ Fuel supply system, diesel engines; Rep. gr. 00 ; Safety
precautions; Safety precautions when working on the fuel sys‐
tem .
– Remove nuts -2-.
© satelettronica
– Swivel bracket downwards, disengage it from mounting points
-arrows- and detach it.
– Place drip tray under fuel filter.
– Using hose clip pliers, disconnect fuel supply hoses -1- and
-3- at T-piece and leading to aluminium pipe, and remove fuel
filter -2-.
Install in reverse sequence. Note tightening torque. Table of tight‐
ening torques for installation ⇒ page 124
Flow direction is indicated by arrows on filter housing.
– Then bleed fuel system ⇒ Engine; Rep. gr. 23 ; Injection sys‐
tem; Filling/bleeding fuel system .
Note
♦ Do not loosen spring-type clips on fuel filter.

♦ Spring-type clips and fuel lines leading from the fuel filter to
the T-piece and to the aluminium pipe must be renewed; refer
to Electronic parts catalogue (ETKA).
3.81.2 Fuel filter with water separator

124 3. Maintenance
♦ Diesel extractor - VAS 5226-
♦ Hose clamps, up to Ø 25 mm - 3094-
© satelettronica
Nm
[Nm]
Bolts for filter housing -8- 9
3. Maintenance 125
Step 1 - removing:
– Clamp off supply hose for underbody hose -14- with hose
clamps, up to Ø 25 mm - 3094- .
– Fit hose of diesel extractor - VAS 5226- together with suitable
adapter onto water drain plug -5-.
– Open water drain plug -5-.
– Operate diesel extractor - VAS 5226- until no more diesel
emerges.
– Unscrew bolts -8- and detach filter housing.
– Remove filter element -4- and seal -3- from filter housing -9-.
– Use diesel extractor - VAS 5226- to draw off remaining diesel
fuel.
– Clean filter housing -9-.
© satelettronica
– Insert new filter element in filter housing so that it is centred.
– Fit new seal.
– Insert and align filter housing. Make sure that filter housing is
screwed on in correct position.
– Fit bolts for filter housing -8- and tighten to specified torque
– Remove hose clamps, up to Ø 25 mm - 3094- from supply hose
for underbody hose.
– Finally, bleed fuel system ⇒ Rep. gr. 23 ; Injection system;
Filling/bleeding fuel system .
3.82 Fuel tank: adding fuel additive

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

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

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

507 53 A or VW 507 53 B.
♦ After adding fuel additive, it is very important to tell the cus‐
tomer to fill up the fuel tank.
♦ Use no more than one container per filling, even if the tank has
a capacity > 60 litres.
3.83 Reducing agent (AdBlue®): filling up

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

♦ The reducing agent is used for the after-treatment of exhaust
gases of diesel-engined vehicles, i.e. to reduce the level of
nitrogen oxides.
♦ The reducing agent is not a diesel additive and must not be
filled into the diesel fuel tank.
♦ Do not add any additives to the reducing agent, and do not
dilute it with water.
♦ Only use the reducing agent as supplied in its original con‐
tainer.
♦ In addition, please observe the reducing agent manufacturer's
notices on usage and storage.
♦ Both filling device for AdBlue - VAS 6542- and AdBlue refuel‐
ling system - VAS 6960- can be used to fill up the reducing
agent.
3. Maintenance 127
Filling up reducing agent (AdBlue®) using filling device for AdBlue

- VAS 6542- ⇒ page 128
Filling up reducing agent (AdBlue®) using AdBlue refuelling sys‐
tem - VAS 6960- ⇒ page 130
3.83.1 Filling up reducing agent (AdBlue®) us‐

ing filling device for AdBlue - VAS 6542-
♦ Filling device for AdBlue - VAS 6542-
© satelettronica
♦ Mounting plate - V.A.G 1383A/1-
Components of filling device -VAS 6542-
128 3. Maintenance
1 - Breather connection for re‐

ducing agent container
2 - Union nut for reducing
agent container
3 - Cut-off valve for breather
line
4 - Quick-release coupling on
breather line
5 - Filler line
6 - Cut-off valve for filler line
7 - Union nut for fuel filler neck
8 - Breather line
© satelettronica
Procedure:
– Open tank flap and unscrew cap of reducing agent tank.
– Close cut-off valves of breather and filler lines of filling device
for AdBlue - VAS 6542- .
– Apply filling device for AdBlue - VAS 6542- to reducing agent
container (see Electronic parts catalogue, ETKA) and screw it
on as far as stop.
3. Maintenance 129
– Position reducing agent container on engine and gearbox jack

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

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

device which operates using gravity. When filling the tank using
VAS 6542 (or other filling device which operates in the same way),
disconnect it from the vehicle immediately once filling is comple‐
ted.
3.83.2 Filling up reducing agent (AdBlue®) us‐

ing AdBlue refuelling system - VAS
6960-
130 3. Maintenance
♦ AdBlue refuelling system - VAS 6960-
Procedure:
– Open tank flap and unscrew filler cap for reducing agent tank.
– Insert nozzle of AdBlue refuelling system - VAS 6960- into filler
neck of reducing agent tank.
© satelettronica
– Operate nozzle to fill up reducing agent completely.
– Remove nozzle from filler neck of reducing agent tank.
– Clean filler neck of reducing agent tank and filler cap with a
lint-free cotton cloth soaked with water.
Note
♦ Observe operating instructions for AdBlue refuelling system -

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

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

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

film, if present
Procedure:
– Remove protective film carefully and completely.
3. Maintenance 131
3.87 Vehicle cover: checking position and

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

manufacturer's instructions
Procedure:
– Vehicle cover: Remove according to manufacturer's instruc‐
tions.
3.89 Paintwork, trims, side windows and wip‐

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

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

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

Procedure:
– The following points must be checked during the road test:
♦ Engine: performance, misfiring, idling speed, acceleration,
starting behaviour (engine cold and warm), engine noise
♦ Clutch: pulling away, pedal pressure, odours, noise due to
load change
♦ Manual gearbox: ease of operation, gear lever position, gear‐
box noise
♦ Automatic gearbox: selector lever position, shift lock / ignition
key lock, gearbox noise, kickdown, shift behaviour, instrument
cluster display
♦ Brake pedal and handbrake: operation, travel and effective‐
ness, pulling to one side, response (delayed braking), judder‐
ing, squeal
132 3. Maintenance
♦ ABS function: pulsing must be felt at brake pedal when per‐

forming ABS-controlled braking.
♦ Steering: operation, steering free play, steering wheel central‐
ised when wheels are in straight-ahead position, moving off
line when travelling straight
♦ Imbalance: wheels, drive shafts
♦ Wheel bearings: noises
♦ Roof insert: unusual noise during operation
♦ Horn: checking
♦ Hybrid vehicles: check electrical operation by pressing EV
button, charging function in overrun phases
Note
To what extent all of these can be checked depends on vehicle

equipment and local conditions (urban/country).
3.93 Stock vehicles: observing measures
© satelettronica
specified in Maintenance table for stock
vehicles (see “Before handing vehicle
over to customer”)
This maintenance item only applies to stock vehicles.
Procedure:
– Before handing vehicle over to customer: Check whether the
following three measures for stock vehicles (as specified in the
Maintenance table) are due, and carry them out as necessary:
♦ For vehicles older than 12 months (from date of manufacture):
Renew brake fluid ⇒ page 40 .
♦ For vehicles with a defective battery: Renew battery ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Removing and installing
battery; Removing and installing battery, vehicles without
high-voltage system .
♦ Check brake discs for surface rust; if necessary, operate
brakes to remove rust according to manufacturer's instruc‐
tions.
– Record measures performed in maintenance table for stock
vehicles.
3.94 Accessories: installing

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

equipment and market.
♦ Depending on the vehicle model, the accessories may be
found in the luggage compartment, glove box or supplied
pack.
3. Maintenance 133
3.95 Protective display films: removing if

present
Procedure:
– If present, pull protective films off all displays in the vehicle and
dispose of them.
3.96 “TQS – Documentation of the vehicle

care” checklist: checking that list is
present
Procedure:
– Check that checklist “TQS - Documentation of the vehicle
care” is in glove box or front passenger footwell. This checklist
is only present in vehicles which remained with the Importer
or manufacturer longer than 14 days without being transported
further; it documents all cleaning and care work carried out
there.
– If missing, place checklist “TQS - Documentation of the vehicle
care” in glove box.
© satelettronica
3.97 “Stock vehicle maintenance” checklist:
signing and placing in vehicle wallet
Procedure:
– Sign “Stock vehicle maintenance” checklist and place it in ve‐
hicle wallet.
3.98 Cleaning and care: checking that re‐

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

ing and recording date of next check
Procedure:
– Decide date of next check with person in charge of stock ve‐
hicle care management.
– Record chosen date in maintenance table.
3.100 Rear final drive: changing gear oil

Procedure:
– Change gear oil according to specifications in Workshop Man‐
ual ⇒ Rear final drive 0BC, 0BD, 0BE, 0BF; Rep. gr. 39 ; Gear
oil; Draining and filling gear oil .
3.101 Rear final drive: changing ATF

Procedure:
134 3. Maintenance
3.102 Display instruments: setting time and

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

lecting 1st gear/park
Procedure:
Vehicles with manual gearbox: Select 1st gear.
Vehicles with automatic gearbox: Select park position.
3.104 Automatic gearbox (multitronic): chang‐

ing ATF
Procedure:
– Change ATF according to Workshop Manual ⇒ ; Rep. gr. 37 ;
© satelettronica
3.105 Automatic gearbox (tiptronic): changing
ATF
Procedure:
– Change ATF according to Workshop Manual ⇒ ; Rep. gr. 37 ;

ATF

ATF and renewing exchangeable ATF
filter
Procedure:
– Renew exchangeable ATF filter according to Workshop Man‐
ual ⇒ ; Rep. gr. 34 ; ATF circuit; Removing and installing ATF
filter .
3.108 Interior mirror: calibrating compass

WARNING
pectedly!
on ⇒ page 8 .
3. Maintenance 135
Procedure:
– Calibrate compass according to Workshop Manual ⇒ General
body repairs, interior; Rep. gr. 68 ; Interior mirror; Calibrating
digital compass .
3.109 Poly V-belt for supercharger with charge

air coolers: renewing
Procedure:
– Renew poly V-belt for supercharger with charge air coolers
according to specifications in Workshop Manual ⇒ ; Rep. gr.
13 ; Cylinder block (pulley end); Removing and installing poly
V-belt .
3.110 Poly V-belt for ancillaries, belt tensioner,

idler rollers and pulley for coolant pump:
renewing
Procedure:
Renew poly V-belt for ancillaries according to specifications in
Workshop Manual ⇒ ; Rep. gr. 13 ; Cylinder block (pulley end);
© satelettronica
Removing and installing poly V-belt .
– Renew belt tensioner, idler rollers and pulley for coolant pump
according to Workshop Manual ⇒ ; Rep. gr. 13 ; Cylinder block
(pulley end); Exploded view - cylinder block (pulley end) .
3.111 Poly V-belt for ancillaries: renewing

Procedure:
3.112 Poly V-belt for ancillaries and pulleys for

coolant pump and power steering pump:
renewing
Procedure:
– Renew pulleys according to Workshop Manual ⇒ ; Rep. gr.
13 ; Cylinder block (pulley end); Exploded view - cylinder block
(pulley end) .
3.113 Instrument cluster: resetting driver infor‐

mation system
Procedure:
– Reset single journey memory and total journey memory of
driver information system; refer to vehicle Owner's Manual.
3.114 Toothed belt for camshaft drive: renew‐

ing
Procedure:
136 3. Maintenance
3.115 Toothed belt for camshaft drive, and

drive sprockets for camshaft, crankshaft
and high-pressure pump: renewing
Procedure:
– Renew drive sprockets for camshaft, crankshaft and high-
pressure pump according to Workshop Manual ⇒ ; Rep. gr.
15 ; Toothed belt drive; Exploded view - toothed belt .
3.116 Toothed belt for camshaft drive and ten‐

sioning roller: renewing
Procedure:
– Renew tensioning roller according to Workshop Manual ⇒ ;
© satelettronica
Rep. gr. 15 ; Toothed belt drive; Exploded view - toothed belt .
3.117 Poly V-belt for ancillaries and pulley for

power steering pump: renewing
Procedure:
– Renew pulley for power steering pump according to Workshop
Manual ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hy‐
draulic power steering; Exploded view - power steering pump .
3. Maintenance 137
4 Exhaust emissions test
Note
♦ Please observe the statutory regulations applicable to your

country.
♦ The exhaust emissions test described below conforms to the
statutory regulations applicable in Germany.
Petrol engines: performing exhaust emissions test ⇒ page 138

Diesel engines: performing exhaust emissions test ⇒ page 145
4.1 Petrol engines: performing exhaust

emissions test
Note
♦ The following description refers to vehicles equipped with on-
© satelettronica
board diagnosis (OBD) with a closed-loop catalytic converter.
♦ The OBD monitors all components and (sub)systems which
affect the exhaust gas quality.

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

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

• Automatic gearbox: selector lever in position “P” or “N”

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

A display for the warm-up period will be shown.
© satelettronica
– Continue exhaust emissions test according to the instructions
on the display.
– When the options for the exhaust emissions test specifications

are shown, select the option required -arrow-:
♦ Either “Standard specifications” (for an initial exhaust emis‐
sions test)
♦ Or “Last vehicle” (to repeat a previous exhaust emissions test)
– Confirm Next -item 1- on display.
4. Exhaust emissions test 139

Entering vehicle data

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

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

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

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

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

Plugging in diagnostic connector

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

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

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

warning lamp does not light up during the visual check.

Visual check of exhaust emissions warning lamp with engine on

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

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

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

Measurement at increased idling speed

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

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

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

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

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

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

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

Note
♦ In order for the exhaust emissions test to be carried out, all

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

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

– Continue exhaust emissions test according to the instructions

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

are shown, select the option required -arrow-:
♦ Either “Standard specifications” (for an initial exhaust emis‐
sions test)
♦ Or “Last vehicle” (to repeat a previous exhaust emissions test)
– Confirm Next -item 1- on display.
© satelettronica
Entering vehicle data
The input menu for vehicle data will be shown.
– Enter the following data from the registration document (part
1):
♦ -1- Vehicle manufacturer, e.g. Audi
♦ -2- Vehicle model, e.g. A6 / 4G
♦ -3- Code for 14.1, e.g. 0572
♦ -4- Code for 2.1, e.g. 0588
♦ -5- Code for 2.2, e.g. 846
♦ -6- Engine code: e.g. CHVA
♦ -7- Number plate: e.g. IN-MV 1234
♦ -8- Vehicle identification number, e.g.
WAUZZZ4GZAN001234
– Enter mileage (km), e.g. 33350, at -item 9-.
Note
♦ Additional functions can be selected using the Go to button.

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

– Select “Diesel OBD” -arrow-.

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

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

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

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

All required data will be shown on display -1-.

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

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

– Check exhaust emissions warning lamp.

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

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

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

Measuring the idling speed

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

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

shown -arrow-.
Measuring the governed speed

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

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

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


Air quality check

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

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

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


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

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

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

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

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

Service
Workshop Manual
Audi A6 2011 ➤
Technical data for engines
Engine ID
CRD CGW CHJA CTU CEU CGX CAE CYN CDN
B D A C B D B B
CWU CGW CHV CRE CYP CRE CAE CYP CTG
C B A C B H B A E
© satelettronica
CVP CYG CWU
A A B
Edition 05.2017

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

Copyright © 2017 Audi AG, Ingolstadt D4B805AB604

Audi A6 2011 ➤
Technical data for engines - Edition 05.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Overview of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Overview of engines with adjustment values (oil gauge tester T40178) . . . . . . . . . . . . . . 1
© satelettronica
Contents i
Audi A6 2011 ➤
© satelettronica
ii Contents
Audi A6 2011 ➤
00 – Technical data
1 Overview of engines
(ARL005216; Edition 05.2017)
⇒ “1.1 Overview of engines with adjustment values (oil gauge
tester T40178)”, page 1
1.1 Overview of engines with adjustment

values (oil gauge tester T40178)
Audi A6, Audi A7 - vehicle model code 4G ⇒ page 1
1) Not available at time of publication. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1.1.1 Audi A6, Audi A7 - vehicle model code
4G
Petrol engines
En‐ En‐ Ca‐ Injec‐ Power Tor‐ Cam‐ Stroke Bore Com‐ Ad‐ Min. Max.
© satelettronica
gine gine pacity tion output que shaft [mm] [mm] press‐ just‐ oil lev‐ oil lev‐
code type/ [ltr.] sys‐ [kW] [Nm] drive ion ra‐ ment el el
num‐ tem (rpm) (rpm) tio value
ber of [:1] for ad‐
cylin‐ juster
ders ring
CAEB R4 2.0 FSI 155 350 Chain 92.80 82.50 9.60 39 0 24
4300- 1500- 0 0
6000 4200
CAED R4 2.0 FSI 162 350 Chain 92.80 82.50 9.60 39 0 24
4300- 3000- 0 0
6000 5000
CDNB R4 2.0 FSI 132 320 Chain 92.80 82.50 9.60 39 0 24
4000- 1500- 0 0
6000 3900
CEUC V8 4.0 FSI 309 550 Chain 89.00 84.50 10.10 185 0 21
5500- 1400- 0 0
6400 5200
CGW V6 3.0 FSI 220 440 Chain 89.00 84.50 10.50 132 0 13
B 5250- 2900- 0 0
6500 4500
CGW V6 3.0 FSI 228 440 Chain 89.00 84.50 10.50 132 0 13
D 5500- 2900- 0 0
6500 4500
CGXB V6 3.0 FSI 228 440 Chain 89.00 84.50 10.50 132 0 13
5500- 2900- 0 0
6500 4500
CHJA R4 2.0 FSI 155 350 Chain 92.80 82.50 9.60 39 0 24
4200- 1500- 0 0
6000 4200
CHVA V6 2.8 FSI 150 280 Chain 82.40 84.50 12.00 132 0 13
5250- 3000- 0 0
6500 5000
CRDB V8 4.0 FSI 412 700 Chain 89.00 84.50 9.30 185 0 24
5700- 1750- 0 0
6600 5500
1. Overview of engines 1
Audi A6 2011 ➤
cylin‐ juster
ders ring
CREC V6 3.0 FSI 245 440 Chain 89.00 84.50 10.80 141 0 11
5500- 2900- 0 0
6500 5300
CREH V6 3.0 FSI 250 440 Chain 89.00 84.50 10.80 141 0 11
6000- 2900- 0 0
6500 4750
CTGE V8 4.0 FSI 331 550 Chain 89.00 84.50 10.10 185 0 24
5800- 1400- 0 0
6400 5700
CTUA V6 3.0 FSI 228 440 Chain 89.00 84.50 10.50 132 0 13
5500- 2900- 0 0
6500 4500
CVPA V6 2.8 FSI 162 280 Chain 82.40 84.50 12.00 132 0 13
© satelettronica
5750- 3000- 0 0
6500 5000
CWU V8 4.0 FSI 412 700 Chain 89.00 84.50 9.30 185 0 24
B 5700- 1750- 0 0
6600 5500
CWU V8 4.0 FSI 445 700 Chain 89.00 84.50 9.30 185 0 24
C 5900- 1750- 0 0
6600 5800
CYGA R4 1.8 FSI 140 320 Chain 84.10 82.50 9.60
32 0 27
0 0
4200- 1400-
6200 4100
CYNB R4 2.0 FSI 185 370 Chain 92.80 82.50 9.60 32 0 27
4900- 1600- 0 0
5900 4700
CYPA R4 2.0 FSI 185 370 Chain 92.80 82.50 9.60 32 0 27
5000- 1600- 0 0
6000 4500
CYPB R4 2.0 FSI 183 370 Chain 92.80 82.50 9.60 32 0 27
4900- 1600- 0 0
5900 4700
2 Rep. gr.00 - Technical data

Service
Workshop Manual
Audi A6 2011 ➤
Technical data for diesel engines
Engine ID
CPN CGL CZVF CDU CGL CRT CTC CNH CGQ
B D D C D C A B
CLAB CDU CRT CVU CVU CZV CSU CKV CLAA
C E A B A E C
© satelettronica
CGL CRT CTC CSU CZV CZV CZJA CKV DDD
E F B D B C B A
CMG DDC CZV DDC
B A D B
Edition 05.2017

Service
Repair Group
00 - Technical data
© satelettronica

Copyright © 2017 Audi AG, Ingolstadt D4B805ADD78

Audi A6 2011 ➤
Technical data for diesel engines - Edition 05.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Overview of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Overview of engines with adjustment values (oil gauge tester T40178) . . . . . . . . . . . . . . 1
© satelettronica
Contents i
Audi A6 2011 ➤
© satelettronica
ii Contents
Audi A6 2011 ➤
1 Overview of engines
(ARL005217; Edition 05.2017)
⇒ “1.1 Overview of engines with adjustment values (oil gauge
tester T40178)”, page 1
1.1 Overview of engines with adjustment

values (oil gauge tester T40178)
Audi A6, Audi A7 - vehicle model code 4G ⇒ page 1
1) Not available at time of publication.
1.1.1 Audi A6, Audi A7 - vehicle model code

4G Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Diesel engines with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
cylin‐ juster
ders ring
CDUC V6 3.0 TDI 180 500 Chain 91.40 83.00 16.80 83 0 16
com‐ 4000- 1400- 0 0
mon 4500 3250
rail
CDUD V6 3.0 TDI 180 580 Chain 91.40 83.00 16.80 83 0 16
com‐ 4000- 1750- 0 0
mon 4500 2500
rail
CGLC R4 2.0 TDI 130 380 Tooth‐ 95.50 81.00 16.00 46 0 24
com‐ 4200 1750- ed 0 0
mon 2500 belt
rail
CGLD R4 2.0 TDI 120 380 Tooth‐ 95.50 81.00 16.00 46 0 24
com‐ 4200 1750- ed 0 0
mon 2500 belt
rail
CGLE R4 2.0 TDI 100 350 Tooth‐ 95.50 81.00 16.00 46 0 24
com‐ 4200 1750- ed 0 0
mon 2500 belt
rail
CGQ V6 3.0 TDI 230 650 Chain 91.40 83.00 16.50 87 0 12
B com‐ 3900- 1450- 0 0
mon 4500 2800
rail
CKVB V6 3.0 TDI 180 500 Chain 91.40 83.00 16.80 87 0 12
com‐ 4000- 1400- 0 0
mon 4500 3250
rail
CKVC V6 3.0 TDI 180 580 Chain 91.40 83.00 16.80 87 0 12
com‐ 4000- 1750- 0 0
mon 4500 2500
rail
CLAA V6 3.0 TDI 150 450 Chain 91.40 83.00 16.80 87 0 12
com‐ 0 0
Audi A6 2011 ➤
cylin‐ juster
ders ring
mon 3250- 1250-
rail 4500 3000
CLAB V6 3.0 TDI 150 400 Chain 91.40 83.00 16.80 87 0 12

com‐ 3750- 1250- 0 0
mon 4500 3500
rail
CMG R4 2.0 TDI 130 380 Tooth‐ 95.50 81.00 16.00 46 0 24
B com‐ 4200 1750- ed 0 0
mon 2500 belt
rail
CNHA R4 2.0 TDI 140 400 Tooth‐ 95.50 81.00 15.50 10 0 18
com‐ 3800- 1750- ed 0 0
mon 4200 3000 belt
rail
© satelettronica
CPNB V6 3.0 TDI 176 580 Chain 91.40 83.00 16.80 87 0 12
com‐ 4000 2100 0 0
mon
rail
CRTD V6 3.0 TDI 200 580 Chain 91.40 83.00 16.00 99 0 13
com‐ 4000 1700- 0 0
mon 2750
rail permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
CRTE V6 3.0 TDI 160 500 Chain 91.40 83.00 16.00 99 0 13
com‐ 4000 1700- 0 0
mon 2750
rail
CRTF V6 3.0 TDI 155 500 Chain 91.40 83.00 16.00 99 0 13
com‐ 4000 1700- 0 0
mon 2750
rail
CSUD R4 2.0 TDI 110 350 Tooth‐ 95.50 81.00 16.20 10 0 18
com‐ 3000- 1500- ed 0 0
mon 4200 3000 belt
rail
CSUE R4 2.0 TDI 100 350 Tooth‐ 95.50 81.00 16.20 10 0 18
com‐ 2750- 1500- ed 0 0
mon 4400 2750 belt
rail
CTCB V6 3.0 TDI 155 400 Chain 91.40 83.00 16.80 87 0 12
com‐ 4000 1250- 0 0
mon 3500
rail
CTCC V6 3.0 TDI 160 400 Chain 91.40 83.00 16.80 87 0 12
com‐ 4000 1250- 0 0
mon 3500
rail
CVUA V6 3.0 TDI 235 650 Chain 91.40 83.00 15.50 87 0 12
com‐ 4250 1450- 0 0
mon 2800
rail
CVUB V6 3.0 TDI 240 650 Chain 91.40 83.00 15.50 87 0 12
com‐ 4250 1450- 0 0
mon 2800
rail

Audi A6 2011 ➤
cylin‐ juster
ders ring
CZJA R4 2.0 TDI 140 400 Tooth‐ 95.50 81.00 15.50 10 0 18
com‐ 4200 1750- ed 0 0
mon 4200 belt
rail
CZVA V6 3.0 TDI 160 500 Chain 91.40 83.00 16.00 99 0 13
com‐ 4000 1250- 0 0
mon 3200
rail
CZVB V6 3.0 TDI 160 400 Chain 91.40 83.00 16.00 99 0 13
com‐ 4000 1250- 0 0
mon 3200
rail
CZVC V6 3.0 TDI 155 500 Chain 91.40 83.00 16.00 99 0 13
com‐ 4000 1250- 0 0
mon 3200
© satelettronica
rail
CZVDby copyright.
Protected V6 Copying 3.0 for private
TDIor commercial
155 purposes,
400 in part
Chain 91.40
or in whole, is not 83.00 16.00 99 0 13
permitted unless authorised by AUDI com‐ 0 0
4000 1250-
AG. AUDI AG does not guarantee or accept any liability
mon in this document.
with respect to the correctness of information
3200
Copyright by AUDI AG.
rail
CZVF V6 3.0 TDI 140 500 Chain 91.40 83.00 16.00 99 0 13
com‐ 2750- 1250- 0 0
mon 5000 2500
rail
DDCA R4 2.0 TDI 100 350 Tooth‐ 95.50 81.00 16.20 10 0 18
com‐ 2750- 1500- ed 0 0
mon 4400 2750 belt
rail
DDCB R4 2.0 TDI 110 350 Tooth‐ 95.50 81.00 16.20 10 0 18
com‐ 3000- 1500- ed 0 0
mon 4200 3000 belt
rail
DDDA R4 2.0 TDI 140 400 Tooth‐ 95.50 81.00 15.50 10 0 18
com‐ 3800- 1750- ed 0 0
mon 4200 3000 belt
rail
Service
Workshop Manual
Audi A6 2011 ➤
Audi A6 China 2012 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve
turbo TFSI - generation II)
© satelettronica
Engine ID
CAE CDN CDZ CHJA CAE
B B A D
Edition 12.2017

Service
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
21 - Turbocharging/supercharging with respect to the correctness of information in this document. Copyright by AUDI AG.
24 - Mixture preparation - injection

26 - Exhaust system
28 - Ignition system
© satelettronica

Copyright © 2017 Audi AG, Ingolstadt D3E80393881

Audi A6 2011 ➤ , Audi A6 China 2012 ➤ , Audi A7 Sportback 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve turbo TFSI - generation II) - Edition 12.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on the high-voltage system . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 3
2.3 Safety precautions for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
© satelettronica
2.3 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4 Removing and installing torque reaction support and cross member . . . . . . . . . . . . . . . . 44
2.5 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.1 Exploded view - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
15 - Cylinder head,Protected
valvebyunless
permitted gear . . .by.AUDI
authorised . . AG.
. . AUDI
. . .AG. does
. . .not. guarantee
. . . . .or.accept
. . .any. .liability
. . . . . . . . . . . . . . . 59
1 Timing chainwithcover ........................................................

59
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.1 Exploded view - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2 Exploded view - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.3 Removing and installing bearing saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.4 Removing camshaft timing chain from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.6 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.7 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2 Installing ball for slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3 Removing and installing actuators for camshaft adjustment . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
4.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.6 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 71
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 Exploded view - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
© satelettronica
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 Exploded view - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.3 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.5 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.7 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 105
2.9 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4 Radiator/radiator fans . . unless
permitted . . . .authorised
. . . . . .by. AUDI
. . . AG.
. . .AUDI
. . .AG. .does
. . .not
. .guarantee
. . . . . or
. .accept
. . . .any
. .liability
............ 118
4.1 Exploded view - radiator/radiator
with respect to the fans
correctness. .of. information
. . . . . . in. this
. . document.
. . . . . . Copyright
. . . . . by
. .AUDI
. . .AG.
............ 118
4.2 Exploded view - radiator cowl and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.4 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.6 Removing and installing radiator fan control unit J293 / J671 . . . . . . . . . . . . . . . . . . . . . . 128
4.7 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.3 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ii Contents
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3 Air cleaner
Protected by. copyright.
. . . . . .Copying
. . . . for
. .private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in. part
. . or
. .in. whole,
. . . .is.not
..................... 151
3.1 Exploded view
permitted - air
unless cleaner
authorised housing
by AUDI AG. AUDI AG . .does
. . .not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
....................... 151
3.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.4 Cleaning throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.5 Checking intake manifold change-over function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
© satelettronica
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.1 Removing and installing intake air temperature sender G42 . . . . . . . . . . . . . . . . . . . . . . 167
6.2 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.4 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.1 Removing and installing engine/motor control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.2 Wiring and component check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.2 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.3 Removing and installing front silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.1 Exploded view - emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.3 Removing and installing exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.1 Exploded view - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.2 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 190
3.3 Removing and installing secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.4 Removing and installing sender 1 for secondary air pressure G609 . . . . . . . . . . . . . . . . . . 191
4 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.1 Exploded view - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.2 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Contents iii
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

1.4 Removing and installing Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
© satelettronica
iv Contents
1 Identification
(ARL005544; Edition 12.2017)
All information can be found in ⇒ Servicing 4-cylinder engine, 1.8
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Identification .
© satelettronica
1. Identification 1
2 Safety precautions
⇒ “2.1 Safety precautions when working on the high-voltage sys‐
tem”, page 2
⇒ “2.2 Safety precautions when working in the vicinity of high-
voltage components”, page 3
⇒ “2.3 Safety precautions for all vehicles”, page 3
2.1 Safety precautions when working on the high-voltage system

High voltage can cause fatal injury.
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock.
– Persons with life-sustaining or other electronic medical devi‐
ces in or on their body must not perform any work on the high-
voltage system. Such medical devices include internal anal‐
gesic pumps, implanted defibrillators, pacemakers, insulin
pumps and hearing aids.
– The high-voltage system must be de-energised by a suitably
qualified person.
© satelettronica
Risk of injury - engine may start unexpectedly
It is difficult to determine whether the drive system of an electric
vehicle or hybrid vehicle is active. Moving parts can trap or draw
in parts of the body and/or clothing (safety hazard).
– Place ignition key outside vehicle interior.
Risk of injury if auxiliary air conditioner is activated

On electric and hybrid vehicles, the auxiliary air conditioner can
switch itself on if it has been activated. The radiator fans can start
up automatically and trap or draw in parts of the body.
– Deactivate the auxiliary air conditioner.
Risk of damage to high-voltage wiring
Incorrect handling may result in damage to the insulation for high-
voltage wires or high-voltage connectors.
– Never use high-voltage wiring or high-voltage connectors as
a support.
– Never support tools or equipment on high-voltage wires and
high-voltage connectors.
– Never bend or kink high-voltage wiring.
– Pay attention to coding when connecting high-voltage con‐
nections.

2.2 Safety precautions when working in the vicinity of high-voltage components

The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock if
high-voltage components or high-voltage wiring are damaged.
– Carry out visual check of high-voltage components and high-
voltage wiring.
– Never use cutting/forming tools or other sharp-edged imple‐
ments.
– Never perform
permitted work by
unless authorised using
AUDI AG.welding,
AUDI AGbrazing, thermal
does not guarantee bonding
or accept any liability
or hot
with air.
2.3 Safety precautions for all vehicles

© satelettronica
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Safety precautions .
2. Safety precautions 3
3 Repair instructions
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair instructions .
© satelettronica

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 5
⇒ “1.2 Securing engine to engine and gearbox support”,
page 32
⇒ “1.3 Installing engine”, page 32
1.1 Removing engine

⇒ “1.1.1 Removing engine - vehicles without hybrid drive”,
page 5
⇒ “1.1.2 Removing engine - vehicles with hybrid drive”,
page 18
1.1.1 Removing engine - vehicles without hybrid drive
Special tools and workshop
© satelettronica
equipment required
♦ Support bracket - 10 - 222 A-

♦ Lifting tackle - 2024 A-
1. Removing and installing engine 5

♦ Gearbox support - 3147-

♦ Workshop hoist - VAS 6100-
♦ Engine bung set - VAS 6122-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Counterhold tool - T10355-
© satelettronica
Procedure
CAUTION
Risk of injury if vehicle tips over when the engine is removed.
Danger of trapping or crushing parts of the body.
– The luggage
Protectedcompartment
by copyright. Copyingmust be or
for private empty.
commercial purposes, in part or in whole, is not
– Make sure the vehicle is secured.

Note
♦ The engine is removed upwards without gearbox.

♦ Fit all cable ties in the original positions when installing.
– Disconnect earth wire from battery terminal ⇒ Electrical sys‐

tem; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
– Remove engine cover panel ⇒ Servicing 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel;
Removing and installing engine cover panel .
6 Rep. gr.10 - Removing and installing engine

CAUTION
The cooling system is under pressure when the engine is hot.
Risk of scalding due to hot steam and hot coolant.
Danger of scalding skin and other parts of the body.
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
– Open filler cap -arrow- on coolant expansion tank.
© satelettronica
– Remove nuts -1 and 2- (accessible from above) for front si‐
lencer.
Note
Nut -3- is removed at a later stage.
– Remove wheel housing liners (front left and front right) ⇒

General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Removing and installing wheel housing liner (front) .
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Remove noise insulation panels ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– Open drain screw -1- at connection and drain off coolant; then
detach connection -2- from radiator (lift retaining clip).
– Move coolant hose clear at longitudinal member.
Vehicles with multitronic gearbox/8-speed automatic gearbox:
– Remove subframe cross brace ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Subframe; Removing and installing subframe
cross brace .

– Place drip tray for workshop hoist - VAS 6208- beneath ATF
cooler.
– Release hose clip -2- and detach coolant hose.
– Remove bolts -arrows- and push ATF cooler slightly to the
side.
Note
Place a cloth underneath to catch escaping coolant.
– Lift retaining clip -arrow-, disconnect coolant hose and move

clear.
© satelettronica
Vehicles with multitronic gearbox:
NOTICE
Risk of irreparable damage due to electrostatic discharge.
– Do NOT touch connector contacts with your hands.
– Touch the lifting platform or other earthed object to discharge
static electricity.
– Touch gearbox housing with your hand (without wearing

gloves) to eliminate static charge.
– Turn retainer catch anti-clockwise -arrow-, then unplug elec‐
trical connector at gearbox and move wiring clear.
Vehicles with 8-speed automatic gearbox:
NOTICE
– Touch the lifting platform or other earthed object to discharge
static electricity.

– Turn retainer catch anti-clockwise -arrow- and unplug electri‐
cal connector at gearbox.

Note
Place a cloth underneath to catch escaping ATF.
– Remove bolts -arrows- and detach ATF line -1- from gearbox.
– Seal off open lines and connections with clean plugs from en‐
gine bung set - VAS 6122- .
All vehicles (continued):

– Release hose clip -arrow-, disconnect air hose and press to
one side.
© satelettronica
– Remove nut -3- for front silencer.
– Remove bolts -arrows- for front exhaust pipe.

NOTICE
Risk of damage to flexible joint if handled incorrectly.
– Do not bend flexible joint more than 10°.
– Install flexible joint so that it is not under tension.
– Unfasten connections -arrows-, push clamp towards rear and

detach front silencer.
– Counterhold crankshaft at vibration damper using counterhold

tool - T10355- when slackening bolts for torque converter.
© satelettronica
– Detach bottom cover -1- from gearbox -arrow-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
When performing the next step, turn the crankshaft only in the
normal direction of rotation -arrow-.
– Remove 3 bolts -arrow- for drive plate, turning crankshaft 120°

in normal direction of rotation each time.

– Remove bolts -1, 7, 8, 9, 10, 11- securing engine to gearbox.
NOTICE
Risk of irreparable damage due to running a used belt in the
opposite direction when it is refitted.
– Mark running direction before removing.
– Pay attention to running direction when reinstalling.
© satelettronica
– Swivel tensioner in clockwise direction -arrow-, detach poly V-
belt from pulley for air conditioner compressor and release
tensioner.
– Take off poly V-belt.
– Detach air conditioner compressor from bracket for ancillaries
and tie up to one side ⇒ Heating, air conditioning; Rep. gr.
87 ; Air conditioner compressor; Detaching and attaching air
conditioner compressor at bracket .
– 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 lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Removing and installing attach‐
ments .
– Remove bolts -arrows- and detach air duct -1-.

– Unplug electrical connector -2-.

– Release hose clip -3- and detach air hose from air mass meter
- G70- .
– Detach air cleaner housing -1-.
© satelettronica
– Lift retaining clips -1- and -2- and disconnect coolant hoses.
– Release hose clips -arrows- and remove air hose.

– Unplug electrical connector for charge pressure sender - G31-
-item 1- and move electrical wiring clear.

– Lift retaining clip -2- and disconnect coolant hose.
– Disconnect fuel line -2- ⇒ Fuel supply system; Rep. gr. 20 ;

Plug-in connectors; Disconnecting plug-in connectors .
– Release hose clip -1- and disconnect hose from activated
charcoal filter.
© satelettronica
– Press foam wedge
permitted-1- toauthorised
unless one side. by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove bolts -arrows-.
– Remove body brace ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Suspension strut, upper links; Removing and installing
body brace .
– Release retainer -arrow A- and open cover -arrow B-.

– Remove nuts -2 and 4- and move electrical wiring clear.

– Detach electrical connector -1- from bracket and unplug.
– Remove nuts -arrows- and detach terminal 30 wiring junction
- TV2- from plenum chamber partition panel.
– If fitted, unplug electrical connector at brake servo pressure

sensor - G294- -arrow-.
© satelettronica
– Unscrew nut -2- on longitudinal member (right-side) and move
earth cables clear. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Release catch -arrow- to with

open wiring
to the duct -1- of
and moveinelec‐
respect correctness information this document. Copyright by AUDI AG.
trical wiring harness clear.
– Unscrew bolts -arrows- and pull filler neck -1- out of washer
fluid reservoir and through opening in body to right side.

– Remove cap nut -2- and move earth wiring clear.

– Release fastener -arrow-, detach engine control unit - J623-
-item 1- from bracket and swivel it to one side.
– Remove bolts -arrows- and detach cover -1- for electronics

box in plenum chamber.
© satelettronica
– Unplug electrical connectors -1- and unscrew nut -2- for elec‐
trical wiring.
– Release catches -arrows- and detach relay carrier with fuse
holder -3-.
– Disengage engine wiring harness at electronics box in plenum
chamber and move clear.
– Release catches -arrows A- and lift off wiring protector -1-

-arrow B-.
– Place wiring harness on engine and secure engine/motor con‐
trol unit - J623- to prevent it from dropping.

– Lift retaining clips -1, 2 and 3-, disconnect coolant hoses and
guide relevant coolant hoses through plenum chamber parti‐
tion panel.
Note
Shown for vehicle with multitronic gearbox in illustration.
– Remove plenum chamber partition panel ⇒ General body re‐

pairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum
chamber partition panel .
Vehicles with manual gearbox:

– Unplug electrical connector -2- at gear detection sensor -
G604- and move electrical wiring clear.
© satelettronica
All vehicles (continued): with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove bolts -2 ... 6- securing gearbox to engine.

– Separate starter from gearbox and leave in position.
Note
Bolt -2- secures the starter to the gearbox and is provided with an
additional spacer sleeve -arrow-.

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

(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 up weight of gearbox with spindle of support bracket.
CAUTION
Risk of injury if engine drops when it is lifted.
– The support hooks and retaining pins on the lifting tackle
must be secured with locking pins.
© satelettronica
– The support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
– Engage lifting tackle - 2024 A- on engine and workshop hoist
- VAS 6100- .
Note
To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.
– Remove bolt -2- for engine mounting on both sides.

– Remove nut -3- 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.
NOTICE
Risk of damage to lines/pipes, hoses and engine compartment
when lifting engine out.
– Check that all connections between engine, gearbox, sub‐
frame and body have been detached.

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.
1.1.2 Removing engine - vehicles with hybrid drive

equipment required
© satelettronica


Procedure
Note
© satelettronica
♦ Fit cable ties in the original positions when installing.

battery .
DANGER
Danger of severe or fatal injuries from electric shock.
qualified person.
– De-energise high-voltage system ⇒ Electric drive; Rep. gr.

93 ; De-energising high-voltage system .
CAUTION


noise insulation .
cross brace .
gine.
© satelettronica
– Release hose clip -arrow- and detach coolant hose.

one side.

– Remove nuts -1, 2, 3- for front silencer.
© satelettronica
NOTICE

– Unplug electrical connector -arrow- for auxiliary hydraulic

pump 1 for gearbox oil - V475- from right side of gearbox and
move electrical wiring clear.

NOTICE
– Touch the lifting platform
Protectedorbyother earthed
copyright. object
Copying for privateto discharge
or commercial purposes, in part or in whole, is not
static electricity. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
– Move electrical wiring harness clear at gearbox.
– Unplug connector -A- for high-voltage wiring harness for drive

motor - PX2- and connector -B- at drive motor rotor position
sender 1 - G713- on top left of gearbox.
– Unplug electrical connector -C- for Lambda probe after cata‐
lytic converter - G130- and detach from cable tie -arrow-.
– Unplug electrical connector -3- on charge pressure sender -

– Release hose clip -2- and detach air hose.
– Remove bolts -arrows- and push connection -1- clear to one
side.

– Unscrew bolts -arrows- and remove torque reaction support

-1-.

– Remove bolts -arrows- on both sides and detach cross mem‐
ber -2- for torque reaction support.
© satelettronica
– Remove bolt -1-.
– Press release tabs -2- and detach resonator.
– Unplug electrical connector -arrow- at secondary air pump

motor - V101- and move electrical wiring clear.

Note

side.
– Detach bottom cover -1- from gearbox -arrow-.
© satelettronica
– Counterhold crankshaft on central bolt for vibration damper
using angled ring spanner -1- when loosening bolts for electric
drive motor - V141- .
Note
– Remove 3 bolts -arrow- for electric drive motor - V141- on drive

plate, turning crankshaft 120° in normal direction of rotation
each time.

– Remove bolts -1, 6, 7, 8, 9, 10, 11- securing engine to gearbox.
– Move clear electrical wiring
permitted unless harness
authorised going
by AUDI to radiator
AG. AUDI AG does notfan con‐ or accept any liability
guarantee
trol unit. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove electrically driven air conditioner compressor from

bracket ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor; Detaching and attaching air conditioner
© satelettronica
compressor at bracket .
ments .

– Unplug electrical connector -2- and move wiring clear.

- G70- .
– Lift off air cleaner housing -1-.

– Press release tabs and disconnect secondary air hose
-arrow-.
© satelettronica
– Lift retaining clips -1 and 2-, detach coolant hoses and move
them clear to one side.
– Unplug electrical connector -1- from charge air cooling pump

- V188- and move clear electrical wiring.
– Remove cap nut -2- and move earth wire -3- clear.

– Release catch -arrow- and open cover -1-.

– Remove nut -2- for electrical wiring.
– Move electrical wiring harness clear.
– Unscrew bolts -arrows- and remove cover -2-.
© satelettronica
– Unplug electricalProtected
connector -arrow-
by copyright. and
Copying move
for private wiring harness
clear. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

charcoal filter.

– Press foam wedge -1- to one side.

body brace .
© satelettronica
– Remove nuts -2, 3 and 4- and move electrical wiring clear.

earth cables clear.
– Release catch -arrow- to open wiring duct -1- and move elec‐


-item 1- from bracket andby swivel
Protected copyright. it to one
Copying side.or commercial purposes, in part or in whole, is not
for private
© satelettronica
trical wiring.
holder -3-.


-arrow B-.
– Move wiring harness clear and place on top of engine.
– Secure engine control unit - J623- to prevent it falling.
– Lift retaining clips -1, 4-, release hose clipProtected

-3- and detachCopying
by copyright. cool‐ for private or commercial purposes, in part or in whole, is not
ant hoses. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unplug electrical connectors -2- and move wiring clear.
© satelettronica
– Release hose clips -1- and detach coolant hoses.
– Unscrew bolts -arrows- and remove pump unit.
– Release hose clip -arrow- and disconnect vacuum hose from

T-piece.


Note with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
– Set up support bracket - 10 - 222 A- on wing mounting flanges
– Attach gearbox support - 3147- to gearbox and to spindle - 10
- 222 A /11- .
Note
♦ For illustration purposes, the installation position is shown with

the engine removed.
♦ If necessary, modify lower part of gearbox support - 3147-
slightly.
CAUTION
Risk of injury if engine drops when it is lifted.
– The support hooks and retaining pins on the lifting tackle
– The support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
– Engage lifting tackle - 2024 A- on engine and workshop hoist
- VAS 6100- .
Note



NOTICE
Risk of damage to lines/pipes, hoses and engine compartment
when lifting engine out.
– Check that all connections between engine, gearbox, sub‐
frame and body have been detached.
Note

© satelettronica
compartment.
1.2 Securing engine to engine and gearbox

support Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
All procedures are described in ⇒ Servicing 4-cylinderwithengine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Removing and installing
engine; Securing engine to engine and gearbox support .
1.3 Installing engine

⇒ “1.3.1 Installing engine - vehicles without hybrid drive”,
page 32
⇒ “1.3.2 Installing engine - vehicles with hybrid drive”,
page 35
1.3.1 Installing engine - vehicles without hy‐

brid drive
♦ All special tools specified in removal procedure
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 .

– Bring engine into position on gearbox, guiding starter, and se‐

cure by tightening bolts (accessible from above) ⇒ Gearbox;
Rep. gr. 34 ; Removing and installing gearbox; Installing gear‐
box , or ⇒ Gearbox; Rep. gr. 37 ; Removing and installing
gearbox; Installing gearbox .
© satelettronica

– Release spindle of support bracket - 10-222 A- .

– Lower workshop hoist and place engine/gearbox assembly
onto engine mounting.
– Install engine mountings ⇒ page 43 .
– Detach workshop hoist - VAS 6100- and lifting tackle - 2024
A- .
– Screw in and tighten bolts for engine to gearbox ⇒ Gearbox;
Rep. gr. 34 ; Removing and installing gearbox; Tightening
torques for gearbox , or ⇒ Gearbox; Rep. gr. 37 ; Removing
and installing gearbox; Tightening torques for gearbox .
– Install front silencer ⇒ page 181 .
– Align the exhaust system so it is free of stress ⇒ page 182 .
– 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 ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0
ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley end);
© satelettronica
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install engine control unit ⇒ page 172 .
– Install electrical wiring, terminal 30 wiring junction 2 - TV22-
and cover for electronics box in plenum chamber ⇒ Electrical
system; Rep. gr. 97 ; Relay carriers, fuse carriers, electronics
boxes; Overview of fitting locations - relay carriers, fuse carri‐
ers, electronics boxes .
– Install plenum chamber partition panel ⇒ General body re‐
– Install body brace ⇒ Running gear, axles, steering; Rep. gr.
40 ; Suspension strut, upper links; Exploded view - suspension
strut, upper links .
– Install filler neck for washer fluid reservoir ⇒ Electrical system;
Rep. gr. 92 ; Windscreen washer system; Exploded view -
windscreen washer system .
– Observe steps required after re-connecting battery ⇒ Electri‐
cal system; Rep. gr. 27 ; Battery; Disconnecting and connect‐
ing battery .
NOTICE
Risk of irreparable damage to control units because of exces‐
sive voltage.
– Do not use a battery charger to boost starting.
– Install air cleaner housing ⇒ page 152 .

– Install air hoses ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr.
4-valve TFSI; Rep. gr. 21 ; Charge airbysystem;
Protected Exploded
copyright. Copying view
for private or commercial purposes, in part or in whole, is not
- hose connections for charge permitted
air systemunless .authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Check oil level ⇒ Maintenance ; Booklet 411 .
Note
Do not reuse coolant.

– Fill up with coolant ⇒ page 83 .

– Install subframe cross brace ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Subframe; Removing and installing subframe
cross brace .
– Install wheel spoilers and wheel housing liners ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Ex‐
ploded view - wheel housing liner (front) .
– After renewing engine, misfire adaptions must be reset. To do
so, select 01 - Reset adaptions misfires in Guided
Functions mode of ⇒ Vehicle diagnostic tester.
Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gear oil may be used,
but do not use lubricants containing graphite.
♦ Do not use degreased parts.
© satelettronica
♦ Tolerance for tightening torques: ± 15 %.
Further tightening torques

Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ ⇒ “2.1 Exploded view - assembly mountings”, page 39
♦ Engine to gearbox ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Tightening torques for gearbox , or ⇒ Gear‐
box; Rep. gr. 37 ; Removing and installing gearbox; Tighten‐
ing torques for gearbox
1.3.2 Installing engine - vehicles with hybrid

drive
♦ All special tools specified in removal procedure
Procedure
Note
and O-rings.
– Bring engine into position on gearbox, guiding starter, and se‐

cure by tightening bolts (accessible from above) ⇒ Gearbox;

Rep. gr. 37 ; Removing and installing gearbox; Installing gear‐

box .
© satelettronica


– Install engine mountings ⇒ page 43 .
A- .
– Screw in and tighten bolts securing engine to gearbox ⇒
Gearbox; Rep. gr. 37 ; Removing and installing gearbox;
Tightening torques for gearbox .
– Install air conditioner
permitted unless authorisedcompressor
by AUDI AG. AUDI ⇒ AGHeating, air conditioning;

© satelettronica
WARNING
– The high-voltage system must be re-energised by a suitably
qualified person.
– Re-energise high-voltage system ⇒ Electric drive; Rep. gr.

93 ; Re-energising high-voltage system .
ing battery .
NOTICE
sive voltage.
– Do not use a battery charger to boost starting.

– Install air hoses ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr.
4-valve TFSI; Rep. gr. 21 ; Charge air system; Exploded view
- hose connections for charge air system .

Note

cross brace .
– After renewing engine, misfire adaptions must be reset. To do
so, select 01 - Reset adaptions misfires in Guided
Functions mode of ⇒ Vehicle diagnostic tester.
Tightening torques
Note
© satelettronica
♦ Additional lubricants such as engine or gearbox oil may be
used, but do not use lubricants containing graphite.
♦ Do not use de-greased parts.
Further tightening torques
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
installing gearbox; Tightening torques for gearbox , or ⇒ Gear‐

2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 39
⇒ “2.2 Supporting engine in installation position”, page 42
⇒ “2.3 Removing and installing engine mountings”, page 43
⇒ “2.4 Removing and installing torque reaction support and cross
member”, page 44
⇒ “2.5 Removing and installing gearbox mounting”, page 47
2.1 Exploded view - assembly mountings

Engine mounting
1 - Not fitted
2 - Bolt
❑ 20 Nm
3 - Bracket
❑ For engine mounting
© satelettronica
❑ Renew retaining plate if
engine mounting is de‐
fective
❑ Check retaining plate on
opposite side; renew if
necessary
4 - Not fitted
5 - Not fitted
6 - Bolt
❑ 40 Nm
7 - Engine support
8 - Bolt
❑ 10 Nm
9 - Heat shield
10 - Bolt
❑ Renew
❑ 90 Nm + turn 90° further
11 - Engine mounting
❑ Depending on equip‐
ment and version, only
with left electrohydraulic
engine
Protected mounting
by copyright. Copyingsole‐
noidunless
permitted valve - N144-
authorised on AG. AUDI AG does not guarantee or accept any liability
by AUDI
leftrespect
with sideto the correctness of information in this document. Copyright by AUDI AG.
ment and version, additionally with right electrohydraulic engine mounting solenoid valve - N145- on right
side
❑ Removing and installing ⇒ page 43
12 - Subframe
13 - Bolt
❑ 55 Nm
2. Assembly mountings 39
Torque reaction support and cross member - tightening torques

1- Bolt: 20 Nm
2- Bolt: 50 Nm
Gearbox mounting for manual gearbox 0B1
1 - Nut
❑ Tightening torque ⇒
Gearbox; Rep. gr. 34 ;
Assembly mountings;
Exploded view - assem‐
bly mountings
© satelettronica
2 - Bolt
Assembly mountings;
blybymountings
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Bolt
Assembly mountings;
bly mountings
4 - Nut
Assembly mountings;
bly mountings
5 - Gearbox support
❑ Removing and installing
⇒ page 47
6 - Gearbox mounting
⇒ page 47
7 - Stop (bottom)
❑ For gearbox mounting
8 - Bolt
❑ Tightening torque ⇒ Gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
9 - Tunnel cross member
❑ Removing and installing ⇒ Gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view - assembly
mountings
Gearbox mounting for multitronic gearbox 0AW

1 - Nut
Assembly mountings;
bly mountings
2 - Bolt
Assembly mountings;
bly mountings
3 - Bolt
Assembly mountings;
bly mountings
4 - Nut
© satelettronica
Assembly mountings;
bly mountings
5 - Gearbox support
⇒ page 48
7 - Stop (bottom)
8 - Bolt
Assembly mountings;
Exploded view - assembly mountings
mountings
Gearbox mounting for automatic gearbox 0BK/0BW
1 - Bolt
Assembly mountings;
bly mountings
⇒ Gearbox; Rep. gr.
37 ; Assembly mount‐
ings; Exploded view -
assembly mountings
3 - Stop plate
⇒ page 49
5 - Bolt
© satelettronica
Assembly mountings;
bly mountings
6 - Nut
❑ Only remove if detach‐
ing gearbox mounting
from gearbox support
Assembly mountings;
bly mountings
7 - Bolt
❑ 40 Nm
8 - Gearbox support
9 - Bolt
❑ Only remove if detaching gearbox mounting from gearbox support
10 - Nut
2.2 Supporting engine in installation posi‐

tion

Supporting
– Remove engine cover
Protected panelCopying
by copyright. ⇒ Servicing
for private or 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve
permitted TFSI;
unless Rep.
authorised gr. AG.
by AUDI 10 AUDI
; Engine
AG doescover panel;
Removing andwith installing engine
respect to the cover
correctness panelin. this document. Copyright by AUDI AG.
of information
– Remove foam wedge -1- on both sides.
© satelettronica
– Set up support bracket - 10 - 222 A- with adapters -10 - 222
A /3- on wing mounting flanges (left and right), as shown in
illustration.
– Attach spindles -10 - 222 A /11- to engine lifting eyes.
– Partly take up weight of engine with spindles.
2.3 Removing and installing engine mount‐

ings
Note
♦ The engine mountings cannot be renewed separately; the cor‐

responding retaining plate must also be renewed.
♦ The following chapter describes the procedure for the engine
mounting (left-side).
Removing
– Support engine with support bracket ⇒ page 42 .
– Remove front wheel (left-side) ⇒ Running gear, axles, steer‐

ing; Rep. gr. 44 ; Wheels, tyres .
– Remove noise insulation (front) ⇒ General body repairs, ex‐
noise insulation .
– Remove wheel spoiler (front left) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Move clear and unplug electrical connector -3- on left electro‐
hydraulic engine mounting solenoid valve - N144- .
– Remove bolts -1, 4, 5- for engine mounting.
– Move retaining plate -2- for engine mounting clear to the side.
– Detach engine mounting.
Installing
Installation is carried out in reverse order; note the following:
Note
© satelettronica
Renew the bolts tightened with specified tightening angle.
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐

tion; Exploded view - noise insulation
2.4 Removing and installing torque reaction

support and cross member
Removing
noise insulation .
– Remove bolts -arrows- and push connection -1- clear to one
side.


one side.

-1-.
© satelettronica
– Remove bolts -arrows- on both sides and detach cross mem‐
ber -2- for torque reaction support.
Installing
– Note installation position and marking of buffer stop.
– 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.
The remaining installation steps are carried out in the reverse se‐
quence.
Note
Secure all hose connections with the correct type of hose clips
Tightening torques
♦ ⇒ Fig. ““Torque reaction support and cross member - tighten‐
ing torques”“ , page 40
© satelettronica
♦ ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI;
Rep. gr. 21 ; Charge air system; Exploded view - hose con‐
nections for charge air system
♦ Wheel spoiler ⇒ General body repairs, exterior; Rep. gr. 66 ;
Wheel housing liners; Exploded view - wheel housing liner
(front)

2.5 Removing and installing gearbox

mounting
⇒ “2.5.1 Removing and installing gearbox support with gearbox
mounting - manual gearbox 0B1”, page 47
⇒ “2.5.2 Removing and installing gearbox mounting - manual
gearbox 0B1”, page 47
⇒ “2.5.3 Removing and installing gearbox mounting - multitronic
gearbox 0AW”, page 48
mounting - automatic gearbox 0BK/0BW”, page 48
⇒ “2.5.5 Removing and installing gearbox mounting - automatic
gearbox 0BK/0BW”, page 49
2.5.1 Removing and installing gearbox sup‐

port with gearbox mounting - manual
gearbox 0B1
Removing
– Remove tunnel cross member ⇒ Gearbox; Rep. gr. 34 ; As‐

© satelettronica
sembly mountings; Exploded view - assembly mountings .
– Remove bolts -arrows- and detach gearbox support and gear‐
box mounting from gearbox.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view
- assembly mountings
2.5.2 Removing and installing gearbox

mounting - manual gearbox 0B1
Removing
– Remove gearbox support with gearbox mounting ⇒ page 47 .
– Unscrew bolts -1- and detach stop (bottom) -2- for gearbox
mounting.
– Remove nut -4- and detach gearbox mounting -5- from gear‐
box support -3-.
Installing
– Position gearbox support -3- on gearbox mounting -5- and
hand-tighten nut -4-.
– Secure stop (bottom) -2- with bolts -1-.
– Tighten nut -4-.
– Install gearbox support with gearbox mounting ⇒ page 47 .
Tightening torques

mounting - multitronic gearbox 0AW
Removing
mounting.
box support -3-.
Installing
Tightening torques
© satelettronica
port with gearbox mounting - automatic
gearbox 0BK/0BW
Removing
Installing
Tightening torques Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ ⇒ Gearbox; Rep. gr. 37 ;with
Assembly mountings; Exploded view


mounting - automatic gearbox 0BK/0BW
Removing
– Unscrew bolt -1- and detach stop -2- for gearbox mounting.
– Remove nut -4- and bolt -5- and detach gearbox mounting
-6- from gearbox support -3-.
Installing
– Position gearbox support -3- on gearbox mounting -6-.
– Hand-tighten nut -4- and bolt -5-.
– Tighten bolt -1- for stop -2-.
– Tighten nut -4- and bolt -5-.
Tightening torques
© satelettronica
3 Engine cover panel

All procedures can be found in ⇒ Servicing 4-cylinder engine, 1.8
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel .
© satelettronica

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 51
⇒ “1.2 Removing and installing poly V-belt”, page 51
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 51
⇒ “1.4 Removing and installing vibration damper”, page 51
⇒ “1.5 Removing and installing bracket for ancillaries”,
page 51
1.1 Exploded view - cylinder block (pulley

end) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
All components are described in ⇒ Servicing 4-cylinder engine,

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley
end); Exploded view - cylinder block (pulley end) .
© satelettronica
1.2 Removing and installing poly V-belt
All procedures are described in ⇒ Servicing 4-cylinder engine,
1.3 Removing and installing tensioner for

poly V-belt
end); Removing and installing poly V-belt tensioner .
1.4 Removing and installing vibration damp‐

er
Removing
– Remove radiator fan control unit - J293- ⇒ page 128 .
All further procedures are described in ⇒ Servicing 4-cylinder
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing vibration damper .
Installing
Additional work:
– Install radiator fan control unit - J293- ⇒ page 128 .
1.5 Removing and installing bracket for an‐

cillaries
⇒ “1.5.1 Removing and installing bracket for ancillaries - vehicles
without hybrid drive”, page 51
⇒ “1.5.2 Removing and installing bracket for ancillaries - vehicles
with hybrid drive”, page 53
1.5.1 Removing and installing bracket for an‐

cillaries - vehicles without hybrid drive
Removing
– Drain coolant ⇒ page 83 .
1. Cylinder block (pulley end) 51

– Unplug electrical connectors -2 and 3- from oil pressure switch

- F22- and oil pressure switch for reduced oil pressure - F378- .
– Release hose clips -arrows- and detach air hose.

– Remove poly V-belt ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
© satelettronica
52 Rep. gr.13 - Crankshaft group

– Remove bolts -1- and -2- and press coolant pipe (front) to side.
– Detach air conditioner compressor from bracket for ancillaries
and tie up to left side ⇒ Heating, air conditioning; Rep. gr. 87 ;
Air conditioner compressor; Detaching and attaching air con‐
ditioner compressor at bracket .
(pulley end); Removing and installing bracket for ancillaries .
Installing
Additional work:
Note
– InstallProtected
air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr.with87 ; Airto the

conditioner
correctness ofcompressor; Detaching andby at‐
respect information in this document. Copyright AUDI AG.
© satelettronica
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
Note

Tightening torques
♦ ⇒ “3.1.1 Exploded view - coolant pipes (engine end)”,
page 108
1.5.2 Removing and installing bracket for an‐

cillaries - vehicles with hybrid drive
Removing
DANGER
qualified person.


– Unplug electrical connectors -1- and -2- at oil pressure switch

- F22- and oil pressure switch for reduced oil pressure - F378- .
– Remove electrical air conditioner compressor -V470- from
bracket for ancillaries and tie up to left side ⇒ Heating, air
conditioning; Rep. gr. 87 ; Air conditioner compressor; De‐
taching and attaching air conditioner compressor at bracket .

– Remove bolts -arrows- and push coolant pump - V36- to one
side.
© satelettronica
Installing
Additional work:
– Install electrical air conditioner compressor -V470- ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor; De‐
WARNING
qualified person.

Tightening torques
♦ ⇒ “2.2 Exploded view - electric coolant pump”, page 90
page 108

2 Cylinder block (gearbox end)

All procedures and components can be found in ⇒ Servicing 4-
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder
block (gearbox end) .
© satelettronica
2. Cylinder block (gearbox end) 55

3 Crankshaft
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ;
Crankshaft .
© satelettronica

4 Balance shaft
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Balance
shaft .
© satelettronica
4. Balance shaft 57
5 Pistons and conrods

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Pistons
and conrods .
© satelettronica

15 – Cylinder head, valve gear

1 Timing chain cover
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing
chain cover .
© satelettronica
1. Timing chain cover 59

2 Chain drive
⇒ “2.1 Exploded view - camshaft timing chains”, page 60
⇒ “2.2 Exploded view - drive chain for balance shaft”, page 60
⇒ “2.3 Removing and installing bearing saddle”, page 60
⇒ “2.4 Removing camshaft timing chain from camshafts”,
page 60
⇒ “2.5 Removing and installing camshaft timing chain”,
page 60
⇒ “2.6 Removing and installing drive chain for balance shaft”,
page 61
⇒ “2.7 Checking valve timing”, page 61
2.1 Exploded view - camshaft timing chains

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Exploded
view - camshaft timing chains .
2.2 Exploded view - drive chain for balance
© satelettronica
shaft
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Exploded
view - drive chain for balance shaft .
2.3 Removing and installing bearing saddle

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Removing and
installing bearing saddle .
2.4 Removing camshaft timing chain from

camshafts
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Removing
camshaft timing chain from camshafts .
2.5 Removing and installing camshaft tim‐

ing chain
Removing
– Remove air cleaner housing ⇒ page 152 .
– Vehicles with hybrid drive: Remove torque reaction support
and cross
Protectedmember
by copyright.⇒Copying
pagefor44 . or commercial purposes, in part or in whole, is not
private
All further with
procedures
respect to the are described
correctness in ⇒in this
of information Servicing 4-cylinder
document. Copyright by AUDI AG.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive;
Removing and installing camshaft timing chain .
Installing
Additional work:
– Vehicles with hybrid drive: Install torque reaction support and
cross member ⇒ page 44 .
60 Rep. gr.15 - Cylinder head, valve gear

2.6 Removing and installing drive chain for

balance shaft
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Removing and
installing drive chain for balance shaft .
2.7 Checking valve timing

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Checking
valve timing .
© satelettronica
2. Chain drive 61
3 Cylinder head
⇒ “3.1 Exploded view - cylinder head”, page 62
⇒ “3.2 Removing and installing cylinder head”, page 62
⇒ “3.3 Checking compression”, page 66
3.1 Exploded view - cylinder head

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Exploded
view - cylinder head .
3.2 Removing and installing cylinder head

⇒ “3.2.1 Removing cylinder head - vehicles without hybrid drive”,
page 62
⇒ “3.2.2 Removing cylinder head - vehicles with hybrid drive”,

page 64
⇒ “3.2.3 Installing cylinder head - all vehicles”, page 65
3.2.1 Removing cylinder head - vehicles with‐
© satelettronica
out hybrid drive
Removing
– Remove camshafts ⇒ page 67 .
NOTICE
Risk of damage to valves and piston crowns if work has been
performed on valve gear.
– Never turn crankshaft with camshafts removed.

– Remove catalytic converter ⇒ page 184 .
– Release hose clip -arrow- and detach vacuum connection.


charcoal filter.
© satelettronica
– Unplug the following electrical connectors:
2 - From knock sensor 1 - G61- (unplug and move clear).
3 - From intake manifold flap valve - N316- , fuel pressure sender
- G247- and Hall sender - G40-
4 - From injectors
5 - From throttle valve module - J338-
6 - From intake air temperature sender - G42-

engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head;
Removing and installing cylinder head .
3. Cylinder head 63
3.2.2 Removing cylinder head - vehicles with

hybrid drive
Removing
DANGER
qualified person.

NOTICE Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Risk of damage to valves and piston crowns if work haswith
been
performed on valve gear.
– Never turn crankshaft with camshafts removed.
© satelettronica
– Release hose clip -arrow- and detach vacuum connection.
– Release hose clip -arrow- and disconnect vacuum hose from

T-piece.

– Unplug electrical connectors -arrows-.
– Unplug the following electrical connectors:

1- From intake air temperature sender - G42-
2- From knock sensor 1 - G61- (unplug and move clear).
3- From sender 2 for secondary air pressure - G610-
4- From activated charcoal filter solenoid valve 1 - N80-
5- From intake manifold flap valve - N316- , fuel pressure
© satelettronica
sender - G247- and Hall sender - G40-
6- From injectors
7- From throttle valve module - J338-
– Unscrew bolts -3- and move
permittedcoolant pumpby- AUDI
unless authorised V36- AG.clear
AUDI AGto does
onenot guarantee or accept any liability
side. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Press release tabs -2- and detach resonator.
3.2.3 Installing cylinder head - all vehicles

Installing
Additional work:
3. Cylinder head 65
Vehicles with hybrid drive:

– Install coolant pump - V36-
⇒ “3.1.2 Exploded view - coolant pipes, vehicles with hybrid
drive”, page 110 .
WARNING
qualified person.

Continued for all vehicles:
– Install catalytic converter:
♦ ⇒ “2.2.1 Removing and installing catalytic converter - vehicles
© satelettronica
♦ ⇒ “2.2.2 Removing and installing catalytic converter - vehicles
Tightening torques
page 108
3.3 Checking compression

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Checking
compression .

4 Valve gear
⇒ “4.1 Exploded view - valve gear”, page 67
⇒ “4.2 Installing ball for slider”, page 67
⇒ “4.3 Removing and installing actuators for camshaft adjust‐
ment”, page 67
⇒ “4.4 Removing and installing camshaft”, page 67
⇒ “4.5 Removing and installing camshaft control valve 1 N205 ”,
page 68
⇒ “4.6 Removing and installing valve stem oil seals”, page 68
4.1 Exploded view - valve gear

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded
view - valve gear .
4.2 Installing ball for slider

© satelettronica
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Installing
ball for slider .
4.3 Removing and installing actuators for

camshaft adjustment
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Removing
and installing actuators for camshaft adjustment .
4.4 Removing and installing camshaft

Removing
noise insulation . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear;
Removing and installing camshaft .
Installing
Additional work:
– Install engine cover panel ⇒ Servicing 4-cylinder engine, 1.8
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel;
Tightening torques
4. Valve gear 67
4.5 Removing and installing camshaft con‐

trol valve 1 - N205-
and installing camshaft control valve 1 - N205- .
4.6 Removing and installing valve stem oil

seals
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep.togr. 15 ; Valve gear; Removing
with respect the correctness of information in this document. Copyright by AUDI AG.
and installing valve stem oil seals .
© satelettronica

5 Inlet and exhaust valves

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Inlet and exhaust
valves .
© satelettronica
5. Inlet and exhaust valves 69

17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 70
⇒ “1.2 Engine oil”, page 70
⇒ “1.3 Removing and installing sump (bottom section)”,
page 70
⇒ “1.4 Removing and installing oil pump”, page 70
⇒ “1.5 Removing and installing sump (top section)”, page 70
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 71
1.1 Exploded view - sump/oil pump

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Ex‐
ploded view - sump/oil pump .
© satelettronica
1.2 Engine oil
♦ Refer to ⇒ Maintenance ; Booklet 411 for instructions on
draining and filling up engine oil, checking oil level, removing
and installing oil filter.
♦ Oil capacities, oil specifications and viscosity grades ⇒ Main‐
tenance tables .
1.3 Removing and installing sump (bottom

section)
Removing
cross brace .
– Remove nuts -arrows- and lower anti-roll bar.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump (bottom section) .
Installing
Additional work:
cross brace .
1.4 Removing and installing oil pump

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Re‐
moving and installing oil pump .
1.5 Removing and installing sump (top sec‐

tion)
moving and installing sump (top section) .
70 Rep. gr.17 - Lubrication

1.6 Removing and installing oil level and oil

temperature sender - G266-
moving and installing oil level and oil temperature sender - G266- .
© satelettronica
1. Sump/oil pump 71
2 Engine oil cooler

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Engine
oil cooler .
© satelettronica

3 Crankcase breather
⇒ “3.1 Exploded view - crankcase breather system”, page 73
⇒ “3.2 Removing and installing oil separator”, page 73
3.1 Exploded view - crankcase breather

system
1.8 ltr., 2.0 ltr. 4-valve TFSI;
ProtectedRep. gr. 17
by copyright. ; Crankcase
Copying breather;
Exploded view - crankcase breather
permitted system
unless authorised . AG. AUDI AG does not guarantee or accept any liability
by AUDI
3.2 Removing and installing oil separator
⇒ “3.2.1 Removing and installing oil separator on cylinder block”,
page 73
⇒ “3.2.2 Removing and installing oil separator on cylinder head
cover”, page 74
3.2.1 Removing and installing oil separator on

cylinder block
© satelettronica
Removing
– Remove engine mounting (left-side) ⇒ page 43 .
Vehicles without hybrid drive:

– Loosen hose clips -arrows-.
– Unscrew bolt -1- and detach air pipe.
3. Crankcase breather 73

– Remove bolts -arrows- and detach engine support (left-side)
-1-.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Crankcase
breather; Removing and installing oil separator .
Installing
Additional work:
Note
(same as original equipment)
permitted unless⇒ Electronic
by AUDIparts catalogue .
authorised AG. AUDI AG does not guarantee or accept any liability
Tightening torques
© satelettronica
3.2.2 Removing and installing oil separator on
cylinder head cover
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Crankcase breather;
Removing and installing oil separator .

4 Oil filter/oil pressure switches

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil
filter/oil pressure switches .
© satelettronica
4. Oil filter/oil pressure switches 75

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 76
⇒ “1.2 Checking cooling system for leaks”, page 83
⇒ “1.3 Draining and filling cooling system”, page 83
1.1 Connection diagram - coolant hoses

⇒ “1.1.1
permittedConnection
unless authoriseddiagram
by AUDI AG.-AUDI
coolant hoses, vehicles with man‐
ual gearbox and
with respect to without ofauxiliary
the correctness information heater”, page
in this document. 76 by AUDI AG.
Copyright
⇒ “1.1.2 Connection diagram - coolant hoses, vehicles with man‐

ual gearbox and auxiliary heater”, page 78
⇒ “1.1.3 Connection diagram - coolant hoses, vehicles with mul‐
titronic/automatic gearbox and without auxiliary heater”,
page 79
⇒ “1.1.4 Connection diagram - coolant hoses, vehicles with mul‐
titronic/automatic gearbox and auxiliary heater”, page 80
© satelettronica
⇒ “1.1.5 Connection diagram - coolant hoses, vehicles with hybrid
drive”, page 82
1.1.1 Connection diagram - coolant hoses, vehicles with manual gearbox and
without auxiliary heater
Note
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Brown = Heating circuit
♦ Arrows show direction of coolant flow.
76 Rep. gr.19 - Cooling

1 - Radiator
2 - Turbocharger
3 - Cylinder head/cylinder
block
4 - Coolant shut-off valve
❑ Activated by Climatronic
coolant shut-off valve -
N422- (negative pres‐
sure)
5 - Bleeder hole
6 - Heat exchanger for heater
7 - Coolant circulation pump -
V50-
❑ Only installed on vehi‐
cles with start/stop sys‐
tem
8 - Coolant pump
9 - Restrictor with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
10 - Filler cap for expansion
tank
❑ Checking pressure re‐
lief valve ⇒ Servicing 4-
cylinder engine, 1.8 ltr.,
2.0 ltr. 4-valve TFSI;
Rep. gr. 19 ; Cooling
system/coolant; Check‐
ing cooling system for
leaks
11 - Coolant expansion tank
12 - Non-return valve
13 - Continued coolant circula‐
tion pump - V51-
❑ Only fitted on vehicles equipped for hot climates
14 - Thermostat
15 - Coolant temperature sender - G62-
16 - Engine oil cooler
1. Cooling system/coolant 77
auxiliary heater
Note

1 - Radiator
2 - Turbocharger
block
4 - Auxiliary heater
5 - Bleeder hole
© satelettronica
6 - Heater coolant shut-off
valve - N279-
❑ Arrow indicates direc‐
tion of flow
9 - Coolant pump
10 - Restrictor
tank
ing cooling system with for

leaks
tion pump - V51-
❑ Only fitted on vehicles
equipped for hot cli‐
mates
15 - Thermostat

1.1.3 Connection diagram - coolant hoses, vehicles with multitronic/automatic

gearbox and without auxiliary heater
Note

♦ Violet = Coolant circuit for ATF.
1 - Radiator
2 - Turbocharger
block
© satelettronica
sure)
5 - Bleeder hole
V50-
cles with start/stop sys‐
tem
8 - Coolant pump
9 - Suction-jet pump
10 - Thermostat
❑ For coolant circuit for
ATF
11 - ATF cooler
12 - Restrictor
tank
ing cooling
Protected by copyright. Copyingsystem
for private for leaks purposes, in part or in whole, is not
or commercial
14 respect
with - Coolant expansion
to the correctness tank in this document. Copyright by AUDI AG.
of information
16 - Continued coolant circulation pump - V51-
17 - Thermostat
1.1.4 Connection diagram - coolant hoses, vehicles with multitronic/automatic

gearbox and auxiliary heater
Note

© satelettronica
1 - Radiator
2 - Turbocharger
block permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 - Bleeder hole
valve - N279-
❑ Arrow indicates direc‐
tion of flow
9 - Coolant pump
11 - Thermostat
ATF
12 - ATF cooler
13 - Restrictor
tank
ing cooling system for
leaks


18 - Thermostat
© satelettronica
1.1.5 Connection diagram - coolant hoses, vehicles with hybrid drive
Note

♦ Green = Coolant circuit for power and control electronics for electric drive (low-temperature circuit).
♦ Orange = Coolant circuit for electric drive motor - V141- .
1 - Auxiliary radiator
power and control elec‐
tronics for electric drive
© satelettronica
2 - Radiator
4 - Turbocharger
block
V50-
8 - Heater coolant shut-off Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
valve - N279-
9 - Bleeder hole
11 - Solenoid for coolant circuit
- N492-
12 - Electric drive motor -
V141-
14 - Thermostat
ATF
15 - ATF cooler
16 - Restrictor
❑ Located in coolant hose
tank
❑ Checking pressure relief valve ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ;
Cooling system/coolant; Checking cooling system for leaks


19 - Coolant pump for high-temperature circuit - V467-
20 - Coolant pump
21 - Thermostat
24 - Bleeder screw
25 - Power and control electronics for electric drive - JX1-
26 - Coolant pump for low-temperature circuit - V468-
1.2 Checking cooling system for leaks

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant;
Checking cooling system for leaks .
© satelettronica
1.3 Draining and filling cooling system
♦ 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-
© satelettronica
♦ Protective gloves
♦ Safety goggles

Draining
CAUTION
Note
Illustration shows a vehicle with hybrid drive as an example.

noise insulation .
© satelettronica
– Vehicles with 8-speed automatic gearbox 0BW: Remove ad‐
ditional rear noise insulation.
gine.
– Remove drain plug -1- and drain off coolant.
– Vehicles with multitronic gearbox: Release hose clip -arrow-,

disconnect coolant hose and drain off coolant.
– Vehicles with 8-speed automatic gearbox 0BW: Release hose

clip -arrow- and detach coolant hose.
– Drain off coolant.
Note
– Close drain plug.

– Re-connect coolant hoses.
Coolant specifications
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant;
Draining and filling cooling system .
Recommended mixture ratio for coolant Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Coolant (40 %) and water (60 %) for frost protection to -25 ℃

• Coolant (50 %) and water (50 %) for frost protection to –36 ℃
© satelettronica
• Coolant ⇒ Electronic parts catalogue
NOTICE
Danger of corrosion damage if unsuitable mixtures of water and
coolant additives are used.
– Always use distilled water as this ensures optimum corrosion
protection.
Filling cooling system
Note
– Fill reservoir of cooling system charge unit - VAS 6096- with

10 litres of premixed coolant (according to recommended ra‐
tio). For recommended ratio, refer to ⇒ page 86 .
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter for
cooling system tester - 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 supply.
• Pressure: 7 ... 10 bar.

– Open valve -B- by setting lever in direction of flow.

• The suction jet pump generates a partial vacuum in the cooling
system; the needle on the gauge should move into the green
zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on reservoir of cooling system charge unit -
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
© satelettronica
♦ 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 the cooling system charge unit -
VAS 6096- ; the cooling system is then filled.
– Detach cooling system charge unit - VAS 6096- from adapter
for cooling system tester - V.A.G 1274/8- on coolant expansion
tank.
– Fit pipe for cooling system tester - V.A.G 1274/10- onto adapt‐
er for cooling system tester - V.A.G 1274/8- .
Note
Illustration shows vehicle without hybrid drive.

– Fill up pipe for cooling system tester - V.A.G 1274/10- with
coolant. If required, add further coolant when performing

bleeding procedure.
chamber cover .
– 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.

– Open bleeder screw -arrow-.
– Fill up with coolant until it comes out at power and control
electronics for electric drive - JX1- .
– Close bleeder screw -arrow-.
© satelettronica
– Close filler cap on expansion tank.
– Start engine.
– Set temperature to “HI” in all zones.
– Set fresh air blower to lowest setting.
– Switch off air conditioner compressor (press ECON button).
– Run engine for 3 minutes at 2000 rpm.
– Allow engine to run at idling speed until both large coolant ho‐
ses at radiator become warm.
– On vehicles with auxiliary heater, switch heater on for approx.
30 seconds and allow engine to run at idling speed.
– Switch off ignition and allow engine to cool down.
– Install noise insulation (front) ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
Checking coolant level
CAUTION

• The coolant level must be at the “MAX” marking when the en‐
gine is cold.
• The coolant level can be above the “MAX” marking when the
engine is warm.
Note
Illustration shows a vehicle with hybrid drive as an example.
© satelettronica
2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump/thermostat”, page 90
⇒ “2.2 Exploded view - electric coolant pump”, page 90
⇒ “2.3 Removing and installing electric coolant pump”,
page 95
⇒ “2.4 Removing and installing coolant pump”, page 103
⇒ “2.5 Removing and installing toothed belt for coolant pump”,
page 104
⇒ “2.6 Removing and installing thermostat”, page 105
⇒ “2.7 Checking thermostat”, page 105
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 105
⇒ “2.9 Removing and installing coolant valves”, page 106
2.1 Exploded view - coolant pump/thermo‐

stat
© satelettronica
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolantwith
pump/thermo‐
stat assembly; Exploded view - coolant pump/thermostat .
2.2 Exploded view - electric coolant pump

⇒ “2.2.1 Exploded view - electric coolant pump, continued coolant
circulation pump V51 , version 1 for vehicles without hybrid drive”,
page 90
⇒ “2.2.2 Exploded view - electric coolant pump, continued coolant
circulation pump V51 , version 2 for vehicles without hybrid drive”,
page 92
⇒ “2.2.3 Exploded view - electric coolant pump, coolant circulation
pump V50 , vehicles with hybrid drive”, page 93
⇒ “2.2.4 Exploded view - electric coolant pump, pump unit, vehi‐
cles with hybrid drive”, page 94
2.2.1 Exploded view - electric coolant pump, continued coolant circulation pump
- V51- , version 1 for vehicles without hybrid drive

1 - Bolt
❑ 2.7 Nm
2 - Spacer sleeve
3 - Grommet
4 - Bracket
5 - Nut
❑ 9 Nm
6 - Coolant hoses
tion pump - V51-
⇒ “2.3.1 Removing and
installing continued
coolant circulation
pump V51 - version 1 for
vehicles without hybrid
drive”, page 95
8 - Centre hex stud
© satelettronica
❑ 9 Nm
2. Coolant pump/thermostat assembly 91

2.2.2 Exploded view - electric coolant pump, continued coolant circulation pump
- V51- , version 2 for vehicles without hybrid drive
1 - Coolant hoses
tion pump - V51-
installing continued
coolant circulation
pump V51 - version 2 for
vehicles without hybrid
drive”, page 96
3 - Bracket
4 - Bolt
❑ 9 Nm
5 - Bracket
6 - Bolt
© satelettronica
❑ 4 Nm

2.2.3 Exploded view - electric coolant pump, coolant circulation pump - V50- ,
vehicles with hybrid drive
1 - Coolant hoses
2 - Bolt
❑ 23 Nm
3 - Bracket
❑ For coolant circulation
pump - V50-
4 - Rubber grommet
5 - Spacer sleeve
6 - Bolt
❑ 2.7 Nm
V50-
© satelettronica
installing coolant circu‐
lation pump V50 ”, page
98

2.2.4 Exploded view - electric coolant pump, pump unit, vehicles with hybrid drive
1 - Bracket
2 - Bolt
❑ 23 Nm
3 - Coolant hose
4 - Coolant pump for high-tem‐
perature circuit - V467-
⇒ page 101
5 - Bolt
❑ 9 Nm
6 - Coolant hose
- N492-
⇒ page 106
© satelettronica
8 - Coolant hoses
9 - Coolant valve for electric
drive - N565-
⇒ page 106
10 - Coolant hose
11 - Bolt
❑ 9 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
12 - Coolant hose
13 - Bolt
❑ 2.7 Nm
14 - Spacer sleeve
15 - Rubber grommet
Coolant pump for low-temperature circuit - V468- - tightening tor‐

que
– Tighten bolt -2- to 9 Nm.

2.3 Removing and installing electric coolant

pump
⇒ “2.3.1 Removing and installing continued coolant circulation
pump V51 - version 1 for vehicles without hybrid drive”,
page 95
pump V51 - version 2 for vehicles without hybrid drive”,
page 96
⇒ “2.3.3 Removing and installing coolant circulation pump V50 ”,
page 98
⇒ “2.3.4 Removing and installing coolant pump V36 ”,
page 99
⇒ “2.3.5 Removing and installing coolant pump for high-temper‐
ature circuit V467 ”, page 101
⇒ “2.3.6 Removing and installing coolant pump for low-tempera‐
ture circuit V468 ”, page 102
2.3.1 Removing and installing continued cool‐

ant circulation pump - V51- - version 1
© satelettronica
for vehicles without hybrid drive
♦ Hose clamps, up to 25 mm - 3094-

Removing

– Remove nut -4-, move earth wire clear and remove centre hex
stud.
– Unscrew nut -2-.
– Clamp off coolant hoses using hose clamps up to 25 mm -
3094- , release hose clips -3- and disconnect hoses.
– Remove bolts -1- and detach continued coolant circulation
© satelettronica
pump - V51- .
Installing
Note

– Check coolant level ⇒ page 88 .
Tightening torques
♦ ⇒ “2.2.1 Exploded view - electric coolant pump, continued
coolant circulation pump V51 , version 1 for vehicles without
hybrid drive”, page 90

ant circulation pump - V51- - version 2
for vehicles without hybrid drive

© satelettronica
Removing

Note
Place a cloth under coolant pipe to catch escaping coolant.
– Clamp off coolant hoses -arrows- with hose clamps up to

25 mm - 3094- and detach.
– Remove bolt -1- and detach continued coolant circulation
pump - V51- .
Installing
Note
© satelettronica
Tightening torques
♦ ⇒ “2.2.2 Exploded view - electric coolant pump, continued
coolant circulation pump V51 , version 2 for vehicles without
2.3.3 Removing and installing coolant circula‐

tion pump - V50-
Note
The procedure described only applies for vehicles with hybrid

drive.


Removing
– Remove noise insulation (rear) ⇒ General body repairs, ex‐
noise insulation .
© satelettronica
Note

3094- ; release hose clips -1- to disconnect hoses and detach
coolant circulation pump - V50- .
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Fit new O-rings.


Tightening torques
♦ ⇒ “2.2.3 Exploded view - electric coolant pump, coolant circu‐
lation pump V50 , vehicles with hybrid drive”,
Protected page 93
♦ ⇒ General body repairs, exterior; Rep.with
gr.respect
66 ;toNoise insula‐
the correctness of information in this document. Copyright by AUDI AG.
2.3.4 Removing and installing coolant pump -

V36-
Note

drive.

© satelettronica
Removing
– Remove bolts -3-.
Note

3094- , release hose clips -arrows- and disconnect hoses.
– Remove bolt -1- and detach continued coolant circulation
pump - V51- from bracket.
Installing
Note
Secure all hose

Protected connections
by copyright. Copying forwith
privatethe correctpurposes,
or commercial type ofin hose
part or inclips
whole, is not
(samepermitted
as original equipment)
unless authorised by AUDI⇒AG.Electronic
AUDI AG doesparts catalogue
not guarantee or accept.any liability

Tightening torques
♦ ⇒ “3.1.2 Exploded view - coolant pipes, vehicles with hybrid
drive”, page 110

2.3.5 Removing and installing coolant pump

for high-temperature circuit - V467-
Note

drive.

© satelettronica
Removing


Note

– Detach coolant pump for high-temperature circuit - V467- .
Installing
Note
© satelettronica
chamber partition panel . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check coolant level ⇒ page 88 . with respect to the correctness of information in this document. Copyright by AUDI AG.
Tightening torques
♦ ⇒ “2.2.4 Exploded view - electric coolant pump, pump unit,
vehicles with hybrid drive”, page 94
2.3.6 Removing and installing coolant pump

for low-temperature circuit - V468-
Note

drive.


Removing
– Unfasten front section of wheel housing liner (front left) ⇒
© satelettronica
liners; Removing and installing wheel housing liner (front) and
push it to rear.
– Disengage resonator -1- from bracket and push to one side.
Note
– Clamp off coolant hoses using

Protected hoseCopying
by copyright. clamps up toor25
for private mm - purposes, in part or in whole, is not
commercial
3094- , release hosepermitted
clips -arrows- and disconnect hoses.
– Unscrew bolt -2-, pivot retaining bracket to front and detach
coolant pump for low-temperature circuit - V468- .
Installing
Note

Tightening torques
♦ ⇒ Fig. ““ Coolant pump for low-temperature circuit -V468- -
tightening torque”“ , page 94
liners; Exploded view - wheel housing liner (front)
2.4 Removing and installing coolant pump

Removing
– Remove small coolant pipe:

♦ ⇒ “3.2.2 Removing and installing small coolant pipe - vehicles

– Remove toothed belt for coolant pump ⇒ page 104 .
– Remove throttle valve module - J338- ⇒ page 164 (if not al‐
ready removed).
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/
thermostat assembly; Removing and installing coolant pump .
Installing
Additional work:
– Install throttle valve module - J338- ⇒ Servicing 4-cylinder
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake mani‐
fold; Removing and installing throttle valve module - J338- .
– Install small coolant pipe ⇒ page 112 .
© satelettronica
2.5 Removing and installing toothed belt for
coolant pump
Removing
– Remove small coolant pipe:
♦ ⇒ “3.2.2 Removing and installing small coolant pipe -Protected
vehicles by copyright. Copying for private or commercial purposes, in part or in whole, is not
without hybrid drive”, page 112 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Disconnect coolant hoses -1 and 2- and move clear to one
side.
– If fitted, remove continued coolant circulation pump - V51-
page 95 .
thermostat assembly; Removing and installing toothed belt for
coolant pump .
Installing
Additional work:
– If previously removed, install continued coolant circulation
pump - V51-
page 95 .
– Install small coolant pipe:

2.6 Removing and installing thermostat

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/thermo‐
stat assembly; Removing and installing thermostat .
2.7 Checking thermostat

stat assembly; Checking thermostat .
2.8 Removing and installing coolant temper‐

ature sender - G62-
⇒ “2.8.1 Removing
permitted and installing
unless authorised by AUDI AG. coolant
AUDI AG temperature
does not guaranteesender G62
- vehicles
withwithout hybrid
respect to the drive”,
correctness page 105
⇒ “2.8.2 Removing and installing coolant temperature sender G62

- vehicles with hybrid drive”, page 105
2.8.1 Removing and installing coolant temper‐

ature sender - G62- - vehicles without
hybrid drive
© satelettronica
Removing
– Remove throttle valve module - J338- ⇒ page 164 .
– Remove support for intake manifold (remove nut -2- and bolt
-1-).
thermostat assembly; Removing and installing coolant tempera‐
ture sender - G62- .
Installing
Additional work:
Tightening torques
♦ ⇒ “3.1 Exploded view - air cleaner housing”, page 151
Rep. gr. 24 ; Intake manifold; Exploded view - intake manifold
2.8.2 Removing and installing coolant temper‐

ature sender - G62- - vehicles with hy‐
brid drive
Removing
DANGER
qualified person.



– Remove support for intake manifold (remove nut -2- and bolt
-1-).
thermostat assembly; Removing and installing coolant tempera‐
ture sender - G62- .
Installing
Additional work:
– permitted
Install unless
throttle valve
authorised by module - J338-
AUDI AG. AUDI AG does ⇒notServicing
guarantee or 4-cylinder
accept any liability
engine, 1.8
with respect ltr.,correctness
to the 2.0 ltr. of
4-valve TFSI;
information Rep. gr.Copyright
in this document. 24 ; Intake
by AUDI mani‐
AG.
© satelettronica
WARNING
qualified person.

Tightening torques
2.9 Removing and installing coolant valves


Removing
– Remove coolant pump for high-temperature circuit - V467-
⇒ page 101 .
Coolant valve for electric drive - N565- :
© satelettronica
– Remove bolts -arrows- and unplug electrical connector -1-.
Solenoid for coolant circuit - N492- :

– Remove bolts -arrows- and unplug electrical connector -2-.
Installingpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
– Install coolant pump for high-temperature circuit - V467-

⇒ page 101 .
Tightening torques

3 Coolant pipes
⇒ “3.1 Exploded view - coolant pipes”, page 108
⇒ “3.2 Removing and installing coolant pipes”, page 111
3.1 Exploded view - coolant pipes

⇒ “3.1.1 Exploded view - coolant pipes (engine end)”, page 108
⇒ “3.1.2 Exploded view - coolant pipes, vehicles with hybrid drive”,
page 110
3.1.1 Exploded view - coolant pipes (engine end)
Note
The arrow markings on coolant pipes and on ends of hoses must align.
1 - Coolant hose
2 - Bolt
© satelettronica
❑ 6 Nm
3 - Small coolant pipe
⇒ page 112
4 - Bolt
❑ 9 Nm
5 - O-ring
❑ Renew
6 - Bolt
❑ 9 Nm
7 - O-ring
❑ Renew
8 - Coolant hose
❑ Lift retaining clip to de‐
tach Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Connectingpermitted
to radiator
⇒ page 119 with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Coolant pipe (front)
⇒ page 111
10 - Coolant hose
11 - Bolt
❑ 6 Nm
12 - Coolant hose
tion pump - V51-
❑ ⇒ Item 2 (page 92)
14 - Bolt

15 - Bracket
16 - Bolt
17 - Bracket
Vehicles with 8-speed automatic gearbox - coolant pipe (right-

side) on gearbox
– Tighten bolts -arrows- to 9 Nm.
© satelettronica
3. Coolant pipes 109

3.1.2 Exploded view - coolant pipes, vehicles with hybrid drive
Note
1 - Rubber grommet
2 - Spacer sleeve
3 - Bolt
❑ 2.7 Nm
⇒ page 111
5 - Bolt
❑ 9 Nm
6 - Bolt
© satelettronica
❑ 9 Nm
7 - Coolant pipe (left-side) on
gearbox
⇒ page 116
8 - Bolt
❑ 23 Nm
9 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 9 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Small coolant pipe

⇒ page 113
11 - Bolt
❑ 9 Nm
12 - O-ring
❑ Renew
13 - Bolt
❑ 9 Nm
14 - Coolant pump - V36-
15 - Bracket
❑ For coolant pump - V36-
16 - Bolt
❑ 23 Nm

3.2 Removing and installing coolant pipes

⇒ “3.2.1 Removing and installing coolant pipe (front)”,
page 111
⇒ “3.2.2 Removing and installing small coolant pipe - vehicles
⇒ “3.2.3 Removing and installing small coolant pipe - vehicles with
⇒ “3.2.4 Removing and installing coolant pipe (right-side) on
gearbox - vehicles without hybrid drive, with 8-speed automatic
gearbox”, page 115
⇒ “3.2.5 Removing and installing coolant pipe (left-side) on gear‐
box - vehicles with hybrid drive”, page 116
3.2.1 Removing and installing coolant pipe

(front)
© satelettronica
♦ Hose clip pliers - VAS 6362- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Removing
Note
– Unscrew bolts -1- and -2- and swivel coolant pipe (front) up‐
wards.
25 mm - 3094- and detach.
Installing
Note
© satelettronica
Tightening torques
♦ ⇒ “3.1 Exploded view - coolant pipes”, page 108
3.2.2 Removing and installing small coolant

pipe - vehicles without hybrid drive
Removing

– Remove bolts -arrows- and detach electrical connectors

-1 ... 3- from retainer.
– Release hose clip -1-, lift retaining clip -2- and detach coolant
hoses.
– Unscrew bolts -arrows- and detach small coolant pipe.
Installing
© satelettronica
Note

– Connect coolant hose with plug-in connector ⇒ page 119 .
Note

Tightening torques
page 108
3.2.3 Removing and installing small coolant

pipe - vehicles with hybrid drive

Removing
– Detach electrical connectors -1, 2, 3- from bracket.
© satelettronica
hoses.
– Unscrew bolts -arrows- and detach small coolant pipe.
Installing
Note


Note

Tightening torques
drive”, page 110


(right-side) on gearbox - vehicles with‐
out hybrid drive, with 8-speed automatic
gearbox
© satelettronica
Removing
CAUTION


noise insulation .
– Place drip tray for workshop hoist - VAS 6208- under connec‐
tion.
– Clamp off coolant hose -1- with hose clamp -3094- .

– Clamp off coolant hose -3- using hose clamp -3094- , release
hose clip and disconnect coolant hose from coolant pipe on
right side of gearbox.
– Release hose clip -2- and detach coolant pipe going to wheel
housing (right-side).
© satelettronica
Installing
Note

Tightening torques
♦ ⇒ Fig. ““Vehicles with 8-speed automatic gearbox - coolant
pipe (right-side) on gearbox”“ , page 109

(left-side) on gearbox - vehicles with hy‐
brid drive

Removing
noise insulation .
Note
© satelettronica

– Remove bolts -1 and 2- and detach coolant pipe from gearbox
(left-side).
Installing
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Tightening torques
drive”, page 110

4 Radiator/radiator fans
⇒ “4.1 Exploded view - radiator/radiator fans”, page 118
⇒ “4.2 Exploded view - radiator cowl and radiator fans”,
page 120
⇒ “4.3 Removing and installing radiator”, page 120
⇒ “4.4 Removing and installing radiator cowl”, page 124
⇒ “4.5 Removing and installing radiator fan V7 ”, page 127
⇒ “4.6 Removing and installing radiator fan control unit J293 /
J671 ”, page 128
⇒ “4.7 Removing and installing auxiliary radiator”, page 128
4.1 Exploded view - radiator/radiator fans
1 - Air duct
2 - Coolant hose
© satelettronica
tach
❑ Connecting
⇒ page 119
3 - O-ring
❑ Renew
4 - Radiator
⇒ page 120
❑ If renewed, change
coolant in entire system
5 - Coolant hose
tach
❑ Connecting
⇒ page 119
6 - Coolant pipe
❑ To coolant expansion
tank
❑ Press release ring to de‐
tach
❑ Connecting
⇒ page 119
7 - O-rings
❑ Renew
8 - Rubber bush permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ For radiator with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Retaining pin
❑ Use screwdriver to release and pull off
10 - Air duct
11 - Bolt
❑ 5 Nm

12 - Condenser
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and
installing condenser
13 - Bracket
❑ For radiator for coolant circuit for power and control electronics for electric drive
14 - Coolant pipe
15 - Bolt
❑ 5 Nm
16 - Cooler
❑ For coolant circuit for power and control electronics for electric drive
17 - Bolt
❑ 8 Nm
18 - Air duct
19 - Radiator bracket
20 - Bolt
© satelettronica
❑ 5 Nm
21 - Washer
22 - Bolt
❑ 4.5 Nm
23 - Rubber mounting
❑ For radiator
Connecting coolant hose with plug-in connector
Note
If damaged, renew retaining clip -4-.
– 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. Radiator/radiator fans 119

4.2 Exploded view - radiator cowl and radiator fans
1 - Radiator fan control unit

❑ Radiator fan control unit
- J293- with radiator fan
control unit 2 - J671-
⇒ page 128
2 - Bolt
❑ 3.5 Nm
3 - Bolt
❑ 5 Nm
4 - Radiator cowl
⇒ page 124
5 - Radiator fan - V7-
⇒ page 127
© satelettronica
6 - Radiator fan 2 - V177-
⇒ page 127
7 - Bolt
❑ 5 Nm
4.3 Removing and installing radiator
Note
Radiator and with

radiator cowl can only be removed and installed
Copyright to‐
respect to the correctness of information in this document. by AUDI AG.
gether as one unit.

© satelettronica
Removing

noise insulation .
– Remove impact absorber (front) ⇒ General body repairs, ex‐
terior; Rep. gr. 63 ; Bumper (front); Removing and installing
impact absorber .
– Unclip air ducts -1 and 2-.
Note
Air duct (left-side) remains in installation position on vehicles with

hybrid drive.

– Detach radiator (front) -1- upwards and swivel to one side with
air duct -2-.
– Remove charge air cooler ⇒ page 136 .

gine.
CAUTION
Risk of injury as the radiator fans may start up automatically.
– Unplug electrical connectors:
– Unplug electrical connector -1- for radiator fan (push retainer

to the rear -arrow- and press down release catch).
© satelettronica
– Lift retaining clips -1- and -2- and detach connection from ra‐
diator.

– Release retaining pins for radiator on both sides and pull out
upwards -arrows-.
© satelettronica
– Have a second mechanic release retaining clips -1- in direction
of -arrow A- and lift condenser -2- out of mountings on radiator
-arrows B-.
NOTICE
Danger of damage to refrigerant lines and hoses when detach‐
ing and pivoting condenser. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Do NOT stretch, kink or bend refrigerant lines and hoses.
– Pivot condenser forwards with pipes/hoses attached.

– Detach radiator.
– Remove bolts -1- on both sides and detach radiator bracket

with radiator from lock carrier -arrow-.

– Press locking tabs on left and right sides of radiator cowl to‐
gether -arrow- and lift radiator cowl off radiator.
Installing
Note
If there are slight impressions on the fins, refer to ⇒ Servicing 4-

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair
notes; Installing radiators and condensers .

– Install charge air cooler ⇒ page 136 .
Note
© satelettronica
– Fill up with coolant ⇒ by
Protected page 83 Copying
copyright. . for private or commercial purposes, in part or in whole, is not
Tightening torques with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ ⇒ “4.1 Exploded view - radiator/radiator fans”, page 118

♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - impact bar
4.4 Removing and installing radiator cowl

♦ Hose clamps, up to 25 mm - 3094- for vehicles with hybrid
drive

♦ Hose clip pliers - VAS 6362- for vehicles with hybrid drive
Removing
ments .
CAUTION
© satelettronica

– Remove closure plate for bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Removing and
installing attachments .
Vehicles with hybrid drive: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove air intake grille (front left) ⇒ General body repairs,
exterior; Rep. gr. 63 ; Bumper (front); Removing and installing
attachments .
– Clamp off coolant hoses -1, 2- with hose clamps up to 25 mm
- 3094- .
Note
– Detach coolant hoses; to do so, release hose clips -arrows-

and guide through air duct -1-.


© satelettronica
– Unclip air ducts -1- and -2-.
– Release retaining clips -1 and 2- and detach connection from

radiator.

upwards -arrows-.
– Press radiator slightly towards front.
Installing
– Install air duct ⇒ page 151 .
– Install lock carrier cover, bumper cover and closure plate for
bumper cover (front) ⇒ General body repairs, exterior; Rep.
© satelettronica
gr. 63 ; Bumper (front); Exploded view - bumper cover .
Note
4.5 Removing and installing radiator fan -

V7-
Removing
Note
Fit all cable ties in the original positions when installing.
– Remove radiator cowl ⇒ page 124 .

– Remove bolts -arrows- and detach radiator fan - V7- (left-side).


– Remove bolts -arrows- and detach radiator fan 2 - V177- (right-
side).
Installing
– Install radiator cowl ⇒ page 124 .
Tightening torques
♦ ⇒ “4.2 Exploded view - radiator cowl and radiator fans”,
page 120
4.6 Removing and installing radiator fan

control unit -J293- / -J671-
Removing
noise insulation .
– Vehicles with torque reaction support: remove cross member
© satelettronica
for torque reaction support ⇒ page 44 .
CAUTION
trol unit.
– Unplug electrical connectors -2- and -3-.

– Unscrew bolt Protected
-arrow-byand remove
copyright. Copyingradiator fan
for private or control
commercial unit -1-.
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.

– Vehicles with torque reaction support: install cross member for
torque reaction support ⇒ page 44 .
Tightening torques
page 120
4.7 Removing and installing auxiliary radia‐

tor

© satelettronica
Removing
– Remove lock carrier cover ⇒ General body
Protectedrepairs, exterior;
Rep. gr. 63 ; Bumper (front); Removingpermitted
and installing attach‐
ments . with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
– Clamp off coolant hoses using hose clamps, up to 25 mm -

3094- , release hose clips -1 and 2- and disconnect hoses.
– Release fasteners -arrows- and detach radiator.
Installing
– Install lock carrier cover ⇒ General body repairs, exterior;
ments .
Tightening torques

21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 130
⇒ “1.2 Removing and installing turbocharger”, page 130
⇒ “1.3 Checking vacuum unit for turbocharger”, page 132
1.1 Exploded view - turbocharger

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger .
1.2 Removing and installing turbocharger

Removingpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Observe rules for cleanliness ⇒ Servicing 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules
for cleanliness .
© satelettronica
– Disconnect coolant hose -arrow-.
Note
The installation position is shown in the following illustrations with

the engine removed.
– Remove heat shield -arrows-.
130 Rep. gr.21 - Turbocharging/supercharging

Turbocharger version 1:
– Remove bolts -arrows- and detach crankcase breather system
from turbocharger.
– Disconnect hose -1- from turbocharger.
– Unscrew bolts -1 and 2- and move oil supply line clear to one
side.
– Unscrew bolt -3- and move coolant pipe clear to one side.
© satelettronica
Turbocharger version 2:
– Remove bolts -arrows- and detach crankcase breather system
from turbocharger.
– Press release tabs and disconnect hose -2-.
– Release hose clip -1-. Detach air pipe.
– Remove banjo bolts -1, 2- and bolts -3- and move pipes to one
side.
1. Turbocharger 131
– Unplug electrical connector -arrow- for Lambda probe - G39-

and Lambda probe heater - Z19- and move wiring clear.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger;
Removing and installing turbocharger .
Installing
Additional work:
– Install catalytic converter ⇒ page 184 .
Tightening torques
© satelettronica
1.3 Checking vacuum unit for turbocharger
Procedure
ments .
Checking vacuum unit for turbocharger .
Installing
Additional work:
ments .
Tightening torques

2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 133
⇒ “2.2 Exploded view - hose connections for charge air system”,
page 136
⇒ “2.3 Removing and installing charge air cooler”, page 136
⇒ “2.4 Removing and installing charge pressure sender G31 ”,
page 139
⇒ “2.5 Checking charge air system for leaks”, page 140
2.1 Exploded view - charge air system

⇒ “2.1.1 Exploded view - charge air system, vehicles without hy‐
brid drive”, page 133
⇒ “2.1.2 Exploded view - charge air system, vehicles with hybrid
drive”, page 135
2.1.1 Exploded view - charge air system, vehicles without hybrid drive
© satelettronica
1 - Charge air cooler
⇒ page 136 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - Hose clip
3 - Air hose
❑ To turbocharger
❑ Must be free of oil or
grease when installing
4 - Hose clip
5 - Hose clip
6 - Air hose
❑ To intake manifold
7 - Hose clip
8 - O-ring
❑ Renew
9 - Charge pressure sender -
G31-
⇒ page 139
10 - Bolt
❑ 5 Nm
11 - Rubber grommet
12 - Bush
13 - Nut
❑ 9 Nm
2. Charge air system 133

14 - Rubber grommet
15 - Hose clip
16 - Air pipe
17 - Hose clip
18 - Air hose
❑ From charge air cooler
❑ Must be free of oil or grease when installing
19 - Hose clip
20 - Bolt
❑ 7 Nm
21 - Resonator
22 - Rubber grommet
23 - Hose clip
24 - Air hose
❑ To resonator
© satelettronica

2.1.2 Exploded view - charge air system, vehicles with hybrid drive

⇒ page 137
2 - Air hose
❑ To turbocharger
3 - Bolt
❑ 23 Nm
4 - Bolts
❑ 9 Nm
G31-
⇒ page 139
© satelettronica
6 - O-ring
❑ Renew
7 - Rubber grommet
8 - Air hose
❑ To resonator
9 - Resonator
10 - Rubber grommet
11 - Rubber grommet
12 - Spacer
13 - Bolt
❑ 9 Nm
14 - Bracket
15 - Air hose Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To intake manifold permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
16 - Air duct
17 - Bolt
❑ 9 Nm
18 - Air hose
19 - Bolt
❑ 23 Nm

20 - Air pipe
21 - Rubber grommet
22 - Spacer
23 - Rubber grommet
24 - Spacer
25 - Air hose
26 - Bolt
❑ 7 Nm
2.2 Exploded view - hose connections for

charge air system
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system;
Exploded view - hose Protected
connections for charge air system .
© satelettronica
2.3 Removing and installing charge air cool‐

er
⇒ “2.3.1 Removing and installing charge air cooler - vehicles with‐
out hybrid drive”, page 136
⇒ “2.3.2 Removing and installing charge air cooler - vehicles with
2.3.1 Removing and installing charge air cool‐

er - vehicles without hybrid drive
Removing
– Remove closure plate at bumper cover and lock carrier cover
⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Removing and installing attachments .

– 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-.
– Disengage and detach charge air cooler upwards.
Installing
© satelettronica
Note
♦ If there are slight impressions on the fins, refer to ⇒ Servicing

4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ;
Repair notes; Installing radiators and condensers .
– Install lock carrier cover and closure plate for bumper cover ⇒
General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Tightening torques
♦ ⇒ “2.1.1 Exploded view - charge air system, vehicles without

er - permitted
vehicles with hybridby AUDI AG.drive
unless authorised AUDI AG does not guarantee or accept any liability
Removing
– Remove closure plate at bumper cover, lock carrier cover and
air intake grille (left and right) ⇒ General body repairs, exterior;
ments .

– Unclip air duct -1-.
cooler.
© satelettronica
cooler.
– Disengage charge air cooler upwards, move clear at air duct
(left-side) and detach.
Installing
Note
♦ If there are slight impressions on the fins, refer to ⇒ Servicing

4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ;
Repair notes; Installing radiators and condensers .
– Install lock carrier cover, closure plate for bumper cover and
air intake grille ⇒ General body repairs, exterior; Rep. gr. 63 ;
Bumper (front); Removing and installing attachments .
Tightening torques
♦ ⇒ “2.1.2 Exploded
with respect view - charge
to the correctness airinsystem,
of information vehicles
this document. Copyright with hy‐
by AUDI AG.

2.4 Removing and installing charge pres‐

sure sender - G31-
⇒ “2.4.1 Removing and installing charge pressure sender G31 -
vehicles without hybrid drive”, page 139
⇒ “2.4.2 Removing and installing charge pressure sender G31 -
2.4.1 Removing and installing charge pres‐

sure sender - G31- - vehicles without
hybrid drive
Removing
– Unscrew bolts -arrows- and pull charge pressure sender -
G31- out of air pipe.
Installing
© satelettronica
Note
Fit new O-ring.
Tightening torques
♦ ⇒ “2.1.1 Exploded view - charge air system, vehicles without
2.4.2 Removing and installing charge pres‐

sure sender - G31- - vehicles with hybrid
drive
Removing
– Unscrew bolts -arrows- and remove charge pressure senderCopying
Protected by copyright. - for private or commercial purposes, in part or in whole, is not
G31- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installing
Note
Fit new O-ring.
Tightening torques
♦ ⇒ “2.1.2 Exploded view - charge air system, vehicles with hy‐
(front)

2.5 Checking charge air system for leaks

Checking charge air system for leaks .
© satelettronica

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 141
⇒ “1.2 Checking fuel system for leaks”, page 149
1.1 Overview of fitting locations - injection system

Overview of fitting locations - engine compartment
1 - Secondary air pump motor

- V101-
❑ Fitting location
⇒ page 143
❑ Exploded view
⇒ “3.1 Exploded view -
secondary air system”,
page 189
© satelettronica
2 - Right electrohydraulic en‐
gine mounting solenoid valve -
N145-
ment and version
⇒ page 143
3 - Air mass meter - G70-
❑ Exploded view
air cleaner housing”,
page 151
4 - Ignition coil 1 with output
stage - N70-
❑ Exploded view ⇒ Serv‐
icing 4-cylinder engine,
TFSI; Rep. gr. 28 ; Igni‐
tion system; Exploded
view - ignition system
stage - N127-
6 - Ignition coil 3 with output stage - N291-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system;
Exploded view - ignition system
7 - Ignition coil 4 with output stage - N292-
8 - Auxiliary hydraulic pump 1 for gearbox oil - V475-
❑ For vehicles with hybrid drive
1. Injection system 141

❑ Fitting location ⇒ page 144

9 - Pressure sensor for activated charcoal filter system - G804-
10 - Accelerator position sender - G79- and accelerator position sender 2 - G185-
11 - Brake light switch - F-
❑ Vehicles with hybrid drive are additionally fitted with brake pedal position sender - G100-
12 - Clutch position sender - G476-
❑ For vehicles with manual gearbox
13 - Brake servo pressure sensor - G294-
14 - Engine control unit - J623-
❑ Removing and installing ⇒ “9.1 Removing and installing engine/motor control unit J623 ”, page 172
15 - Left electrohydraulic engine mounting solenoid valve - N144-
© satelettronica
❑ Left-side only depending on equipment and version
❑ Exploded view ⇒ “3.1.1 Exploded view - coolant pipes (engine end)”, page 108
17 - Coolant pump for low-temperature circuit - V468-
18 - Charge pressure sender - G31-
❑ Exploded view ⇒ “2.1 Exploded view - charge air system”, page 133
19 - Brake servo vacuum pump - V469-
Fitting location of engine control unit - J623-

♦ In electronics box (plenum chamber)
142 Rep. gr.24 - Mixture preparation - injection

Fitting location of accelerator position sender - G79- / accelerator

position sender 2 - G185-
♦ Integrated 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.
Exploded view ⇒ Fuel supply system, petrol engines; Rep. gr.

20 ; Accelerator mechanism; Exploded view - accelerator pedal
module
Fitting location of brake light switch - F- / clutch position sender -

G476-
© satelettronica
1- Brake light switch - F-
2- Clutch position sender - G476- for vehicles with manual
gearbox
Removing and installing brake light switch - F- ⇒ Brake system;
Rep. gr. 45 ; Sensors; Removing and installing brake light switch
Fitting location of secondary air pump motor - V101-

♦ In front right wheel housing behind liner
Fitting location of electrohydraulic engine mounting solenoid

valves -N144- / -N145-
♦ -Item 3- integrated in engine mountings on both sides

Fitting location of coolant pump for low-temperature circuit -

V468- , brake servo vacuum pump - V469-
♦ In left wheel housing behind liner
1- Brake servo vacuum pump - V469-
2- Coolant pump for low-temperature circuit - V468-
Fitting location of brake servo pressure sensor - G294-

♦ On left side of plenum chamber -arrow-
© satelettronica
Fitting location of exhaust flap control unit - J883-
♦ -Item 2- on rear silencer tailpipe
Fitting location of auxiliary hydraulic pump 1 for gearbox oil -

V475-

Fitting location of charge pressure sender - G31-

♦ -Item 1- at air pipe (front left)
Overview of fitting locations - engine (view from left side)
1 - Valve for oil pressure con‐

trol - N428-
TFSI; Rep. gr. 17 ; Oil
© satelettronica
filter/oil pressure
switches; Exploded
view - oil pressure
switches/oil pressure
control
tion pump - V51-
❑ Not fitted on all versions
❑ Exploded view
⇒ “3.1.1 Exploded view
- coolant pipes (engine
end)”, page 108
3 - Coolant temperature send‐
er - G62-
TFSI; Rep. gr. 19 ; Cool‐
ant pump/thermostat
assembly; Exploded
view - coolant pump/
thermostat
4 - Oil pressure switch - F22-
filter/oil pressure
switches; Exploded
view - oil pressure
control
5 - Oilbypressure
Protected switch
copyright. Copying for reduced
for private or commercialoilpurposes,
pressure in part- or
F378-
in whole, is not
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0
ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil
pressure switches; Exploded view - oil pressure switches/oil pressure control

6 - Intake manifold flap potentiometer - G336-

❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold;
Exploded view - intake manifold

7 - Fuel pressure sender - G247-

❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors;
Exploded view - fuel rail with injectors
8 - Intake air temperature sender - G42-
9 - Hall sender - G40-
10 - Throttle valve module - J338-
❑ Including throttle valve drive (electric throttle operation) - G186- , angle sender for throttle valve drive -
G187- and angle sender 2 for throttle valve drive - G188-
11 - Activated charcoal filter solenoid valve 1 - N80-
12 - Fuel metering valve - N290- or fuel pressure regulating valve - N276-
❑ Fuel metering valve - N290- or fuel pressure regulating valve - N276- may be fitted, depending on version
❑ Integrated in high-pressure pump
© satelettronica
13 - Intake manifold flap valve - N316-
14 - Knock sensor 1 - G61-
15 - Engine speed sender - G28-
Overview of fitting locations - engine (view from right side)

1 - Lambda probe after catalyt‐

ic converter - G130- and Lamb‐
da probe heater 1 after catalyt‐
ic converter - Z29-
TFSI; Rep. gr. 24 ;
Lambda probe; Explo‐
ded view - Lambda
probe
2 - Lambda probe - G39- and
Lambda probe heater - Z19-
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
3 - Actuator 8 for camshaft ad‐
justment - F373- (for cylinder
No. 4)
© satelettronica
TFSI; Rep. gr. 15 ;
Valve gear; Exploded
view - valve gear
No. 4)
❑ Exploded view ⇒ Serv‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
icing 4-cylinder engine, with respect to the correctness of information in this document. Copyright by AUDI AG.
TFSI; Rep. gr. 15 ;
view - valve gear
5 - Actuator 5 for camshaft adjustment - F370- (for cylinder No. 3)
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear;
Exploded view - valve gear

11 - Camshaft control valve 1 - N205-

❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain
cover; Exploded view - timing chain cover
12 - Charge pressure control solenoid valve - N75-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger;
Exploded view - turbocharger
13 - Turbocharger air recirculation valve - N249-
14 - Oil level and oil temperature sender - G266-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump;
Exploded view - sump/oil pump
Overview of fitting locations - engine/gearbox (view from rear)
1 - Coolant pump for high-tem‐

perature circuit - V467-
❑ For vehicles with hybrid
© satelettronica
drive
❑ Exploded view
- electric coolant pump,
pump unit, vehicles with
V50-
drive
❑ Exploded view
coolant circulation
pump V50 , vehicles Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
with hybrid drive”, permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
page 93 with respect to the correctness of information in this document. Copyright by AUDI AG.
3 - Coolant valve for electric

drive - N565-
drive
❑ Exploded view
pump unit, vehicles with
4 - Coolant shut-off valve -
N82-
drive
❑ Exploded view
pump unit, vehicles with hybrid drive”, page 94
5 - Secondary air inlet valve - N112-
❑ Exploded view ⇒ “3.1 Exploded view - secondary air system”, page 189

6 - Sender 1 for secondary air pressure - G609-

1.2 Checking fuel system for leaks

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injection system ;
Checking fuel system for leaks.
© satelettronica

2 Vacuum system
All procedures and components are described in ⇒ Servicing 4-
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Vacuum
system .
© satelettronica

3 Air cleaner
⇒ “3.1 Exploded view - air cleaner housing”, page 151
⇒ “3.2 Removing and installing air cleaner housing”, page 152
3.1 Exploded view - air cleaner housing
1 - Air duct
❑ Clean out salt deposits,
dirt and leaves, etc.
2 - Sealing element
3 - Mounting
❑ For air cleaner housing
4 - Air cleaner housing
⇒ page 152
© satelettronica
5 - Air filter element permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Use genuine air filter el‐
ement ⇒ Electronic
parts catalogue
❑ Change intervals ⇒
Maintenance tables
⇒ Maintenance ; Book‐
let 411
6 - Cover
❑ Remove any salt depos‐
its or dirt
7 - Housing for air mass meter
- G70-
8 - Bolt
❑ 1.5 Nm
⇒ page 167
10 - Screw-type clip
❑ Tightening torque ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air
system; Exploded view - hose connections for charge air system
11 - Air pipe
❑ Tightening torque ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air
system; Exploded view - hose connections for charge air system
13 - Air duct
❑ Clean out salt deposits, dirt and leaves, etc.
14 - Bolt
❑ 1.5 Nm
3. Air cleaner 151

3.2 Removing and installing air cleaner

housing
Removing
ments .
– Unplug electrical connector -2- at air mass meter - G70- .
© satelettronica
– Open hose clip -3- on air hose and disconnect hose at air mass
meter - G70- .

– Lift out air cleaner housing -1-.

– Vehicles with hybrid drive: Press release tabs and disconnect
secondary air hose -arrow-.
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 always be clean.

♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Hose connections and air pipes/hoses must be free of oil and
grease prior to fitting.
♦ Use a lubricant (silicone-free) when installing air hoses.
© satelettronica
– Check water drain hose 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 air duct leading from lock carrier to air cleaner housing
for dirt and leaves.
– Re-install air cleaner housing.
– Make sure that air hose is correctly seated at air mass meter
- G70- .
The remaining installation steps areunless
permitted carried outbyinAUDI
authorised theAG.reverse
AUDI AGse‐ does not guarantee or accept any liability
quence. with respect to the correctness of information in this document. Copyright by AUDI AG.

ments .
Tightening torques
3. Air cleaner 153

4 Intake manifold
⇒ “4.1 Exploded view - intake manifold”, page 154
⇒ “4.2 Removing and installing intake manifold”, page 154
⇒ “4.3 Removing and installing throttle valve module J338 ”, page
164
⇒ “4.4 Cleaning throttle valve module”, page 165
⇒ “4.5 Checking intake manifold change-over function”,
page 165
4.1 Exploded view - intake manifold

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Ex‐
ploded view - intake manifold .
4.2 Removing and installing intake manifold

⇒ “4.2.1 Removing and installing intake manifold - vehicles with‐
out hybrid drive”, page 154
© satelettronica
⇒ “4.2.2 Removing and installing intake manifold - vehicles with
4.2.1 Removing and installing intake manifold
- vehicles without hybrid drive
♦ Assembly tool - T10118-

♦ Socket - T10347-
Removing
Note
♦ In order to reach the injectors, first remove the intake manifold

with the fuel rail.
♦ The combustion chamber ring seal (teflon) and the O-ring
© satelettronica
must be renewed.

– Disconnect vacuum line -arrow- leading to activated charcoal
filter.
– Unplug following electrical connectors:
2 - From knock sensor 1 - G61-
4 - From injectors
– Unplug electrical connector -1- at Hall sender - G40- .
4. Intake manifold 155

– Open hose clip -arrow- securing air hose and disconnect hose
downwards from throttle valve module - J338- .
– Disconnect vacuum line -1- at connection -2-.

– Remove crankcase breather hose -3-.
© satelettronica
CAUTION
The fuel system is pressurised.
Risk of injury as fuel may spray out.
– Put on protective gloves. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Release pressure (wrap a clean cloth around connection
and open connection carefully).
– Release spring-type clip -top arrow- and detach fuel supply

hose from high-pressure pump.
– Unscrew union nut for high-pressure fuel pipe
-bottom arrow- at high-pressure pump.
– Seal off open lines and connections with plugs (thoroughly
cleaned) from engine bung set - VAS 6122- .
– Disconnect vacuum line -arrow- at intake manifold flap valve -

N316- .

– Unplug electrical connector at fuel pressure sender - G247-

-1-.
© satelettronica
– Remove intake manifold support (remove securing nut -1- and
bolt -2-).
– Remove oil filter ⇒ Maintenance ; Booklet 411 .
– Unscrew bolts from intake manifold using socket - T10347- .

Note
To remove the bolts that cannot be accessed if you do not have

socket - T10347- , the throttle valve module - J338- must be re‐
moved.
– Remove bolts -arrows- and nuts -2, 3-.

– Carefully pull intake manifold and fuel rail slightly away from
cylinder head.
– Unplug electrical connector -1- from intake manifold flap po‐
tentiometer - G336- and then detach intake manifold.
Note
♦ The injectors can remain in the fuel rail. Unplug electrical con‐
nector from corresponding injector.
♦ Block off intake ports with clean cloths.
– Disconnect intake manifold from fuel rail ⇒ Servicing 4-cylin‐
© satelettronica
der engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors;
Removing and installing fuel rail .
Installing
Note
Make sure that injectors are installed correctly.
– Fit intake manifold onto studs (left and right) on cylinder head.
– Remaining installation steps are carried out in reverse se‐
quence; note the following:
– Install oil filter ⇒ Maintenance ; Booklet 411 .
– After installing intake manifold, perform “Adaption” using ⇒ Ve‐
hicle diagnostic tester, Guided Functions .
Tightening torques
page 108
Rep. gr. 24 ; Injectors; Exploded view - fuel rail with injectors
4.2.2 Removing and installing intake manifold

- vehicles with hybrid drive

© satelettronica
♦ Socket - T10347- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing
WARNING
– Note safety precautions when working in the vicinity of high-
voltage components.
– Safety precautions when working in the vicinity of high-voltage

components

– Disconnect vacuum line -arrow- leading to activated charcoal

filter.
– Unplug following electrical connectors:
2 - From knock sensor 1 - G61-
4 - From injectors
© satelettronica

– Disconnect vacuum line -1- at connection -2-.

– Remove crankcase breather hose -3-.

CAUTION
– Release pressure (wrap a clean cloth around connection
– Release spring-type clip -top arrow- and detach fuel supply

hose from high-pressure pump.
– Unscrew union nut for high-pressure fuel pipe
-bottom arrow- at high-pressure pump.
– Disconnect vacuum line -arrow- at intake manifold flap valve -

N316- .
© satelettronica
– Remove continued coolant circulation pump - V51- -2-.


-1-.
– Remove electrically driven air conditioner compressor from
bracket ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor; Detaching and attaching air conditioner
– Remove intake manifold support (remove securing nut -1- and

bolt -2-).
– Remove oil filter ⇒ Maintenance ; Booklet 411 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
© satelettronica

Note
To remove the bolts that cannot be accessed if you do not have

socket - T10347- , the throttle valve module - J338- must be re‐
moved.
– Remove bolts -arrows- and nuts -2, 3-.

– Carefully pull intake manifold and fuel rail slightly away from
cylinder head.
– Unplug electrical connector -1- from intake manifold flap po‐
tentiometer - G336- and then detach intake manifold.
Note
♦ The injectors can remain in the fuel rail. Unplug electrical con‐
nector from corresponding injector.
♦ Block off intake ports with clean cloths.
– Disconnect intake manifold from fuel rail ⇒ Servicing 4-cylin‐
© satelettronica
der engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors;
Removing and installing fuel rail .
Installing
Note
Make sure that injectors are installed correctly.
– Fit intake manifold onto studs (left and right) on cylinder head.
– Remaining installation steps are carried out in reverse se‐
quence; note the following:
– Install oil filter ⇒ Maintenance ; Booklet 411 .
– After installing intake manifold, perform “Adaption” using ⇒ Ve‐
hicle diagnostic tester, Guided Functions .
Tightening torques
drive”, page 110
Rep. gr. 24 ; Injectors; Exploded view - fuel rail with injectors

4.3 Removing and installing throttle valve

module - J338-
⇒ “4.3.1 Removing and installing throttle valve module J338 - ve‐
hicles without hybrid drive”, page 164
⇒ “4.3.2 Removing and installing throttle valve module J338 - ve‐
hicles with hybrid drive”, page 164
4.3.1 Removing and installing throttle valve

module - J338- - vehicles without hybrid
drive
Removing
– Open hose clip -arrow- securing air hose and disconnect hose
downwards from throttle valve module - J338- .
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold;
© satelettronica
Removing and installing throttle valve module - J338- .
Installing
Additional work:
Tightening torques
4.3.2 Removing and installing throttle valve

module - J338- - vehicles with hybrid
drive
Removing
WARNING
voltage components.
components
– Detach coolant expansion tank and place to one side (coolant
hose remains connected).


Installing
Additional work:
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; unless
Engine cover panel;
permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing and installing engine cover panel
with respect to the. correctness of information in this document. Copyright by AUDI AG.
Tightening torques
4.4 Cleaning throttle valve module

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Clean‐
© satelettronica
ing throttle valve module .
4.5 Checking intake manifold change-over

function
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Check‐
ing intake manifold change-over function .

5 Injectors
Injectors .
© satelettronica

6 Senders and sensors

⇒ “6.1 Removing and installing intake air temperature sender G42
”, page 167
⇒ “6.2 Removing and installing air mass meter G70 ”, page 167
⇒ “6.3 Removing and installing fuel pressure sender G247 ”, page
167
⇒ “6.4 Checking fuel pressure sender G247 ”, page 167
6.1 Removing and installing intake air tem‐

perature sender - G42-
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors ;
Removing and installing intake air temperature sender - G42- .
6.2 Removing and installing air mass meter

- G70-
Removing
© satelettronica
meter - G70- .
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and
sensors; Removing and installing air mass meter - G70- .
Installing
Additional work:
Note
Tightening torques
♦ ⇒ Servicing 4-cylinder
permitted unless engine,
authorised by AUDI AG.1.8 AUDIltr., 2.0not
AG does ltr.guarantee
4-valve TFSI;
Rep. gr. 21 ; Charge
with respect air system;
to the correctness Exploded
of information viewCopyright
in this document. - hosebycon‐AUDI AG.
6.3 Removing and installing fuel pressure

sender - G247-
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors;
Removing and installing fuel pressure sender - G247- .
6.4 Checking fuel pressure sender - G247-

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors;
Checking fuel pressure sender - G247- .
6. Senders and sensors 167

7 High-pressure pump
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-
pressure pump .
© satelettronica

8 Lambda probe
⇒ “8.1 Exploded view - Lambda probe”, page 169
⇒ “8.2 Removing and installing Lambda probe”, page 169
8.1 Exploded view - Lambda probe

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe; Explo‐
ded view - Lambda probe .
8.2 Removing and installing Lambda probe

⇒ “8.2.1 Removing and installing Lambda probe G39 ”,
page 169
⇒ “8.2.2 Removing and installing Lambda probe after catalytic
converter G130 ”, page 170
8.2.1 Removing and installing Lambda probe

- G39-
© satelettronica
♦ Lambda probe open ring spanner set - 3337-
8. Lambda probe 169

Removing
– Unplug electrical connector -2- for Lambda probe - G39- and
Lambda probe heater - Z19- .
– Unscrew Lambda probe - G39- -1- using tool from Lambda
probe open ring spanner set - 3337- .
Installing
When installing, note the following:
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. High-temperature paste ⇒
Electronic parts catalogue
♦ When installing, the Lambda probe wiring must always be re‐
attached Protected
at the same locations
by copyright. Copying fortoprivate
prevent it from
or commercial coming
purposes, into
© satelettronica
contact with the exhaust pipe.
Tightening torques
Rep. gr. 24 ; Lambda probe; Exploded view - Lambda probe

after catalytic converter - G130-

Removing
– Unplug electrical connector -1- for Lambda probe after cata‐
lytic converter - G130- and Lambda probe 1 heater after
catalytic converter - Z29- .
– Unscrew Lambda probe after catalytic converter - G130- -2-
using tool from Lambda probe open ring spanner set - 3337- .
Installing
When installing, note the following:
Note

body.
© satelettronica
attached at the same locations to prevent it from coming into
Tightening torques
Rep. gr. 24 ; Lambda probe; Exploded view - Lambda probe
8. Lambda probe 171

9 Engine control unit

⇒ “9.1 Removing and installing engine/motor control unit J623 ”,
page 172
⇒ “9.2 Wiring and component check”, page 174
9.1 Removing and installing engine/motor

control unit - J623-
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 a protective casing
-2 and 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
© satelettronica
connect the test box or renew the engine control unit).
The following special tools are required if a protective housing is

fitted:

♦ 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-
Removing
– When renewing engine control unit, select diagnosis object
“Replace engine control unit” in “Guided Functions” mode of
⇒ Vehicle diagnostic tester.
– Switch off ignition and remove ignition key.
chamber coverProtected
. by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Unscrew bolts -arrows- and pull filler neck out of washer fluid
reservoir and through opening in body to right side.
– Release catch -arrow- and detach engine control unit - J623-

-item 1-.
© satelettronica
Perform the following work steps if a protective housing is fitted:
To help prevent unauthorised access to the connectors on the
engine control unit, the engine control unit -1- is bolted to a pro‐
tective housing -5- by means of shear bolts -3 and 4- and a locking
plate -2-.
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.
– 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.
NOTICE
Risk of damage to surrounding components caused by hot air
blower (overheating).
– Cover surrounding components if necessary.
Apply heat to the threads of the shear bolts on the connector side
as shown in the illustration.
9. Engine control unit 173

– Apply heat to the threads of the shear bolts on the connector

side for approx. 25 to 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- .
© satelettronica
Installing
Installation is performed in the reverse sequence.
– It is important that the protective housing is re-fitted on the
engine/motor control unit - J623- (if fitted previously).
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Always use new shear bolts.
After installing a new engine control unit, the following operation
must be performed:
– Activate engine control unit in “Guided Functions” mode, “Re‐
place engine control unit”; use ⇒ Vehicle diagnostic tester.
9.2 Wiring and component check

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Engine control unit ; Wiring
and component check.

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 175
⇒ “1.2 Separating exhaust pipes/silencers”, page 179
⇒ “1.3 Removing and installing front silencer”, page 181
⇒ “1.4 Stress-free alignment of exhaust system”, page 182
⇒ “1.5 Checking exhaust system for leaks”, page 183
1.1 Exploded view - silencers

⇒ “1.1.1 Exploded view - silencers, vehicles without hybrid drive”,
page 175
⇒ “1.1.2 Exploded view - silencers, vehicles with hybrid drive”,
page 178
1.1.1 Exploded view - silencers, vehicles without hybrid drive
© satelettronica
1 - Centre silencer
❑ Combined in one unit
with rear silencers as
original equipment. Can
be renewed individually
for repair purposes
❑ Cutting point
⇒ page 179
❑ Align exhaust system so
it is free of stress
⇒ page 182
2 - Bolt
❑ 23 Nm
3 - Mounting
❑ Renew if damaged
❑ Check preload
⇒ “1.4 Stress-free align‐
ment of exhaust sys‐
tem”, page 182
4 - Gasket
❑ Renew
5 - Nut permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Servicing 4-cylinder en‐

gine, 1.8 ltr., 2.0 ltr. 4-
valve TFSI; Rep. gr. 26 ;
Emission control sys‐
tem; Exploded view -
emission control system
6 - Gasket
❑ Renew
1. Exhaust pipes/silencers 175

8 - Catalytic converter
❑ Protect catalytic converter from damage by knocks and impact
❑ Align exhaust system so it is free of stress ⇒ page 182
9 - Lambda probe after catalytic converter - G130- and Lambda probe heater 1 after catalytic converter - Z29-
10 - Nut
❑ Tightening torque ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Emission
control system; Exploded view - emission control system
11 - Mounting
❑ Check preload ⇒ “1.4 Stress-free alignment of exhaust system”, page 182
12 - Bolt
❑ 23 Nm
13 - Front silencer
❑ With flexible joint
❑ Do not bend flexible joint more than 10° - otherwise it can be damaged
© satelettronica
❑ Install flexible joint so that it is not under tension.
❑ Take care not to damage wire mesh on flexible joint
14 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 182
❑ Installation position ⇒ page 177
❑ Tighten bolt connections evenly.
15 - Nut Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
16 - Clamp (rear left)
❑ For separate replacement of centre and rear silencers
❑ Tighten bolted connections evenly
17 - Rear silencer (left-side)
❑ Combined as one unit with centre silencer as original equipment
❑ Centre silencer and rear silencer can be renewed separately as required
❑ Cutting point between centre silencer and rear silencer ⇒ page 179
18 - Tailpipe
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point ⇒ page 179
❑ Aligning ⇒ page 183
19 - Clamp
❑ 23 Nm
20 - Mounting
176 Rep. gr.26 - Exhaust system

21 - Bolt
❑ 23 Nm
22 - Nut
❑ 23 Nm
Installation position of front clamp

– Fit the clamp at the angle shown.
• Bolted connections face to right.
• Nuts face upwards.
• α = approx. 20°
© satelettronica
Installation position of rear clamps
– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp.
• Installation position: bolted connections
permitted unlessface forwards.

1.1.2 Exploded view - silencers, vehicles with hybrid drive
1 - Centre silencer
for repair purposes
❑ Cutting point
⇒ page 179
⇒ page 182
2 - Bolt
❑ 23 Nm
3 - Mounting
❑ Check preload
© satelettronica
tem”, page 182
4 - Mounting
❑ Check preload
tem”, page 182
5 - Gasket
❑ Renew
❑ Protect catalytic con‐
verter from damage by
knocks and impact
⇒ page 184
7 - Nut
❑ Renew
❑ 20 Nm
8 - Protected
Seal by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑permitted
Renew unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
9 - Lambda probe - G39- and Lambda probe heater - Z19-
10 - Lambda probe after catalytic converter - G130- and Lambda probe heater 1 after catalytic converter - Z29-
11 - Nut
❑ Renew
❑ 20 Nm
12 - Mounting

13 - Bolt
❑ 23 Nm
14 - Front silencer
❑ Do not bend flexible joint more than 10° - otherwise it can be damaged
❑ Install flexible joint so that it is not under tension.
❑ Take care not to damage wire mesh on flexible joint
15 - Clamp (front)
16 - Nut
❑ 23 Nm
17 - Bolt
❑ 23 Nm
© satelettronica
❑ Centre silencer and rear silencer can be renewed separately as required
19 - Tailpipe
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes
❑ Aligning ⇒ page 183
20 - Mounting
21 - Nut
❑ 23 Nm
22 - Clamp (rear left)
23 - Nut
❑ 23 Nm
1.2 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at the cutting point in
order to renew the centre or rear silencer separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.

♦ Chain pipe cutter - VAS 6254-
Procedure
– Cut through exhaust pipes at right angles at the positions
marked -arrows- using chain pipe cutter - VAS 6254- .
© satelettronica
– Position centre of clamps -arrows- over cutting location.

bottom of clamp.
• Installation position: bolted connections face forwards.
Tightening torques
♦ ⇒ “1.1 Exploded view - silencers”, page 175

1.3 Removing and installing front silencer

Removing
– Remove nuts -1 and 2- (accessible from above) for front si‐
lencer.
Note
Nut -3- is removed at a later stage.

noise insulation .
– Remove nut -3- for front silencer.

– Remove nuts -1 and 2-.
© satelettronica

NOTICE

Installing
Note
Renew seals, gaskets and self-locking nuts.

Tightening torques
© satelettronica
tion; Exploded view - noise insulation Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.4 Stress-free alignment of exhaust system

Procedure
• The exhaust system must be aligned when it is cool.
Vehicles without clamps between centre silencer and rear silenc‐
ers
– Loosen bolted connections on front clamps.
– Push exhaust system towards front of vehicle -arrow- until
mountings in front of centre silencer are preloaded by -a- =
6 ... 10 mm.
– Tighten bolted connections on clamps evenly.
– Align tailpipes ⇒ page 183 .
Vehicles with clamps between centre silencer and rear silencers
Note
On a vehicle with clamps fitted between the centre silencer and

rear silencers, it is also necessary to align the centre silencer.
– Loosen bolted connections on front and rear clamps.

6 ... 10 mm.
– Tighten bolt connections on front clamp evenly.

– Push rear section of exhaust system towards front of vehicle

-arrow-, so that mountings (rear) for rear silencers are preloa‐
ded by -a- = 11 ... 15 mm.
– Align rear silencers so they are horizontal.
– Tighten bolted connections on rear clamps evenly.
Aligning tailpipes
– Check clearance between tailpipes and bumper on both sides:
• Dimension -x- (left-side) = dimension -x- (right-side)
Tightening torques
© satelettronica
1.5 Checking exhaust system for leaks
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Exhaust pipes/silencers;
Checking exhaust system for leaks .

2 Emission control system

⇒ “2.1 Exploded view - emission control system”, page 184
⇒ “2.2 Removing and installing catalytic converter”, page 184
⇒ “2.3 Removing and installing exhaust flap control unit J883 ”,
page 187
2.1 Exploded view - emission control sys‐

tem
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Emission control sys‐
tem; Exploded view - emission control system .
Exhaust flap control unit - J883- - tightening torque
Note
Renew nuts.
© satelettronica
– Tighten nuts -4- to 3 Nm.
2.2 Removing and installing catalytic con‐

verter
⇒ “2.2.1 Removing and installing catalytic converter - vehicles
2.2.1 Removing and installing catalytic con‐

verter - vehicles without hybrid drive
Removing
– Unplug electrical connector -arrow- for Lambda probe after
catalytic converter - G130- and Lambda probe 1 heater after
catalytic converter - Z29- and move wiring clear.

– Unplug electrical connector -arrow- for Lambda probe - G39-

and Lambda probe heater - Z19- and move wiring clear.
– Remove front silencer ⇒ page 181 .
– Remove nuts -arrows- and lift out catalytic converter.

Installing
Note
© satelettronica
♦ ⇒ “1.1 Exploded view - silencers”, pagewith175

verter - vehicles with hybrid drive
Removing
DANGER
qualified person.

– Drain coolant
⇒ “1.3 Draining and filling cooling system”, page 83 .
2. Emission control system 185


– Unplug connector -A- for high-voltage wiring harness for drive
motor - PX2- and connector -B- at drive motor rotor position
sender 1 - G713- on top left of gearbox.
– Unplug electrical connector -C- for Lambda probe after cata‐
lytic converter - G130- and detach from cable tie -arrow-.
– Lift retaining clips -1, 4-, release hose clip -3- and detach cool‐
ant hoses.
– Unplug electrical connectors -2- and move wiring clear.
© satelettronica
– Release hose clips -1- and detach coolant hoses.

– Unscrew bolts -arrows- and remove pump unit.

– Remove nuts -arrows- and lift out catalytic converter.

Installing
Note
♦ Renew seals, gaskets and self-locking nuts.


WARNING
© satelettronica
qualified person.

Note

Tightening torques
vehicles with hybrid drive”, page 94 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ ⇒ Servicing 4-cylinder engine, 1.8 ltr., with
2.0respect
ltr. 4-valve TFSI;of information in this document. Copyright by AUDI AG.
to the correctness
Rep. gr. 26 ; Emission control system; Exploded view - emis‐
sion control system
2.3 Removing and installing exhaust flap

Removing
– Lower exhaust system (rear left).

– Remove nuts -4- and detach exhaust flap control unit -2-.
Installing
© satelettronica
Note
Renew nuts.
– Move exhaust flap control unit - J883- into installation position.

• Spring -2- must engage in grooves -arrows- on exhaust flap
-1-.
Tightening torques
♦ ⇒ Fig. ““ Exhaust flap control unit -J883- - tightening torque”“ ,
page 184

3 Secondary air system

⇒ “3.1 Exploded view - secondary air system”, page 189
⇒ “3.2 Removing and installing secondary air pump motor V101
”, page 190
⇒ “3.3 Removing and installing secondary air inlet valve N112 ”,
page 190
⇒ “3.4 Removing and installing sender 1 for secondary air pres‐
sure G609 ”, page 191
3.1 Exploded view - secondary air system
1 - Hose
❑ For secondary air
❑ With resonator
2 - O-ring
❑ Renew
3 - Nut
© satelettronica
❑ 9 Nm
4 - Hose
5 - O-ring
❑ Renew
6 - Bonded rubber bush
- V101-
⇒ page 190
8 - Bolt
9 - Pipe
10 - Bolt
❑ 23 Nm
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 9 Nm
13 - Heat shield
14 - Hose
16 - O-ring
❑ Renew
3. Secondary air system 189

17 - Connection
18 - Bolt
❑ 9 Nm
19 - Bolt
❑ 19 Nm
21 - Bolt
❑ 9 Nm
22 - Gasket
23 - Nut
❑ 9 Nm
24 - Bracket
❑ For secondary air pump motor - V101-
25 - O-ring
❑ Renew
© satelettronica
3.2 Removing and installing secondary air
pump motor - V101-
Removing
– Press release tabs and disconnect secondary air hoses -1-.
– Disengage secondary air pump motor - V101- at bonded rub‐
ber bushes -arrows- and detach.
Installing
Note
Fit new O-rings.
Tightening torques
♦ ⇒ “3.1 Exploded view - secondary air system”, page 189
(front)
inlet valve - N112-

Removing


– Remove bolts -arrows- and detach heat shield -1-.
– Unplug electrical connectors -1-.

– Loosen clamp -2-.
– Remove bolts -arrows- and detach secondary air inlet valve -
N112- from hose for secondary air system.
© satelettronica
Installing
Note
Renew seal.

chamber partition
Protected panel
by copyright. . for private or commercial purposes, in part or in whole, is not
Copying
– Install engine cover
with respect to thepanel ⇒ Servicing
correctness of information in4-cylinder
this document.engine, 1.8
Tightening torques
3.4 Removing and installing sender 1 for

secondary air pressure - G609-
Removing


– Release catches -arrows- and detach sender 1 for secondary
air pressure - G609- .
Installing
Note
Fit new O-ring.

© satelettronica

4 Exhaust manifold
The exhaust manifold and the turbocharger are combined as one
unit; removing and installing
⇒ “1.2 Removing and installing turbocharger”, page 130 .
© satelettronica
4. Exhaust manifold 193

28 – Ignition system
1 Ignition system
⇒ “1.1 Exploded view - ignition system”, page 194
⇒ “1.2 Removing and installing ignition coils with output stages”,
page 194
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 194
⇒ “1.4 Removing and installing Hall sender”, page 194
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
195
1.1 Exploded view - ignition system

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system; Ex‐
ploded view - ignition system .
1.2 Removing and installing ignition coils
© satelettronica
with output stages
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system; Re‐
moving and installing ignition coils with output stages .
1.3 Removing and installing knock sensor 1

- G61-
WARNING
voltage components.

components
All vehicles:
1.8 ltr., 2.0 ltr. 4-valve TFSI;byRep.
Protected gr.Copying
copyright. 28 ; for
Ignition
private or system; Re‐ in part or in whole, is not
commercial purposes,
moving and installingpermitted
knockunless
sensor 1 - G61-
authorised by AUDI.AG. AUDI AG does not guarantee or accept any liability
1.4 Removing and installing Hall sender
moving and installing Hall senders .
194 Rep. gr.28 - Ignition system

1.5 Removing and installing engine speed

sender - G28-
WARNING
voltage components.

components
All vehicles:
moving and installing engine speed sender - G28- .
© satelettronica
1. Ignition system 195

Service
Workshop Manual
Audi A6 2011 ➤
4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve
TFSI - generation III)
© satelettronica
Engine ID
CYG CYN CYP CYP CYY
A B A B A
Edition 08.2017

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
26 - Exhaust system
© satelettronica

Copyright © 2017 Audi AG, Ingolstadt D4B804896FC

4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - generation III) - Edition 08.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 by copyright.
Protected Assembly Copyingmountings . . . . .purposes,
for private or commercial . . . . . in. .part
. .or. in. .whole,
. . . is. not
................................. 27
with respect to the correctness of information in this document. Copyright by AUDI AG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Exploded view - assembly mountings . . . . . . . . 27

© satelettronica
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1 Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.3 Installing ball for slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4 Removing and installing actuators for camshaft adjustment . . . . . . . . . . . . . . . . . . . . . . . . 52
4.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 52
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Contents i

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.4 Exploded view - coolant valve for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.7 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
© satelettronica
2.8 Removing and installing actuator for engine temperature regulation N493 . . . . . . . . . . . . 75
2.10 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 76
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4 Radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.1 Exploded view - radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2 Exploded view - radiator cowl and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
ii Contents

3.5 Checking intake manifold change-over function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.1 Exploded view - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1.3 Removing and installing front silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
© satelettronica
2.3 Removing and installing exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . . . 135
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Contents iii
© satelettronica
iv Contents
1 Identification
(ARL005389; Edition 08.2017)
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Identification .
© satelettronica
1. Identification 1
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Safety precautions .
© satelettronica

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair instructions .
© satelettronica
3. Repair instructions 3

page 20
1.1 Removing engine

© satelettronica

© satelettronica
♦ Safety goggles

Procedure
WARNING
Make sure the vehicle cannot tip over when the engine is re‐
moved.
♦ Secure the vehicle, to do so, the luggage compartment
must be empty.
Note

♦ Re-install all cable ties in the same locations when installing.
♦ On four-wheel drive vehicles the electromechanical parking
brake must be released before disconnecting theCopying
Protected by copyright. battery, so or commercial purposes, in part or in whole, is not
for private
that the propshaft can be turned permitted
during removal.
© satelettronica
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.

battery .
another -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
WARNING

• Put on protective gloves.
• Put on safety goggles.
• Cover filler cap on expansion tank with a cloth and open

– Remove nuts -1- (accessible from above) for front silencer.
Note
The nut -2- and bolt -3- are removed at a later stage.

© satelettronica
cross brace .
Caution
Risk of damage to running gear components.

♦ The vehicle must NOT be lowered onto its wheels if the
engine/gearbox mountings, steering rack or subframe
cross brace are not properly installed.
– Place drip tray for workshop hoist - VAS 6208- underneath.

– Lift retaining clip -3-, disconnect coolant hose from radiator
(bottom left) and drain off coolant.
Note
Disregard -item 2-.

Vehicles with dual clutch gearbox 0CK:

– Release hose clip -2-, disconnect coolant hose from gearbox
and drain off coolant.
– Release hose clip -1- and detach coolant hose from coolant
pipe (left-side) on gearbox.
– Unplug electrical connector -2- at gear oil pump -1-.
Note
Disregard -arrows-.
© satelettronica
Caution
Risk of irreparable damage to gearbox control unit (mecha‐

tronic unit) because of electrostatic discharge.
♦ Before unplugging or plugging in electrical connector, me‐
chanic must discharge static electricity. To do so, touch
vehicle earth, heater radiator, or lifting platform, with your
hand.
♦ Do NOT touch connector contacts in gearbox connector
with your hands.
– Unplug electrical connector -1- by pressing catch -arrow B-

and pulling fastener -2- in direction of -arrow A-.
– Move electrical wiring harness clear at gearbox and at cross
member.
Vehicles with dual clutch gearbox 0B5:

– Release hose clip -1-, disconnect coolant hose from ATF cool‐
er and drain off coolant.
– Remove bolts -arrows- and pivot ATF cooler to one side.

Caution

hand.
with your hands.

Vehicles with automatic gearbox 0BK:

© satelettronica
– Remove bolts -arrows- and tie up ATF cooler -1- to side with
coolant hose -2- attached.
Caution

hand.
with your hands.



one side.
– Remove bolts -arrows- from bracket for B+ wire and earth wire
at longitudinal member (right-side). permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
– Remove nut -2- and bolt -3- for front silencer.

Caution
Risk of damage to flexible joints in front silencer.

♦ Do NOT bend the flexible joints in the front silencer more
than 10°.

Note
normal direction of rotation.
© satelettronica
– Remove 3 bolts -arrow- for flywheel, turning crankshaft 120°
– Remove bolts -1- and -6 … 11- securing engine to gearbox.
Note
♦ The illustration shows automatic gearbox 0BK.

♦ Number and installation position of bolts for other gearboxes
⇒ Gearbox; Rep. gr. 34 ; Removing and installing gearbox;
♦ Disregard -item A-.

Caution
Wrong direction of rotation for a used poly V-belt can lead to

irreparable damage.
♦ Before removing the poly V-belt mark the direction of ro‐
tation with chalk or a felt-tip pen for re-installation.

belt from pulley for air conditioner compressor and release
tensioner.
Note
Ignore -T10060A- .
© satelettronica
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).
– Unplug electrical connectors and move wiring clear:

1- For left electrohydraulic engine mounting solenoid valve -
N144- / right electrohydraulic engine mounting solenoid
valve - N145- (depending on gearbox)
2- For continued coolant circulation pump - V51-

trol unit.
– Remove bolt for engine mountings -arrow- on both sides.
© satelettronica
ments .
– Remove bolts -arrows- and detach air duct -2- from lock car‐
rier.
Note
Disregardpermitted
-item 1-.unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability


WARNING

© satelettronica
• Release pressure (wrap a clean cloth around connection

charcoal filter.
Note
Disregard -item 3-.

– Unplug electrical connector for charge pressure sender - G31-
-item 1- and move electrical wiring clear.

– Release retaining clips -1, 3- and disconnect coolant hoses.
Note
Disregard -item 2-.
© satelettronica
body brace .

Note
Disregard -item 2-.


earth cables clear.
© satelettronica


trical wiring.
holder -3-.

-arrow B-.
© satelettronica
Note
Disregard items -1 and 3-.
– If fitted, unplug electrical connector -arrow- for gearbox neutral

position sender - G701- and move wiring clear.

Vehicles with manual gearbox/dual clutch gearbox 0B5/automatic

gearbox 0BK:
– Lift retaining clips -1 and 3-, disconnect coolant hoses and
guide them through plenum chamber partition panel.
Vehicles with dual clutch gearbox 0B5/automatic gearbox 0BK:
– Release hose clip -2- and disconnect coolant hose.

guide them through plenum chamber partition panel.
– Remove plenum chamber partition panel ⇒ General body
Protected re‐
chamber partition panel . with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
Note

⇒ Rep. gr. 34 ; Removing and installing gearbox; Tightening
torques for gearbox .
♦ Disregard -item A-.
Note
– Set up support bracket - 10-222A- at top of longitudinal mem‐

bers for wheel housing (left and right), as shown in illustration.

– Attach gearbox support - 3147- to gearbox and to spindle -

10-222A/11- .
Note

the engine removed.
– 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
© satelettronica
Note


– Tighten spindle of support bracket - 10-222A- 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 ascopyright.

Protected by muchCopying for private or commercial purposes, in part or in whole, is not
as possible when lifting engine out. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

compartment.


support
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Removing and installing
engine; Securing engine to engine and gearbox support .

♦ Assembly aid - T40169-
© satelettronica
♦ Transport lock - T40170-
Tightening torques
Note

Component Nm
Bolts/nuts M6 9
M8 20
M10 40
M12 65
installing gearbox; Tightening torques for gearbox / ⇒ Gear‐


Procedure
Note
♦ After removing, renew bolts tightened with specified tightening

angle.
and O-rings after removal.
♦ Hose connections and hoses for charge air system must be
free of oil and grease prior to fitting.
♦ To secure the charge air hoses at their connections, spray rust
remover onto the worm thread of the used hose clips before
installing.
♦ Re-install all bycable
Protected ties
copyright. in the
Copying sameorlocations
for private when ininstalling.
commercial purposes, part or in whole, is not
© satelettronica
– Ensure that intermediate plate is engaged on sealing flange
and pushed onto dowel sleeves -arrows-.
– Check whether dowel sleeves -A- for centring engine and

gearbox are fitted in cylinder block; install missing dowel
sleeves.
Note
The illustration shows automatic gearbox 0BK.
– Check whether aluminium bolts securing engine to gearbox

can be reused; if so, apply marking ⇒ Gearbox; Rep. gr. 34 ;
Removing and installing gearbox; Tightening torques for gear‐
box or ⇒ Gearbox; Rep. gr. 37 ; Removing and installing
gearbox; Tightening torques for gearbox .
– Check that needle bearing is fitted in drive plate. Removing
and installing needle bearing in drive plate (pressing in and
out) ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve
TFSI; Rep. gr. 13 ; Cylinder block (gearbox end); Renewing
needle bearing in drive plate .

Vehicles with manual gearbox or dual clutch gearbox:

– The following preparations are required before joining engine
and gearbox:
– Insert assembly aid - T40169- into gearbox housing and fly‐
wheel 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

clutch module accordingly.
© satelettronica
and gearbox:
– Turn torque converter until hole is visible next to notch
-arrow- in recess
Protected in Copying
by copyright. bottom for of gearbox
private housing,
or commercial asin part
purposes, shown in is not
or in whole,
illustration.
Note
There is only one notch on the circumference; turn the torque

converter accordingly.

– Insert transport lock - T40170- into gearbox housing from be‐
low and clamp onto flange shaft -1-.

Note
♦ Bolt -2- secures the starter to the gearbox and is provided with
a spacer sleeve -arrow-.
♦ Pay attention to the spacer sleeve -arrow- when removing and
installing the engine. The spacer sleeve must be fitted be‐
tween starter and gearbox.
– Bring gearbox into position on engine and tighten bolts

-1 … 11- securing engine to gearbox. Tightening torques ⇒
Gearbox; Rep. gr. 34 ; Removing and installing gearbox;
Tightening torques for gearbox or ⇒ Gearbox; Rep. gr. 37 ;
box
Note
© satelettronica
⇒ Gearbox; Rep. gr. 34 ; Removing and installing gearbox;

– Fit bolt -arrow- for left and right engine mountings.
A- .
– Screw in and tighten remaining bolts securing engine to gear‐
box.


– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
– Engage 4th gear and turn front wheels in direction of travel
until flywheel is rotated by one complete turn (360°).
• The inspection hole -arrow- should be visible again in the re‐
cess on the gearbox housing.
© satelettronica
– Remove transport lock - T40170- and assembly aid - T40169- .
Note
The following step is necessary to ensure that the flywheel/torque

converter is straight and that it makes even contact with the drive
plate.
– Use assembly lever -1- to press flywheel/torque converter

-2- slightly against drive plate -3- in direction of -arrow-.

Tightening sequence - flywheel/torque converter to drive plate

– Screw in first bolt -arrow- hand-tight.
– Turn crankshaft by 120° in direction of engine rotation and fit
second bolt hand-tight.
– Turn crankshaft by 120° in direction of engine rotation once
again.
– Now tighten third bolt to specified torque ⇒ Gearbox; Rep. gr.
30 ; Clutch; Exploded view - clutch module or ⇒ Gearbox; Rep.
gr. 37 ; Removing and installing gearbox .
– Then tighten remaining bolts to final torque.
quence.
– Install exhaust system ⇒ page 128 .
© satelettronica
Rep. gr. 92 ; Windscreen washer system; Exploded
permitted unless view
authorised - AG. AUDI AG does not guarantee or accept any liability
by AUDI
windscreen washer system . with respect to the correctness of information in this document. Copyright by AUDI AG.

ments .
– Install ATF cooler ⇒ Gearbox; Rep. gr. 34 ; ATF circuit; Re‐
moving and installing ATF cooler / ⇒ Gearbox; Rep. gr. 37 ;
ATF circuit; Removing and installing ATF cooler .
ing battery .
Caution

sive voltage.
♦ Never use battery charging equipment for boost starting.


– Check oil level ⇒ Maintenance ; Booklet 411 or ⇒ Mainte‐
nance ; Booklet 412 .
Note
Do not reuse coolant. with respect to the correctness of information in this document. Copyright by AUDI AG.

cross brace .
© satelettronica
– After renewing engine
♦ Adapt chain elongation ⇒ Vehicle diagnostic tester ; Guided
Functions ; 01 - Chain elongation adaption diagno-
sis .
♦ Reset misfire adaptions ⇒ Vehicle diagnostic tester, Guided

Functions , 01 - Reset adaptions misfires .


Engine mounting
1 - Not fitted
2 - Bolt
❑ 20 Nm
3 - Retaining plate
© satelettronica
fective
necessary
4 - Not fitted
5 - Not fitted
6 - Bolt
❑ 40 Nm
7 - Engine support
8 - Bolt
❑ 10 Nm
9 - Heat shield
10 - Bolt
❑ Renew after removing
❑ 90 Nm +90°
11 - Engine mounting
❑ Depending on gearbox:
with left electrohydraulic
engine mounting sole‐
noid valve - N144- / right
electrohydraulic engine
mounting solenoid valve
- N145-
12 - Subframe
13 - Bolt
❑ 55 Nm
Gearbox
with respect mounting forofmanual
to the correctness informationgearbox
1 - Nut
Assembly mountings;
bly mountings
2 - Bolt
Assembly mountings;
bly mountings
3 - Bolt
Assembly mountings;
bly mountings
4 - Nut
© satelettronica
Assembly mountings;
bly mountings
5 - Gearbox support
⇒ page 35
⇒ page 34
7 - Stop (bottom)
8 - Bolt
mountings
Gearbox mounting for dual clutch gearbox 0CK


assembly mountings
2 - Bolt
Assembly mountings;
bly mountings
3 - Nut
Assembly mountings;
bly mountings
4 - Gearbox support
5 - Bolt
© satelettronica
Assembly mountings;
bly mountings
⇒ page 35
7 - Stop plate
8 - Bolt
Assembly mountings;
Exploded view - assembly mountings
9 - Nut
Gearbox mounting for dual clutch gearbox 0B5/automatic gear‐

box 0BK
1 - Bolt
Assembly mountings;
bly mountings / ⇒ Gear‐
box; Rep. gr. 37 ; As‐
sembly mountings; Ex‐
ploded view - assembly
mountings
❑ Different versions avail‐
able; for correct version
refer to ⇒ Electronic
parts catalogue
assembly mountings / ⇒
Assembly mountings;
© satelettronica
bly mountings
3 - Stop plate
parts catalogue
⇒ page 36
5 - Bolt
❑ Protected
Tightening torque ⇒
Gearbox; Rep.
with respect to gr. 34of; information in this document. Copyright by AUDI AG.
the correctness
Assembly mountings; Exploded view - assembly mountings / ⇒ Gearbox; Rep. gr. 37 ; Assembly
mountings; Exploded view - assembly mountings
6 - Nut
❑ Tightening torque ⇒ Gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings /
⇒ Gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view - assembly mountings
7 - Bolt
8 - Gearbox support
❑ Different versions available; for correct version refer to ⇒ Electronic parts catalogue
9 - Bolt
10 - Nut


tion
♦ Support bracket - 10-222A-
Procedure
• Tunnel cross member installed.
© satelettronica
– Remove foam wedge -1- on both sides.
Note
Disregard -arrows-.
– Set up support bracket - 10-222A- at top of longitudinal mem‐

bers for wheel housing on both sides, as illustrated.
– Attach spindles -10-222A/11- to engine lifting eyes.
Assembling
Assembly is carried out in reverse sequence; note the following:

ings
Note
♦ Also renew corresponding retaining plates.

♦ The following chapter describes the procedure for the engine
mounting (left-side).
Removing
– Support engine in installation position ⇒ page 31 .
– Remove corresponding front wheel ⇒ Running gear, axles,
steering; Rep. gr. 44 ; Wheels, tyres .
noise insulation .
– Remove relevant front wheel spoiler ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
© satelettronica
– Detach corresponding electrical connector -1- for left electro‐
hydraulic engine mounting solenoid valve - N144- / right elec‐
trohydraulic engine mounting solenoid valve - N145- (depend‐
ing on gearbox) from bracket and unplug connector.
Note
Disregard -item 2-.
Engine mounting (right-side):

– Remove bolts -arrows- from bracket for B+ wire and earth wire
at longitudinal member (right-side).
– Move electrical wires slightly to one side.

Both sides (continued):

– Remove bolts -1- and -arrows- for engine mounting (left-side).
– Move retaining plate for engine mounting clear to one side.
Note
Disregard -item 2-.
Installing
Note
After removing, renew bolts tightened with specified tightening

angle.
Tightening torques
© satelettronica
(front)

mounting
mounting - manual gearbox”, page 34
gearbox”, page 34
mounting - dual clutch gearbox 0CK”, page 35
⇒ “2.4.4 Removing and installing gearbox mounting - dual clutch
gearbox 0CK”, page 35
mounting - dual clutch gearbox 0B5 / automatic gearbox 0BK”,
page 36
gearbox 0B5 / automatic gearbox 0BK”, page 36

gearbox
© satelettronica
Removing
Installing
Tightening torques

mounting - manual
permitted unlessgearbox
Removing
mounting.
box support -3-.
Installing
Tightening torques


port with gearbox mounting - dual clutch
gearbox 0CK
Removing
Installing
Tightening torques
⇒ Gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view -
assembly mountings

mounting - dual clutch gearbox 0CK
© satelettronica
Removing
– Unscrew bolts -1- and detach stop -2- for gearbox mounting.
box support -4-.
Installing
– Hand-tighten nut -5-.
– Tighten bolts -1- for stop -2-.
Tightening torques

gearbox 0B5 / automatic gearbox 0BK
Removing
sembly mountings; Exploded view - assembly mountings / ⇒
Gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view
- assembly mountings .
Installing
Tightening torques
- assembly mountings / ⇒ Gearbox; Rep. gr. 37 ; Assembly

© satelettronica
mounting - dual clutch gearbox 0B5 /

automatic gearbox 0BK
Removing
Installing
Tightening torques
- assembly mountings / ⇒ Gearbox; Rep. gr. 37 ; Assembly


ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel .
© satelettronica
3. Engine cover panel 37

page 38
page 38
1.1 Exploded view - cylinder block (pulley

end)
end); Exploded view - cylinder block (pulley end) .
© satelettronica

poly V-belt
end); Removing and installing poly V-belt tensioner .

er
Removing
– Remove radiator fan control unit ⇒ page 98 .
engine, 1.8 ltr., 2.0 by
Protected ltr.copyright.
4-valve TFSI;
Copying Rep.orgr.
for private 13 ; Cylinder
commercial block
(pulley end);permitted
Removing and installing
unless authorised by AUDI AG. vibration damper
AUDI AG does .
Installing
Additional work:

cillaries
Removing

– Unplug electrical connector -1- for charge pressure sender -

G31- and move clear.
Installing
Additional work:
Tightening torques
© satelettronica


cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder
block (gearbox end) .
© satelettronica

3 Crankshaft
Crankshaft .
© satelettronica
3. Crankshaft 41
4 Balance shaft
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Balance
shaft .
© satelettronica


cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Pistons
and conrods .
© satelettronica
5. Pistons and conrods 43


cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing
chain cover .
© satelettronica

2 Chain drive
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain
drive .
© satelettronica
2. Chain drive 45
3 Cylinder head

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Exploded
view - cylinder head .

Removing
– Remove camshafts ⇒ page
permitted unless 50 . by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
Caution
Risk of damage to valves and piston crowns.
© satelettronica
♦ Do not turn the crankshaft after the camshafts have been
removed.

– Unscrew bolts -arrows- for front silencer.
– Loosen bolted connections -arrows- and push clamp towards

rear.

– Lower front silencer -2- slightly and secure it with a cable tie
-1-, as shown in illustration.
Note
Place a cloth underneath to catch escaping engine oil.
– Unscrew bolt -1- and detach oil return connection.
© satelettronica
Note
Disregard -item 3-.

lytic converter - G130- -item 2- and move wiring clear.
– Unplug electrical connector -1- for Lambda probe - G39-

-item 2- and move wiring clear.
3. Cylinder head 47
– Remove heat shield -arrows-.
– Remove bolt -2- and detach oil supply line.

– Remove nuts -arrows- and pull turbocharger off studs.
Note
© satelettronica
G31- and move clear.
– Detach electrical connectors -2 and 3- from bracket and un‐

plug.
– Unplug electrical connectors -4, 5-.
– Remove bolts -1- securing bracket.

– Unplug electrical connectors -1, 2, 3-.

– Remove bolt -arrow- for coolant pipe (left-side).
Tightening torques
Rep. gr. 26 ; Emission control system; Exploded view - emis‐
sion control system

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Checking
compression .
© satelettronica
3. Cylinder head 49
4 Valve gear
⇒ “4.3 Installing ball for slider”, page 52
⇒ “4.4 Removing and installing actuators for camshaft adjust‐
ment”, page 52
⇒ “4.5 Removing and installing camshaft control valve 1 N205 ”,
page 52

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded
view - valve gear .

Removing
© satelettronica
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Unplug electrical connector -arrow- for oil level and oil tem‐
perature sender - G266- .
– Remove timing chain cover (top) ⇒ Servicing 4-cylinder en‐
gine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain
cover; Removing and installing timing chain cover .
– Unplug electrical connector -1- from charge pressure posi‐

tioner - V465-
– Unplug electrical connector -2- from turbocharger air recircu‐
lation valve - N249- .
Note
Disregard -item 3-.


1- For Hall sender 3 - G300-
2- For Lambda probe - G39- (take out of bracket)
3- For activated charcoal filter solenoid valve 1 - N80-
– Unplug electrical connectors -arrows- at actuators for cam‐

shaft adjustment.
– Remove ignition coils with output stages ⇒ Servicing 4-cylin‐
der engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition
system; Removing and installing ignition coils with output
stages .
© satelettronica
– Move electrical wiring clear.
– Release retainers -arrows-, detach wiring duct -1- with elec‐
trical wiring harness and move to one side.
– Disconnect hose -2- for activated charcoal filter system.
Note
Disregard -item 1-.
4. Valve gear 51
– Lift retaining clip -3-, detach coolant hose -2-, move it clear at
cylinder head and push it towards right side.
– Detach vacuum hose -4-, disconnect vacuum line -1- for intake
manifold flap valve - N316- and move clear at cylinder head.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear;
Removing and installing camshaft .
4.3 Installing ball for slider

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Installing
ball for slider .
4.4 Removing and installing actuators for

camshaft adjustment Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
© satelettronica
Removing with respect to the correctness of information in this document. Copyright by AUDI AG.

and installing actuators for camshaft adjustment .

and installing camshaft control valve 1 - N205- .

seals
and installing valve stem oil seals .


ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Inlet and exhaust valves .
© satelettronica

17 – Lubrication
1 Sump/oil pump
page 54
⇒ “1.6 Removingpermitted
and installing oil level
unless authorised and
by AUDI AG.oil temperature
AUDI send‐or accept any liability
AG does not guarantee
er G266 ”, page 55with respect to the correctness of information in this document. Copyright by AUDI AG.

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Ex‐
ploded view - sump/oil pump .
© satelettronica
1.2 Engine oil
Refer to ⇒ Maintenance ; Booklet 411 or ⇒ Maintenance ; Booklet
412 for instructions on draining and filling up engine oil, checking
oil level, removing and installing oil filter element.

section)
Removing
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres .
– Remove front noise insulation ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .

– Remove bolt -1- from engine mountings (left and right) and
raise engine slightly via spindle.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump (bottom section) .
Tightening torques
♦ Anti-roll bar ⇒ Running gear, axles, steering; Rep. gr. 40 ;
Subframe; Exploded view - subframe
♦ Wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels,
tyres

moving and installing oil pump .
© satelettronica
tion)
All procedures are todescribed
with respect inof⇒information
the correctness Servicing
in this 4-cylinder engine,
moving and installing sump (top section) .

moving and installing oil level and oil temperature sender - G266- .
1. Sump/oil pump 55
2 Engine oil cooler

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Engine
oil cooler .
© satelettronica

Crankcase breather .
© satelettronica

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil
filter/oil pressure switches .
© satelettronica

19 – Cooling

⇒ “1.1.1 Connection diagram - coolant hoses, vehicles without
auxiliary heater”, page 59
⇒ “1.1.2 Connection diagram - coolant hoses, vehicles with aux‐
iliary heater”, page 61
1.1.1 Connection diagram - coolant hoses, vehicles without auxiliary heater
Note
© satelettronica
♦ Brown = Heating circuit.
♦ Green = Coolant circuit for ATF.
1 - Radiator
2 - Exhaust manifold
3 - Turbocharger
block
er - G62-
sure)
9 - Bleeder hole
⇒ Heating, air condi‐
© satelettronica
tioning; Rep. gr. 87 ;
Front air conditioning
unit; Removing and in‐
stalling heat exchanger
V50-
12 - Coolant pump
13 - Thermostat
ATF
❑ For vehicles with dual
clutch gearbox/auto‐
matic gearbox
14 - ATF cooler
❑ For vehicles with dual clutch gearbox/automatic gearbox
16 - Restrictor
17 - Filler cap
20 - Radiator outlet coolant temperature sender - G83-
21 - Actuator for engine temperature regulation - N493-

1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater
Note

♦ Green = Coolant circuit for ATF.
1 - Radiator
3 - Turbocharger
block
© satelettronica
er - G62-
valve - N279-
10 - Bleeder hole
12 - Coolant pump
13 - Thermostat
ATF
❑ For vehicles with dual
matic gearbox
14 - ATF cooler
❑ For vehicles with dual Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
matic gearbox
16 - Restrictor
17 - Filler cap

21 - Actuator for engine temperature regulation - N493-

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant;
Checking cooling system for leaks .

♦ Vehicle diagnostic tester
© satelettronica

♦ Coolant collecting system - VAS 5014- or drip tray for work‐

shop hoist - VAS 6208-
© satelettronica
♦ Refractometer - T10007A-
♦ Safety goggles
Draining Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
WARNING


noise insulation .
gine.
– Lift retaining clip -3-, disconnect coolant hose from radiator
(bottom left) and drain off coolant.
Note
© satelettronica
Disregard -item 2-.
Vehicles with dual clutch gearbox 0CK: with respect to the correctness of information in this document. Copyright by AUDI AG.
– Release hose clip -2-, disconnect coolant hose from gearbox

Note
Disregard -item 1-.

Note
Disregard -arrows-.


er -1- and drain off coolant.
Note
-Arrows- and -item 2- can be disregarded.
– Connect coolant hoses (version with plug-in connectors)

⇒ page 91 .
Coolant specifications
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant;
Draining and filling cooling system .
Recommended mixture ratio for coolant
• Coolant (40 %) and distilled water (60 %) for frost protection
to -25 °C
• Coolant (50by%)
Protected and distilled
copyright. Copying for water
private or(50 %) for
commercial frost inprotection
purposes, part or in whole, is not
to -36permitted
°C unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
Filling cooling system

– Fill reservoir of -VAS 6096- with 10 litres of premixed coolant
(according to recommended ratio; for recommended ratio see
⇒ page 65 ).
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
Note
rection of flow).
– Open valves in coolant circuit; select 01 - Coolant circuit
bleeding routine in Guided Functions ⇒ Vehicle diag‐
nostic tester.

zone.
that hose on reservoir of -VAS 6096- can fill with coolant.
in the green zone.
sequent filling.
• If the needle does not reach the green zone, repeat the proc‐
ess.
• Check cooling system for leaks if the vacuum is not main‐
© satelettronica
tained.
– Open valve -A-.
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
-V.A.G 1274/8- on coolant expansion tank.
– Attach pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .

coolant. If required, add further coolant when performing
bleeding procedure.
Bleeding cooling system
chamber cover .


– Fill up with coolant until it flows out at bleeder hole in coolant
hose.
– Close filler cap on expansion tank.
– Start engine.
– Set fresh air blower to lowest setting.
– Switch off air conditioner compressor (press AC button).
• LED in button should not light up.
© satelettronica
– On vehicles with auxiliary heater, switch heater on for approx.
30 seconds and allow engine to run at idling speed.
tion .
Checking coolant level
WARNING

gine is cold.
engine is warm.

⇒ “2.3 Exploded view - coolant temperature senders”,
page 70
⇒ “2.4 Exploded view - coolant valve for gearbox”, page 71
page 71
⇒ “2.7 Removing and installing toothed belt for coolant pump”,
page 75
⇒ “2.8 Removing and installing actuator for engine temperature
regulation N493 ”, page 75
”, page 75
⇒ “2.10 Removing and installing radiator outlet coolant tempera‐
© satelettronica
ture sender G83 ”, page 76
2.1 Exploded view -Protected

coolant pump/thermo‐
stat permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

stat assembly; Exploded view - coolant pump/thermostat .


tion pump - V51-
⇒ page 73
2 - Coolant hoses
3 - Bracket
pump - V50-
4 - Bolt
gearbox; Tightening tor‐
ques for gearbox or ⇒
gearbox; Tightening tor‐
ques for gearbox
5 - Bolt
❑ 2.7 Nm
© satelettronica
6 - Coolant hose
V50-
⇒ page 71
8 - Coolant hose
9 - Bolt
❑ 23 Nm
10 - Bracket
❑ For continued coolant
circulation pump - V51-
11 - Bolt
❑ 2.7 Nm
12 - Rubber grommet

2.3 Exploded view - coolant temperature senders
1 - O-ring
❑ Lubricate with coolant
2 - Radiator outlet coolant tem‐
⇒ page 76
3 - Retaining clip
❑ Check for firm attach‐
ment
4, 5 - O-rings
❑ Installation instructions
⇒ Servicing 4-cylinder
engine, 1.8 ltr., 2.0 ltr. 4-
Coolant pump/thermo‐
stat assembly; Explo‐
© satelettronica
ded view - coolant tem‐
perature senders
6 - Bolt
❑ Tightening torques ⇒
Servicing 4-cylinder en‐
gine, 1.8 ltr., 2.0 ltr. 4-
Coolant pump/thermo‐
stat assembly; Explo‐
ded view - coolant tem‐
perature senders
er - G62-
❑ On cylinder head (gear‐
box end)
engine, 1.8with
ltr., 2.0 toltr.
the4-
respect correctness of information in this document. Copyright by AUDI AG.
valve TFSI; Rep. gr. 19 ; Coolant pump/thermostat assembly; Removing and installing coolant temper‐
ature sender - G62-

2.4 Exploded view - coolant valve for gearbox
1 - Coolant valve for gearbox -

N488-
⇒ page 76
2 - Coolant hose
3 - Bolt
❑ 23 Nm
4 - Bracket
❑ For coolant valve for
gearbox - N488-
5 - Nut
❑ 9 Nm
6 - Coolant hose
© satelettronica
pump
page 71
pump V51 ”, page 73

tion pump - V50-

© satelettronica

Removing
Note
– Clamp off coolant hoses using hose clamps -3094- , release

hose clips -1- and disconnect coolant hoses.
– Remove bolts -arrows- and detach coolant circulation pump -
V50- .
Installing
Note
© satelettronica
Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
Note

– Fill up with coolant ⇒ page 62
with.respect to the correctness of information in this document. Copyright by AUDI AG.

Tightening torques

ant circulation pump - V51-

Removing
noise insulation .
Note
© satelettronica

– Remove bolts -1- and detach continued coolant circulation
pump - V51- .
Installing
Note
♦ Secure all hose connections with correct type of hose clips (as

Tightening torques

Removing

– Lift retaining clips -1 and 2- and disconnect coolant hoses.
Note
Disregard -item 3-.

thermostat assembly; Removing and installing coolant pump .
Installing
Additional work:
2.7 Removing and installing toothed belt for

coolant pump
© satelettronica
stat assembly; Removing and installing toothed belt for coolant
pump .
2.8 Removing and installing actuator for en‐

gine temperature regulation - N493-
Removing
– Remove coolant pump ⇒ page 74 .
– Lift retaining clips and disconnect coolant hoses -1, 2 and 3-.
thermostat assembly ; Removing and installing actuator for en‐
gine temperature regulation - N493- .
Installing
– Install coolant pump ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0
ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Exploded view - coolant pump/thermostat .

ature sender - G62-
stat assembly; Removing and installing coolant temperature
sender - G62- .

2.10 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
• Engine cold.
– Open filler cap -arrow- on coolant expansion tank briefly to
relieve residual pressure in cooling system.
noise insulation .
– Unplug electrical connector -1- at radiator outlet coolant tem‐

Note
© satelettronica
♦ Place a cloth underneath to catch escaping coolant.
♦ Insert new radiator outlet coolant temperature sender - G83-
immediately into connection to avoid loss of coolant.
– Lift retaining clip -2- and pull out radiator outlet coolant tem‐
Installing
Note
Fit new O-rings.

Tightening torques
2.11.1 Removing and installing coolant valve

for gearbox - N488-
Coolant valve for gearbox - N488- is fitted on some vehicle ver‐
sions.

© satelettronica
Removing
noise insulation .
– Remove nuts -arrows- and detach coolant valve for gearbox -
N488- .
Installing
Installation is carried out permitted
in the reverse order; noteAG.the following:
unless authorised by AUDI AUDI AG does not guarantee or accept any liability
• Tightening torque
⇒ “2.4 Exploded view - coolant valve for gearbox”, page 71
Note
– Install noise insulation panels ⇒ General body repairs, exte‐

rior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .

3 Coolant pipes
Note
The arrow markings on coolant pipes and on ends of hoses must

align.
Coolant pipes on
withengine
1 - Coolant hose
2 - Bolt
❑ 9 Nm
3 - Coolant pipe (left-side)
© satelettronica
⇒ page 80
4 - Coolant hose
5 - Bolt
❑ 20 Nm
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 20 Nm
8 - Coolant pipe (right-side)
❑ With non-return valve
⇒ page 82
9 - O-ring
10 - Coolant hose
11 - O-ring
12 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by
hand so that it is
screwed into old thread.
Then tighten bolt to tor‐
que
❑ 6 Nm
13 - Coolant hose
Coolant pipes on dual clutch gearbox 0CK

1 - Subframe
2 - Coolant hose
3 - Coolant pipe on subframe
⇒ page 87
4 - Coolant hose
5 - Gearbox
gearbox
⇒ page 83
7 - Bolt
❑ 9 Nm
8 - Coolant hose
9 - Bolt
❑ 9 Nm
10 - Coolant hose
© satelettronica
11 - Bolt
❑ 23 Nm
12 - Bolt
❑ 23 Nm
Coolant pipes on dual clutch gearbox 0B5/automatic gearbox

0BK
3. Coolant pipes 79
1 - Bolt
❑ 23 Nm
2 - Coolant pipe on subframe
⇒ page 87
3 - Not fitted
4 - Not fitted
5 - Not fitted
6 - Bolt
❑ 9 Nm
7 - Coolant pipe (right-side) on
gearbox
parts catalogue
⇒ page 85
© satelettronica
8 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 9 Nm
9 - Not fitted
10 - Not fitted
11 - Bolt
❑ 23 Nm

⇒ “3.2.1 Removing and installing coolant pipe (left-side)”,
page 80
⇒ “3.2.2 Removing and installing coolant pipe (right-side)”,
page 82
⇒ “3.2.3 Removing and installing coolant pipe on gearbox (left-
side) - vehicles with dual clutch gearbox 0CK”, page 83
⇒ “3.2.4 Removing and installing coolant pipe on gearbox (right-
side) - vehicles with dual clutch gearbox 0B5/automatic gearbox
0BK”, page 85
⇒ “3.2.5 Removing and installing coolant pipe on subframe”, page
87

(left-side)

© satelettronica
Removing
Note

– Clamp off coolant hoses with hose clamps up to 25 mm - 3094-
and detach -arrows-.
Note

Tightening torques
3. Coolant pipes 81

(right-side)
Removing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
– Remove bolt -arrow- and detach crankcase breather pipe from
turbocharger.

– Lift retaining clip -1-, release hose clip -2- and detach coolant
hoses.
– Remove bolts -arrows-, detach coolant pipe (right-side) from
cylinder block and remove coolant pipe.
Installing
Note

Note
© satelettronica
Tightening torques
3.2.3 Removing and installing coolant pipe on

gearbox (left-side) - vehicles with dual
clutch gearbox 0CK
3. Coolant pipes 83
© satelettronica
♦ Safety goggles
Removing
WARNING


noise insulation .
tion.


– Clamp off coolant hose using hose clamp -3094- , release
hose clip -1- and disconnect coolant hose.
– Loosen hose clip -2- and detach coolant pipe.
Installing
Note

© satelettronica
Tightening torques
♦ ⇒ General body repairs, exterior;
Protected Rep.Copying
by copyright. gr. 66 for;private
Noise insula‐ purposes, in part or in whole, is not
or commercial

gearbox (right-side) - vehicles with dual
clutch gearbox 0B5/automatic gearbox
0BK
3. Coolant pipes 85
© satelettronica
♦ Safety goggles
Removing
WARNING

Danger of scalding
permitted unless skin andby other
authorised parts
AUDI AG. of does
AUDI AG the not
body.
guarantee or accept any liability

noise insulation .

– Remove bolts -arrows- and detach heat shield (right-side)

-1- on subframe.
tion.
© satelettronica
Note
The illustration shows dual clutch gearbox 0B5.
Installing
Note

Tightening torques
♦ Heat shield ⇒ Running gear, axles, steering; Rep. gr. 40 ;
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ;byNoise
Protected insula‐
tion; Exploded view - noise insulation permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

subframe
3. Coolant pipes 87
© satelettronica
Removing
noise insulation .
– Remove bolts for engine mounting -arrows-.
– Move retaining plate for engine mounting clear to one side.



hose clips -arrows- and disconnect hoses.
– Unscrew bolts -1, 2- and detach coolant pipe.
Installing
Note
– Fill up with coolant ⇒ page 62Protected

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

© satelettronica
(front)
3. Coolant pipes 89
⇒ “4.2 Exploded view - radiator cowl and radiator fans”,
page 92
1 - Air duct
2 - Coolant hose
tach
❑ Connecting
⇒ page 91
3 - O-ring
© satelettronica
❑ Renew
4 - Radiator
⇒ page 92
5 - Coolant hose
tach
❑ Connecting
⇒ page 91
6 - O-ring
❑ Renew
7 - Coolant pipe
tank
tach
❑ Connecting
⇒ page 91
8 - O-ring
❑ Renew
9 - Rubber bush
❑ For radiator
10 - Retaining pin
11 - Air duct
❑ 2.5 permitted
Nm unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
13 - Condenser

14 - Air duct
15 - Rubber bush
❑ For radiator
17 - Bolt
❑ 5 Nm
18 - Washer
19 - Bolt
❑ 4.5 Nm
Note
© satelettronica
– Lubricate new O-ring lightly with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto coolant pipe -1- until it engages with
a click.
4.2 Exploded view - radiator cowl and radiator fans

⇒ page 98
2 - Bolt
❑ 3.5 Nm
3 - Bolt
❑ 5 Nm
4 - Radiator cowl
⇒ page 95
⇒ page 98
© satelettronica
⇒ page 98
7 - Bolt
❑ 5 Nm
Note
Radiator and radiator cowl can only be removed and installed to‐
gether.
Removing
– Remove bumper cover (front) ⇒ General body repairs, exte‐
rior; Rep. gr. 63 ; Bumper (front); Removing and installing
bumper cover .
– Remove headlight (right-side) ⇒ Electrical system; Rep. gr.
94 ; Headlights; Removing and installing headlights .

WARNING

♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.

– Remove bolts -arrows- and permitted

detachunless
air duct -1-.by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
© satelettronica
Note
Disregard -item 2-.
diator.
– Unplug electrical connector -2- on refrigerant pressure and

temperature sender - G395- .
Caution
Risk of damage to condenser, refrigerant lines and refrigerant

hoses.
– Disengage retaining clip in direction of -arrow B- on both sides.

– First pull condenser -1- out of radiator on right side in direction
of -arrow A-.
– Then carefully guide condenser out on the left, paying atten‐
tion to the refrigerant lines.
– Swivel condenser to left side.
– Move electrical
with respect wiring ofharness
to the correctness information-2- clear.
© satelettronica
– Remove bolts -3 and 4- and loosen bolt -5-.
– Swivel impact bar -1- towards front -arrow-.
upwards -arrows-.

– Remove bolt -1- on both sides and detach radiator bracket with
radiator from lock carrier -arrow-.
Installing
Note
© satelettronica

– Install headlight (right-side) ⇒ Electrical system; Rep. gr. 94 ;
Headlights; Removing and installing headlights .
– Install bumper cover (front) ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Removing and installing bumper
cover .
Note

Tightening torques
♦ ⇒ “4.1 Exploded view - radiator/radiator fans”,
Protected page 90
♦ ⇒ “2.1 Exploded view - air cleaner housing”, page
with respect to the114


Removing
ments .

Note
Disregard -item 2-.
© satelettronica
Note
♦ Depending on the version, an air duct -2- that surrounds the

refrigerant line -1- may be fitted on the left, as shown in the
illustration.
♦ This air duct cannot be removed; it remains in its installation
position after the radiator has been unclipped and may have
to be pushed to one side.

WARNING

cooler (left and right).
© satelettronica
– Press locking tabs on left and right sides of radiator cowl si‐
multaneously -arrow- and detach radiator cowl downwards
from radiator.
Installing
– Install lock carrier cover and closure plate at bumper cover
(front) ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper
(front); Exploded view - bumper cover .
Note

Tightening torques

V7-
⇒ “4.5.1 Removing and installing radiator fans V7 / V177 ”,
page 98
⇒ “4.5.2 Removing and installing radiator fan control unit”,
page 98
4.5.1 Removing and installing radiator fans -

V7- / -V177-
Removing
Note

© satelettronica
side).
Installing
Tightening torques
page 92
4.5.2 Removing and installing radiator fan

control unit
Removing
noise insulation .

WARNING

trol unit.

– Unscrew bolt -arrow- and remove radiator fan control unit -1-.
Installing
Tightening torques
© satelettronica
page 92
1 Turbocharger

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.2 Removing and installing

with respect to turbocharger
Removing
noise insulation .
© satelettronica
– Open hose clip -arrow-, detach air hose and swivel to side.
– Unscrew bolts -arrows- for front silencer.
Caution

♦ Do NOT bend the flexible joints in the front silencer more
than 10°.

rear.

– Lower front silencer -2- slightly and secure it with a cable tie
-1-, as shown in illustration.
Removing and installing turbocharger .
Installing
Additional work:
Tightening torques
© satelettronica
1. Turbocharger 101
2 Charge air system

page 103
page 104

– Observe rules for cleanliness ⇒ Servicing 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules
for cleanliness .

⇒ page 103
© satelettronica
2 - Hose clip
3 - Air hose
❑ To turbocharger
❑ Installing ⇒ page 103
4 - Hose clip
5 - Hose clip
6 - Air hose
7 - Hose
permittedclip
8 - O-ring
❑ Renew
G31-
⇒ page 104
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

19 - Hose clip
20 - Bolt
❑ 7 Nm
21 - Resonator
22 - Rubber grommet
23 - Hose clip
24 - Air hose
❑ To resonator
2.2 Exploded view

Protected by - hose
copyright. Copying forconnections for in part or in whole, is not
private or commercial purposes,
chargewithair system

Exploded view - hose connections for charge air system .
© satelettronica
er
Removing
– Remove closure plate at bumper cover and lock carrier cover
⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Note

illustration.
♦ This air duct cannot be removed; it remains in its installation
position after the radiator has been unclipped and may have
to be pushed to one side.

cooler.
cooler.
Installing
© satelettronica
Note

– Install lock carrier cover and closure plate for bumper cover ⇒
Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 102
♦ ⇒ “2.2 Exploded view - hose connections for charge air sys‐
tem”, page 103

sure sender - G31-
Removing
Installing
Note
Fit new O-ring.
Tightening torques


♦ Charge air system tester - V.A.G 1687-
Procedure
– Remove noise insulation ⇒ General body repairs, exterior;
insulation .
© satelettronica
– Open hose clip -arrow-, detach air hose and swivel to side.
– Depending on hose diameter, insert adapter - 1687/10- ,

-1687/11- or -1687/12- into air hose -1- and secure with hose
clip.
– Connect charge air system tester - V.A.G 1687- as shown on
illustration.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air
system; Checking charge air system for leaks .
Note
Tightening torques
♦ ⇒ Servicing 4-cylinder engine,permitted
1.8 ltr.,unless
2.0authorised
ltr. 4-valve TFSI;
Rep. gr. 21 ; Charge air system;with
Exploded view
respect to the - hose
correctness con‐ in this document. Copyright by AUDI AG.
of information


1 Injection system
page 106

Overview of fitting locations - engine compartment

N145-
⇒ page 108
© satelettronica
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
ic converter - G130- and Lamb‐
da probe heater 1 after catalyt‐
ic converter - Z29-
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
V50-
⇒ page 108
❑ Exploded view
⇒ page 68
5 - Gear detection sensor -
G604-
❑ For vehicles with man‐
ual gearbox
⇒ page 108
❑ Exploded view ⇒ Fuel supply system; Rep. gr. 20 ; Accelerator mechanism; Exploded view - accelerator
Protectedpedal module
7 - with
Brake light
respect to theswitch - F-

❑ Removing and installing ⇒ Brake system; Rep. gr. 45 ; Sensors; Removing and installing brake light
sensor


❑ With clutch pedal switch - F36- / clutch pedal switch for engine start - F194-
❑ For vehicles with manual gearbox
❑ Exploded view ⇒ page 102
© satelettronica
Accelerator position sender - G79- and accelerator position send‐
er 2 - G185-
2 - Electrical connector
Brake light switch - F- / clutch position sender - G476-

♦ On mounting bracket for pedal cluster
2- Clutch position sender - G476- with clutch pedal switch -
F36- / clutch pedal switch for engine start - F194- for vehi‐
cles with manual gearbox


valves -N144- / -N145- , continued coolant circulation pump - V51-
♦ Electrohydraulic engine mounting solenoid valves -N144- / -
N145- integrated in engine mountings (both sides)
1- Electrical connector for electrohydraulic engine mounting
solenoid valve
♦ Continued coolant circulation pump - V51- on longitudinal
member (left-side)
2 - Electrical connector for continued coolant circulation pump -
V51-
Fitting location of radiator outlet coolant temperature sender -

G83-
♦ -Item 1- in coolant hose on radiator (bottom left)
© satelettronica
Fitting location of coolant circulation pump - V50-
♦ On top of gearbox.
2 - Electrical connector for coolant circulation pump - V50-
Fitting location of gear detection sensor - G604-

♦ On right side of manual gearbox
2 - Electrical connector for gear detection sensor - G604-
Overview of fitting locations - engine (view from above)


stage - N70-
stage - N127-
stage - N291-
© satelettronica
stage - N292-
5 - Hall sender 3 - G300-


tion system; Exploded view - ignition system
6 - Fuel metering valve - N290- or fuel pressure regulating valve - N276-
❑ Fuel metering valve - N290- or fuel pressure regulating valve - N276- may be fitted, depending on version
❑ Integrated in high-pressure pump
7 - Injector 2, cylinder 4 - N535-
8 - Fuel pressure sender for low pressure - G410-
9 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-


Overview of fitting locations - engine (view from left side)
1 - Actuator for engine temper‐

ature regulation - N493-
ant pump/thermostat
assembly; Exploded
view - coolant pump/
thermostat
© satelettronica
2 - Injector, cylinder 2 - N31-
TFSI; Rep. gr. 24 ; In‐
jectors; Exploded view -
fuel rail with injectors Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Injector, cylinder 1 - N30- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
fuel rail with injectors
4 - Fuel pressure sender -
G247-
fuel rail with injectors
5 - Throttle valve module -
J338-
❑ Including throttle valve
drive (electric throttle
operation) - G186- , an‐
gle sender for throttle valve drive - G187- and angle sender 2 for throttle valve drive - G188-


10 - Stage 3 oil pressure switch - F447-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil
Overview of fitting locations - engine (view from right side)
© satelettronica
er - G62-
ant pump/thermostat
assembly; Exploded
view - coolant tempera‐
ture senders
2 - Actuator 8 for camshaft ad‐ unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
justment - F373- (for cylinder with respect to the correctness of information in this document. Copyright by AUDI AG.
No. 4)
TFSI; Rep. gr. 15 ;
view - valve gear
No. 4)
TFSI; Rep. gr. 15 ;
view - valve gear
No. 3)
TFSI; Rep. gr. 15 ;
view - valve gear


9 - Actuator 1 for camshaft adjustment
permitted - F366-
unless authorised by AUDI(for
AG. cylinder
AUDI AG does No.
not 1)
10 - Charge pressure positioner - V465- with position sender for charge pressure positioner - G581-
11 - Turbocharger air recirculation valve - N249-
© satelettronica
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump;
Overview of fitting locations - engine (view from front)

1 - Exhaust camshaft control

valve 1 - N318-
TFSI; Rep. gr. 15 ; Tim‐
ing chain cover; Explo‐
ded view - timing chain
cover
2 - Camshaft control valve 1 -
N205-
TFSI; Rep. gr. 15 ; Tim‐
ing chain cover; Explo‐
ded view - timing chain
cover
© satelettronica
filter/oil pressure
switches; Exploded
view - oil pressure
control
4 - Oil pressure switch for re‐
duced oil pressure - F378-
filter/oil pressure
switches; Exploded
view - oil pressurepermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
switches/oil pressure with respect to the correctness of information in this document. Copyright by AUDI AG.
control
5 - Piston cooling jet control valve - N522-
6 - Valve for oil pressure control - N428-

2 Air cleaner
1 - Air duct
2 - Mounting
⇒ page 114
4 - Air filter element
© satelettronica
parts catalogue
Maintenance tables
let 411 or ⇒ Mainte‐
nance ; Booklet 412
5 - Cover
its or dirt
6 - Air pipe
❑ Tightening torque for
screw-type clips
⇒ page 103
7 - Air duct
8 - Bolt
❑ 1.5 Nm

housing

Removing
ments .
© satelettronica
rier.
Note
Disregard -item 1-.
2. Air cleaner 115


– Seal off turbocharger connection with sealing plug from engine
bung set - VAS 6122- .
Installing
Note

♦ Always use genuine air filter elements (same as original equip‐
ment).
♦ Use a silicone-free lubricant when installing the air hose.
© satelettronica
take side).
ments .
Tightening torques

3 Intake manifold
120
⇒ “3.5 Checking intake manifold change-over function”,
page 120

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Ex‐
ploded view - intake manifold .

Removing
© satelettronica
– If there is no B+ cover on the alternator, disconnect battery to
avoid short circuits ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Release hose clip -arrow- and detach air hose downwards
from throttle valve module - J338- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

1- For intake manifold flap potentiometer - G336-
2- For fuel pressure sender for low pressure - G410-
3- Main connector for MPI injectors
4- For intake air temperature sender - G42-
5- For Hall sender - G40-
6- For throttle valve module - J338-

– Unplug electrical connector -1- for intake manifold flap valve -

N316- .
– Disconnect vacuum hose -2-.

– Remove nut -2- and bolt -1- and detach intake manifold sup‐
port.
– Remove rubber bush -3- for intake manifold support.
© satelettronica
– Remove bolts -1 and 2- and press coolant pipe (left-side) to

the side.
Note
Disregard -arrows-.
WARNING


– Unscrew bolt -arrow- and union nuts -1, 2-.

– Detach high-pressure pipe.
Note
♦ The fuel system must not be under pressure.

♦ Use a clean cloth to catch escaping fuel.
♦ Seal off open connections with clean caps. Make sure no dirt
gets into the fuel system.
– Release hose clip -arrow- and detach fuel hose for MPI injec‐
tion system.
© satelettronica
– Move coolant line -2- clear at intake manifold and push to one
side.
– Move vacuum line -1- for intake manifold flap valve - N316-
clear at intake manifold.
Note
Disregard -item 3-.

Removing and installing intake manifold .
Additional work:
ing battery .
Tightening torques


module - J338-
Removing
– Release hose clip -arrow- and detach air hose downwards
from throttle valve module - J338- .
Installing
Additional work:
Tightening torques
© satelettronica

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Clean‐
ing throttle valve module .
3.5 Checking intake manifold change-over

function permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Check‐
ing intake manifold change-over function .

4 Injectors
⇒ “4.1 Exploded view - fuel rail with injectors”, page 121
⇒ “4.2 Removing and installing fuel rail”, page 121
⇒ “4.3 Removing and installing injectors”, page 121
⇒ “4.4 Cleaning injectors”, page 121
4.1 Exploded view - fuel rail with injectors

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded view
- fuel rail with injectors .
4.2 Removing and installing fuel rail

The following procedure applies to the fuel rail for FSI injectors.
Removing
© satelettronica
– Remove intake manifold ⇒ page 117 .
– Unplug electrical connector -1- at fuel pressure sender -
G247- .
– Move wiring duct -2- clear of fuel rail and detach fuel rail from
injectors.
Note
Unplug electrical connectors of any injectors that remained

lodged in fuel rail.
Installing
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Removing
and installing fuel rail .
4.3 Removing and installing injectors

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Removing
and installing injectors .
4.4 Cleaning injectors

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Cleaning
injectors .
4. Injectors 121

Senders and sensors .
© satelettronica

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-
pressure pump .
© satelettronica
6. High-pressure pump 123

7 Lambda probe
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda
probe .
© satelettronica


page 125

Note

locking fluid.
© satelettronica
The following special tools are required if a protective housing is
fitted:

Removing
chamber cover .


-item 1-.
Note
Disregard -item 2-.
© satelettronica
plate -2-.
air blower.
engine control unit are not secured with locking fluid. permitted
Do notunless
apply

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.
Apply heat to the threads of the shear bolts on the connector side
as shown in the illustration.


in illustration).
heated.
nectors.
© satelettronica
Installing
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
must be performed:
– Activate engine control unit in “Guided Functions”, “Replace
engine control unit” ⇒ Vehicle diagnostic tester.

⇒ “1.3 Removing and installing front silencers”, page 131
1 - Mounting
❑ Check preload
⇒ page 133
2 - Bolt
© satelettronica
❑ 23 Nm
3 - Centre silencer
with rear silencer as
for repair purposes
❑ Cutting point
⇒ page 130
⇒ page 133
4 - Mounting
❑ Check preload
⇒ page 133
5 - Front silencer
Caution
Risk of damage to flexi‐
ble joint.
Do
♦ not bend flexible joint Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
more than 10°. with respect to the correctness of information in this document. Copyright by AUDI AG.
Install
♦ flexible joint so that
it is not under tension.
Take
♦ care not to damage
wire mesh on flexible
joint.

6 - Gasket

7 - Nut
❑ 23 Nm
8 - Mounting
❑ Check preload ⇒ page 133
9 - Bolt
❑ 23 Nm
10 - Clamp (front)
11 - Nut
❑ 23 Nm
12 - Bolt
❑ 23 Nm
13 - Mounting
© satelettronica
❑ Check preload ⇒ page 133
14 - Bolt
❑ 23 Nm
15 - Rear silencer
❑ Left-side: with exhaust flap control unit - J883-
❑ Combined in one unit with centre silencer as original equipment. Can be renewed individually for repair
purposes
❑ Removing and installing exhaust flap control unit - J883- ⇒ page 135
16 - Nut
❑ 23 Nm
17 - Clamp (rear) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability



Components of mountings for front exhaust pipe

1- Spacer sleeve
2- Compression spring
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Buffer
8- Bracket
9- Bolt, 23 Nm
10 - Bracket
11 - Nut
Installation position of front clamp with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
– Fit the clamp at the angle shown.
• Bolted connections face to right.
• Nuts face upwards.
• α = approx. 20°
Installation position of rear clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolt connections face to left.

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.

Procedure
– Cut through exhaust pipes at right angle at notches -arrow-
using chain pipe cutter - VAS 6254- .
© satelettronica

bottom of clamp.
1.3 Removing and installing front silencers

Removing


terior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
– Remove nuts -1- (accessible from above) for front silencer.
– Remove nut -1- and bolt -3- for front silencer.
© satelettronica
Caution
Risk of damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.

Installing
Renew seals, gaskets and self-locking nuts.with respect to the correctness of information in this document. Copyright by AUDI AG.

Tightening torques


Procedure
ers
6 ... 10 mm.
Note
© satelettronica

6 ... 10 mm.

ded by -a- = 11 ... 15 mm.
Tightening torques

All procedures are described in ⇒ Servicingwith 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Exhaust pipes/silencers;
Checking exhaust system for leaks .


⇒ “2.3 Removing and installing exhaust flap control unit J883 ”,
page 135

tem
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Emission control sys‐
tem; Exploded view - emission control system .
Exhaust flapunless
permitted control unitby- AUDI
authorised J883-AG.-AUDI
tightening torque
Note
Renew nuts after removing.
© satelettronica
– Tighten nuts -arrows- to 3 Nm.

verter
Removing
Note

– Remove nut -2- from underneath.
Note
The nuts -1- are removed at a later stage.


lytic converter - G130- -item 2- and move wiring clear.
– Remove nuts -1- from above and lift out catalytic converter.
Installing
Note
© satelettronica
Tightening torques
2.3 Removing and installing exhaust flap

Removing
– Remove nuts -arrows- and detach exhaust flap control unit -
J883- -item 1-.
Installing
Note
Renew nuts.
– Move exhaust flap control unit - J883- into installation position.

• Spring -2- must engage in grooves -arrows- on exhaust flap
-1-.
Tightening torques
♦ ⇒ Fig. ““ Exhaust flap control unit -J883- - tightening torque”“ ,
page 134

1 Ignition system
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition
system .
© satelettronica

Service
Workshop Manual
Audi A6 2011 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail -
generation II)
Engine ID
CGL CGL CMG CGL
C D B E
© satelettronica
Edition 05.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
28 - Glow plug system
© satelettronica

Copyright © 2019 Audi AG, Ingolstadt D3E8034DF28

4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II) - Edition 05.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 2
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2.4 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Nuts, bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
© satelettronica
3.6 Use of impact wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.9 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.10 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Removing and installing torque reaction support and cross member . . . . . . . . . . . . . . . . 38
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.7 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.8 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.4 Renewing needle bearing in drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.5 Renewing spur gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.5 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.1 Exploded view - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.2 Exploded view - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
© satelettronica
2.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.5 Removing and installing seals for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.3 Measuring radial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.4 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.1 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Exploded view - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.4 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4 Balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.1 Removing and installing balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ii Contents

2.6 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4 Radiator/radiator fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.1 Exploded view - radiator/radiator fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.2 Exploded view - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
© satelettronica
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

1.1 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
1.3 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.4 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5 Injectors/high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.2 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Contents iii
5.3 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

5.4 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.5 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 243
5.6 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5.8 Removing and installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
5.9 Removing and installing high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.1 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 255
6.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
© satelettronica
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
1.4 Renewing tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
2.1 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2.2 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 282
3 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3.2 Removing and installing exhaust gas temperature sender . . . . . . . . . . . . . . . . . . . . . . . . 285
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 291
4.3 Checking exhaust gas recirculation cooler change-over . . . . . . . . . . . . . . . . . . . . . . . . . . 293
4.4 Cleaning exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
5.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
5.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
1.1 Exploded view - glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
1.3 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
iv Contents
1 Identification
(ARL006460; Edition 05.2019)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

Engine number
♦ The engine number (“engine code” and “serial number”)
-arrow- can be found on the left side (seen in the direction of
travel) at the joint between engine and gearbox.
♦ There is also a sticker with “engine code” and “serial number”
attached to the toothed belt cover.
♦ Engine codes starting with the letter “C” have four letters (pre‐
viously three letters).
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
© satelettronica
are stamped onto the cylinder block together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine and is determined by the engine control unit.
Note
♦ The four-letter engine code is found on the type plate (certain

countries only), vehicle data sticker and engine control unit.
♦ Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 411 .
For engine data refer to ⇒ Technical data for diesel engines; Rep.
gr. 00 ; Overview of engines .
1. Identification 1
⇒ “2.1 Safety precautions when working on the fuel system”, page
2
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 2
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “2.4 Safety precautions when working on the subframe”,
page 3
⇒ “2.5 Safety precautions when working on the cooling system”,
page 3
⇒ “2.6 Safety precautions when working on the exhaust system”,
page 4
2.1 Safety precautions when working on the

fuel system
When working on the fuel system note the following warnings:
© satelettronica
Risk of injury - fuel system operates under high pressure
The fuel system is pressurised. There is a risk of injury as fuel
may spray out.
Before opening the fuel system:
– Release pressure (wrap a clean cloth around connection and
open connection carefully).
Risk of fire due to escaping fuel

If the battery is connected, the door contact switch activates the
fuel pump when the driver's door is opened. Escaping fuel may
ignite, causing a fire.
– Before opening the fuel system, disconnect power supply to
fuel pump.
2.2 Safety precautions when working on ve‐

hicles with start/stop system
Please note the following when working on vehicles with start/stop
system:
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.

2.3 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or:
– Have a second mechanic operate test equipment on the rear
seat.
© satelettronica
subframe
Please note the following warnings when working on the sub‐
frame:
Caution

♦ 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:
Risk of scalding as hot coolant can escape
The cooling system is under pressure when the power unit is hot.
– Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
Caution
Overheating can occur if the filler cap is not fitted properly.

♦ Close filler cap on coolant expansion tank (make sure it
engages).
2.6 Safety precautions when working on the exhaust system

Risk of injury when disconnecting the exhaust system
There is a risk of eye irritation caused by soot particles in the air.
Danger from toxic exhaust gases

The auxiliary/supplementary heater produces toxic exhaust
gases during operation. There is a risk of poisoning and of dam‐
© satelettronica
age to the respiratory tract.
– In enclosed spaces, only switch on the auxiliary/supplemen‐
tary heater if there is an exhaust extraction system.
– In enclosed spaces without an exhaust extraction system,
switch off the auxiliary/supplementary heater.
Risk of damage to flexible joint

The flexible joint can be damaged or develop leaks if it is handled
incorrectly.

⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 General notes”, page 5
⇒ “3.3 General repair instructions”, page 6
⇒ “3.4 Nuts, bolts”, page 7
⇒ “3.5 Identification plates”, page 7
⇒ “3.6 Use of impact wrenches”, page 7
⇒ “3.7 Foreign particles in engine”, page 8
⇒ “3.8 Contact corrosion”, page 8
⇒ “3.9 Routing and attachment of pipes, hoses and wiring”, page
8
⇒ “3.10 Installing radiators and condensers”, page 8
3.1 Rules for cleanliness

Even small quantities of dirt can lead to defects. For this reason,
please observe the following rules when working on the fuel sup‐
© satelettronica
ply system, injection system and turbocharger:
♦ Clean connections and surrounding area thoroughly with en‐
gine cleaner or brake cleaner and dry cleaned area before
loosening.
♦ Seal off open pipes and connections immediately with clean
plugs, e.g. from engine bung set - VAS 6122- .
♦ After removal, place parts on a clean surface and cover them.
Only use lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ Do not work with compressed air when the system is open. If
possible, do not move vehicle.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.2 General notes

Fuel supply/injection
♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash fuel shut-off system. This
system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system ⇒ page 2 .
3.3 General repair instructions
Caution
The high-pressure 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 renewed, 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
fuel system must be filled and bled before the engine is
started for the first time
⇒ “1.3 Filling and bleeding fuel system”, page 222 .
© satelettronica
♦ Clean tools and workbench etc. before working on the injection
system.
♦ Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
♦ If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
♦ Take care not to damage the injectors when removing the old
copper seals.
♦ Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
♦ Position high-pressure pipes so they are free of stress. Tighten
all unions lightly to start with before tightening to final torque.
♦ Never attempt to bend high-pressure fuel lines to shape.
♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely and sealed properly by
pulling them by hand from above.
♦ Do not dismantle individual common rail components. If there
is a fault, the complete components must be renewed.
♦ When the engine is running, do not perform any repairs to the
common rail system.
♦ Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
♦ All cable ties which are released or cut open when removing
must be refitted in the same position when installing.

♦ Fuel hoses in engine compartment must only be secured with

spring-type clips. O-type clips or screw-type clips must not be
used.
3.4 Nuts, bolts

♦ Loosen bolts in reverse sequence to specified tightening se‐
quence.
♦ Bolts and nuts used to secure covers and housings must be
tightened in steps according to the specified tightening se‐
quence and method.
♦ Bolts and nuts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Always renew self-locking bolts and nuts.
♦ Unless otherwise specified, use a wire brush to clean the
threads of bolts which are secured with locking fluid. Then in‐
stall bolts with locking fluid; for locking fluid refer to ⇒ Elec‐
tronic parts catalogue .
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned using a thread tap or similar.
© satelettronica
Otherwise there is a danger of the bolts shearing off the next
time they are removed.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
3.5 Identification plates

When renewing vehicle components, the identification plates on
the old parts that have a replacement part number (see ⇒ Elec‐
tronic parts catalogue ) must be attached to the new parts due to
approval regulations.
3.6 Use of impact wrenches

In general, it is permitted to use an impact wrench to unscrew
bolts and nuts. An exception to this is when work is performed
inside an open high-voltage battery. For this work, it is not per‐
mitted to use an impact wrench.
An impact wrench may be used to screw in bolts and nuts when
performing repair work if the following requirements are observed.
In general, electric and compressed-air impact wrenches should
be used.
Requirements:
• Only screw in bolts with locking fluid or self-locking nuts at low
speed.
• Use a suitable impact wrench with variable speed and adjust‐
able torque range.
• Use suitable bits when working in the vicinity of sensitive sur‐
faces, e.g. plastic-coated bits for aluminium rims.
• When working in the vicinity of natural gas systems, observe
the information in the Workshop Manual “Natural gas engines
- General information”.
Use:
• Fit bolts/nuts by hand.
• Only use an impact wrench to screw in bolts/nuts until the head

of the bolt/nut makes contact and then continue tightening with
a torque wrench.
• Clean threaded pins before unscrewing the bolt/nut.
3.7 Foreign particles in engine

♦ When performing assembly work on the engine, all open pas‐
sages in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set - VAS 6122- ) to
prevent foreign particles from entering the engine.
Note
If the turbocharger has suffered mechanical damage

⇒ page 203
3.8 Contact corrosion
© satelettronica
Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.
3.9 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 avoid damaging pipes, hoses and wiring, ensure sufficient
clearance from all moving or hot components in engine com‐
partment (limited space in engine compartment).
3.10 Installing radiators and condensers

Even when the radiator, condenser and charge air cooler are cor‐
rectly installed, slight impressions may be visible on the fins of
these components. This does not mean that the components are
damaged. If the fins are only very slightly distorted, this does not
justify renewal of the radiator, charge air cooler or condenser.


page 27
1.1 Removing engine

equipment required
© satelettronica

♦ Hook - 10 - 222 A /10-

♦ Hooks - 10 - 222 A /2-
♦ Removal lever - 80 - 200-
© satelettronica
♦ Locking tool - T40098-

Procedure
Note

Caution
When disconnecting the battery there is a risk of irreparable

damage to electronic components.

battery .
– Remove engine cover panel -arrows-.
© satelettronica
WARNING

♦ The cooling system is under pressure when the power unit
is hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.

– Remove drive shaft cover on both sides ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
noise insulation .

gine.

– Release hose clip -arrow-, disconnect coolant hose and drain
off coolant.
© satelettronica
one side.
– Remove nuts -arrows- and bolts -1- for front exhaust pipe.

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-.
© satelettronica
– Remove bolts -1- and detach torque reaction support.
– Remove bolts -2- on both sides and detach cross member
-3-.
cross brace .
Caution

♦ The vehicle must NOT be lowered onto all four wheels if
the engine/gearbox mountings, steering rack or subframe
– Unplug electrical connector -3- and move clear.

Note
-Item 1- and -arrows- can be disregarded.

Note
Place a cloth underneath the ATF cooler to catch escaping cool‐

ant.

– Remove bolts -arrows-, detach ATF cooler and push to one
side.
Note
Disregard -item 2-.
Caution

tronic unit) because of static discharge.
© satelettronica
hand.
with your hands.
– Turn retainer catch anti-clockwise -arrow-, then unplug elec‐

trical connector at gearbox and move wiring clear.
Note


– 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
– Remove 3 bolts -arrow- for drive plate, turning crankshaft 120°

© satelettronica
– Remove bolts -1, 7, 8, 9, 10- securing engine to gearbox.
Note
Disregard -item A-.

Caution
Running a used poly V-belt in the opposite direction could

cause irreparable damage.
♦ Before removing the poly V-belt, mark the direction of ro‐

belt from pulley for air conditioner compressor and lock ten‐
sioner using locking tool - T40098- .
© satelettronica
WARNING

Caution
Risk of damage to refrigerant lines and hoses.


trol unit.

– Remove bolt -arrow-, release fastener and move radiator fan

control unit - J293- -item 1- clear to one side.
Note
– Remove bolts -arrows- (counterhold at central bolt).

– Remove vibration damper.
© satelettronica
– Pull off cover cap for idler roller.
– Remove bolt -arrow- and detach idler roller.
– Remove bolts -arrows- and move bracket -1- to the rear.

ments .

Note
Disregard -item 1-.
© satelettronica
- G70- .
– Detach air cleaner housing -1-.
Note
Disregard -item 3-.


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

© satelettronica
– Unscrew terminal 30/B+ -item 1-.

– 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.

– Remove bolt -1- and take off poly V-belt tensioner -2-
-arrow-.
– Release retaining clips -arrows- and detach toothed belt cover

(top).
© satelettronica
Caution
Protect fuel system against contamination.

♦ Rules for cleanliness when working on the injection sys‐
tem ⇒ page 5 .
– Disconnect fuel supply hose -3- and fuel return hoses -1, 2-.

body brace .

– Release catch -arrow A- and open cover -arrow B-.

Note
© satelettronica
Disregard -item 3-.
– If fitted, unplug electrical connector at brake servo pressure

sensor - G294- -arrow-.

earth cables clear.


© satelettronica
trical wiring.
holder -3-.


-arrow B-.

guide coolant hose through plenum chamber partition panel.
Note
Disregard -item 3-.
© satelettronica
– Lift retaining clips -1, 2 and 3-, disconnect coolant hoses and
guide relevant coolant hoses through plenum chamber parti‐
tion 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.
– Remove Lambda probe - G39- ⇒ page 266 .

– Unplug electrical connectors -4- for exhaust gas temperature

sender 3 - G495- and move electrical wiring clear.
– Remove nuts -arrows- and move particulate filter to rear.
© satelettronica
– Unplug electrical connector -2- at reversing light switch - F4-
and move electrical wire clear.
Note
– Unclip electrical connector -C- from bracket -B- and unplug.
Note
Disregard -item A- and -arrows-.

– Unplug electrical connector -arrow- for gearbox neutral posi‐

tion sender - G701- and move electrical wire clear.

Note
Disregard -item A-.
© satelettronica
– Detach electrical connector -1- from bracket and move elec‐
trical wiring harness -2- clear using removal lever - 80 - 200- .
Note

– 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

the engine removed.
– Remove lifting eye of lifting tackle - 2024 A- (pull out split pin
and press out pin).
– Reinsert lifting eye in 4th hole from front on lifting tackle.
– Secure pin with split pin again.
– Attach lifting tackle - 2024 A- to engine and workshop hoist -
VAS 6100- as shown in illustration.
© satelettronica
WARNING

– Remove bolts -2- for engine mounting on both sides.

Note
Disregard -item 1-.

Caution

♦ Carefully guide engine out of engine compartment when
lifting out.

Note


compartment.

support
When carrying out repairs, secure engine to engine and gearbox
support - VAS 6095A- using universal support - VAS 6095/1- .
♦ Engine and gearbox support - VAS 6095A-
© satelettronica
♦ Lifting tackle - 3033-

Procedure
• Gearbox detached from engine.
– Attach lifting tackle - 3033- to engine and workshop hoist - VAS
6100- as shown in illustration.
♦ Gearbox end: position 3.
♦ Pulley end: position 9.
– Lift engine off engine bracket - T10497A- using workshop hoist
- VAS 6100- .
– Secure engine to engine and gearbox support - VAS 6095A-

using universal support - VAS 6095/1- .
© satelettronica
Tightening torque
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65

When installing a new base engine, you must check whether
there is a sticker on the cylinder head cover.
If a sticker is attached which states Spannpratzen auf vor-
geschriebenes Drehmoment angezogen (clamping pieces tight‐
ened to specified torque), the clamping pieces have already been
tightened to the specified final torque at the factory.
If no sticker is attached, it is essential that the clamping pieces for
the injectors are tightened to the specified torque
⇒ Item 7 (page 237) after installing the high-pressure pipes. If
these instructions are not observed, the engine could be dam‐
aged.

♦ Transportation lock - T40170-
Tightening torques
Note

© satelettronica
♦ Tolerance for tightening torques: ± 15 %
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ Engine to gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Tightening torques for gearbox or ⇒ Rep. gr. 37 ;
box
Procedure
Note

and O-rings.
♦ On vehicles with manual gearbox, a needle bearing must be
fitted in the drive plate. Before installing, check whether a nee‐
dle bearing is fitted. Press needle bearing into drive plate
⇒ page 65 .


and gearbox:
– Insert assembly aid - T40169- into gearbox housing between
flywheel/torque converter and gearbox housing from below, as
illustrated.
• The assembly aid must engage in the semi-circular recess
-1- and in the inspection hole -2-.
Note

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

below and clamp onto flange shaft -1-.
© satelettronica
can be reused; if so, apply marking ⇒ Rep. gr. 34 ; Removing
and installing gearbox; Tightening torques for gearbox or ⇒

sleeves.
– Bring engine into position on gearbox, fit bolts -2 … 6- and
tighten.

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 the starter and the
gearbox.
– Slacken hook - 10 - 222 A /10- .

onto engine mountings.
– Secure engine mounting ⇒ page 34 .
A- .
© satelettronica
– Tighten bolts -1, 7, 8, 9, 10- to secure engine to gearbox.
Note
The following step is necessary to ensure that the clutch module

is straight and that it makes even contact with the drive plate.
– Install wheel housing liners ⇒ General body repairs, exterior;

Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
Wheels, tyres .
– Engage 4th gear and turn front wheels in direction of travel
until clutch module is rotated by one complete turn (360°).
• The inspection hole -arrow- should be visible again in the re‐
cess on the gearbox housing.

– Bolt clutch module onto drive plate as follows:

– Screw in first bolt -arrow- hand-tight (2 Nm).
– Turn front wheels in direction of travel until clutch module is
rotated by 240°.
– Tighten bolt accessible in this position to specified torque ⇒
Rep. gr. 30 ; Clutch; Exploded view - clutch module .
– Turn front wheels in direction of travel until clutch module is
rotated by 120° each time and tighten remaining 2 bolts to
specified torque ⇒ Rep. gr. 30 ; Clutch; Exploded view -
clutch .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install particulate filter ⇒ page 281 .
– Install pressure differential sender - G505- ⇒ page 282 .
© satelettronica
ments .
– Install tensioner and idler roller ⇒ page 42 .
– Install vibration damper ⇒ page 47 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Exploded view - alternator .
– Install poly V-belt ⇒ page 45 .
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 cross member and torque reaction support
⇒ page 38 .
ing battery .
Caution

sive voltage.

– Install air hoses with screw-type clips ⇒ page 209 .

– Bleed fuel system
– Connect coolant hoses with plug-in connector ⇒ page 190 .
Note

– Install wheel spoilers ⇒ General body repairs, exterior; Rep.
gr. 66 ; Wheel housing liners; Exploded view - wheel housing
liner (front) .
insulation .
© satelettronica

⇒ “2.4 Removing and installing torque reaction support and cross
member”, page 38

Engine mounting
1 - Bolt
❑ 20 Nm
2 - Bracket
© satelettronica
fective
necessary
3 - Bolt
❑ 40 Nm
4 - Engine support
5 - Bolt
❑ 10 Nm
6 - Heat shield
❑ Right-side only
7 - Bolt
❑ Renew
❑ 90 Nm +90°
8 - Engine mounting
❑ Left side: with left elec‐
trohydraulic engine
- N144-
❑ Right side: with right
- N145-
⇒ page 37
❑ Renew in pairs
9 - Subframe
10 - Bolt
❑ 55 Nm

Torque reaction support and cross member - tightening torques

1- Bolt, 25 Nm
2- Bolt, 40 Nm
Gearbox mounting for manual gearbox
1 - Nut
Rep. gr. 34 ; Assembly
mountings; Exploded
view - assembly mount‐
ings
© satelettronica
2 - Bolt
mountings; Exploded
ings
3 - Bolt
mountings; Exploded
ings
4 - Nut
mountings; Exploded
ings
5 - Gearbox support
⇒ page 39
⇒ page 39
7 - Stop (bottom)
8 - Bolt
❑ Tightening torque ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
❑ Removing and installing ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
Gearbox mounting for multitronic gearbox
1 - Nut
mountings; Exploded
ings
2 - Bolt
mountings; Exploded
ings
3 - Bolt
mountings; Exploded
ings
4 - Nut
© satelettronica
mountings; Exploded
ings
5 - Gearbox support
⇒ page 40
7 - Stop (bottom)
8 - Bolt
mountings; Exploded
view - assembly mountings

tion

Procedure
- G505- .

– Attach spindles -10 - 222 A /11- to engine lifting eyes.
© satelettronica
ings
Note
♦ To avoid repeat repairs, proceed as follows if an engine

mounting is defective:
♦ Renew engine mounting and corresponding retaining plate.
♦ Also renew engine mounting on opposite side; check corre‐
sponding bracket and renew if necessary.
Removing
– Remove drive shaft cover on both sides ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
noise insulation .
– 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
Note

Tightening torques
♦ Drive shaft covers, wheel spoilers ⇒ General body repairs,
wheel housing liner (front)
© satelettronica

support and cross member
Removing
noise insulation .
one side.

– Remove bolts -1- and detach torque reaction support.
– Remove bolts -2- on both sides and detach cross member
-3-.

Installing
– 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.
quence.
Tightening torques
♦ ⇒ Fig. ““Torque reaction support and cross member - tighten‐
ing torques”“ , page 35
tem”, page 209

mounting
© satelettronica
mounting - vehicles with manual gearbox”, page 39
⇒ “2.5.2 Removing and installing gearbox mounting - vehicles
with manual gearbox”, page 39
with multitronic gearbox”, page 40

port with gearbox mounting - vehicles
with manual gearbox
Removing
– Remove tunnel cross-piece ⇒ Rep. gr. 34 ; Assembly mount‐
ings; Exploded view - assembly mountings .
Installing
– Secure gearbox support with gearbox mounting to gearbox
-arrows-.
– Install tunnel cross-piece ⇒ Rep. gr. 34 ; Assembly mount‐
Tightening torques

mounting - vehicles with manual gear‐
box
Removing
mounting.
box support -3-.
Installing
Tightening torques
♦ ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - as‐
sembly mountings

mounting - vehicles with multitronic
© satelettronica
gearbox
Removing
mounting.
box support -3-.
Installing
– Install tunnel cross-piece ⇒ Rep. gr. 37 ; Assembly mount‐
Tightening torques
sembly mountings


⇒ “3.1 Removing and installing engine cover panel”, page 41
3.1 Removing and installing engine cover

panel
Removing
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– When fitting engine cover panel, take care not to damage oil
filler neck.
– First press engine cover panel onto rear rubber grommets and
then onto front rubber grommets with both hands.
© satelettronica

⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 44
page 47
page 48
⇒ “1.7 Renewing crankshaft oil seal (pulley end)”, page 49
⇒ “1.8 Removing and installing sealing flange (pulley end)”, page
51
1.1 Exploded view - cylinder block (pulley end)
© satelettronica
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 45
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ Renew
❑ 10 Nm +90°
3 - Cap
❑ For vibration damper
4 - Vibration damper
❑ Can only be installed in
one position
⇒ page 47
5 - Tensioner
❑ For poly V-belt
❑ Use locking tool -
T40098- to lock tension‐
er.
⇒ page 47
6 - Bolt
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
❑ Bolt can be re-used; tightening torque for re-used bolt: 20 Nm + 90°
❑ New bolt: 20 Nm +180°
10 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 44
11 - Dowel sleeve
❑ 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
© satelettronica
❑ Pay attention to dowel sleeves ⇒ Item 11 (page 43) 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
❑ Note installation position
15 - Bolt
❑ Renew
❑ 20 Nm +90°
16 - Cap
❑ For idler roller

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:
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
© satelettronica
1.2 Exploded view - sealing flange (pulley end)

1 - Bolt
❑ Tightening torque
⇒ Item 27 (page 82)
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 49
❑ Do not lubricate with oil
4 - Sealing flange (pulley end)
❑ Should be positioned on
dowel pins
© satelettronica
⇒ page 51
5 - Cylinder block
6 - Dowel pin
❑ 2x
7 - Bolt
❑ Tightening torque and
sequence ⇒ page 45
Sealing flange (pulley end) - tightening torque and sequence

Stage Bolts Tightening torque
2. -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 15 Nm
3. -7 … 10- 15 Nm


Removing
Caution

© satelettronica
belt from alternator pulley and lock tensioner using locking tool
- T40098- .
Installing
– Fit poly V-belt on poly V-belt pulleys:
1- Vibration damper
2- Idler roller
3- Poly V-belt tensioner
4- Alternator
5- Air conditioner compressor
Note
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Start engine and check that poly V-belt(s) run properly.


poly V-belt
Removing
– Remove poly V-belt ⇒ page 45 .
Note
Disregard -item 1-.
– Remove bolt -1- and detach poly V-belt tensioner -2-.
Note
♦ If bolt -1- makes contact with engine bracket, leave bolt in in‐
© satelettronica
stallation position.
♦ Due to lack of space, the tensioner must be guided out up‐
wards by rotating it.
Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 42
tem”, page 209

er
Removing
– Remove torque reaction support and cross member
⇒ page 38 .
– Remove radiator fan control unit - J293- ⇒ page 200 .
– Counterhold crankshaft on central bolt using angled ring span‐
ner -1- when loosening bolts for vibration damper.

– 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.
– Install torque reaction support and cross member ⇒ page 38 .
Tightening torques
© satelettronica
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 42

cillaries
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove high-pressure pump ⇒ page 263 .
– Remove 4/2-way valve ⇒ page 173 .
– Remove bolt -arrow-.
– Remove bolts -1- and -2- and remove idler rollers for toothed
belt.

WARNING

Caution


– Remove bolts -1 ... 6- and detach bracket for ancillaries.
© satelettronica
Installing
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 44 .
– Install 4/2-way valve ⇒ page 173 .
– Install high-pressure pump ⇒ page 263 .
– Install toothed belt (adjust valve timing) ⇒ page 87 .
Tightening torques
♦ ⇒ Fig. ““Bracket for ancillaries - tightening torque and tighten‐
ing sequence”“ , page 44
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Exploded view - air conditioner compressor drive unit
♦ ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view
- alternator
1.7 Renewing crankshaft oil seal (pulley

end)

♦ Oil seal extractor - 3203-
♦ Counterhold tool - 3415-
© satelettronica
Procedure
– Remove toothed belt ⇒ page 83 .
– 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.
– Fit guide sleeve -T10053/1- onto crankshaft journal.
© satelettronica
– 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 81 .
1.8 Removing and installing sealing flange

(pulley end)

♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
– Loosen bolt for crankshaft sprocket using counterhold tool -
© satelettronica
3415- .
– Remove bolt and detach crankshaft sprocket.
– Remove bolts -1 ... 10- and carefully release sealing flange

from bonded joint.
– Drive out oil seal with sealing flange removed.
Installing
Caution
Make sure sealant residue does not enter lubrication system.

♦ Place a clean cloth over the exposed section of the sump.
– 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 sealing surfaces; they must be free of oil and grease.

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-.
© satelettronica
Caution
Make sure lubrication system is not clogged by excess sealant.

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

ing 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 45 .

– Install crankshaft oil seal (pulley end) ⇒ page 49 .
Tightening torques
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 44
© satelettronica


⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 55
⇒ “2.2 Removing and installing drive plate”, page 56
⇒ “2.3 Removing and installing sealing flange (gearbox end)”,
page 57
⇒ “2.4 Renewing needle bearing in drive plate”, page 65
2.1 Exploded view - cylinder block (gearbox end)
1 - Cylinder block
2 - Dowel pins
3 - Engine speed sender -
G28-
⇒ page 308
4 - Bolt
© satelettronica
5 - Sealing flange (gearbox
end)
❑ With oil seal
6 - Bolt
❑ 15 Nm
7 - Drive plate
❑ Lock with counterhold
tool - 3067- to slacken
off bolts
8 - Bolt
❑ Renew
❑ 60 Nm +90°
9 - Needle bearing
ual gearbox
⇒ page 65
10 - Intermediate plate
❑ Do not damage or bend
when assembling

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
© satelettronica
2.2 Removing and installing drive plate
♦ Counterhold tool - 10 - 201-

Removing
• Gearbox removed ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox or ⇒ Rep. gr. 37 ; Removing and
installing gearbox; Removing gearbox .
– 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
© satelettronica
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 65 .
– 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.
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 55

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

♦ Depth gauge - VAS 6082-
© satelettronica
♦ Bolt, M6x35 (3x)
♦ Bolt, M7x35 (2x)
Pressing out sealing flange with sender wheel
– Remove drive plate ⇒ page 56 .
– Remove engine speed sender - G28- ⇒ page 308 .
Note
For illustration purposes, the following procedure is shown with

the engine removed.
– Pull intermediate plate off dowel pins -bottom arrows- and de‐
tach from sealing flange -top arrow-.

– Rotate crankshaft by turning bolt for toothed belt sprocket until

crankshaft is positioned at “TDC”, as shown in illustration.
– Remove sump ⇒ page 139 .
– Remove bolts -1 ... 6- for sealing flange.
© satelettronica
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 flange with PTFE oil seal is fitted with a sealing lip
support ring. This support ring acts as an assembly sleeve and
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.

Construction of assembly tool - T10134-

A - Tensioning flats
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket-head bolt
F - Guide pin for diesel engines (black handle)
G - Guide pin for petrol engines (red 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-.
© satelettronica
– 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.

• The locating hole -A- on the sender wheel -C- must align with
the marking -B- on the sealing flange.
– Place sealing flange (with 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.
© satelettronica
• 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 that sealing flange lies flat on assembly tool.

– 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 and 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‐
© satelettronica
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.

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-.
© satelettronica
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.

– 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 64 .
– If reading matches specification, continue with assembly
⇒ page 65 .
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.
© satelettronica
– 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 63 .
– 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 63 .

Assembling:
– Tighten sealing flange bolts ⇒ page 56 .
– Install engine speed sender - G28- ⇒ page 308 .
– Install sump ⇒ page 139 .
– Install intermediate plate ⇒ page 56 .
– Install drive plate ⇒ page 56 .
2.4 Renewing needle bearing in drive plate

♦ Tube - VW 418 A-
© satelettronica
♦ Tube - VW 421-
♦ Support - 40 - 103-

Procedure
– Place support - 40 - 103- under drive plate when pressing out
and pressing in needle bearing.
– Use tube - VW 421- and workshop press and press out needle
bearing.
• Smaller diameter of tube -VW 421- faces drive plate.
– Carefully press in needle bearing as far as stop, using tube -

VW 418 A- and workshop press.
• Installation position: closed side of needle bearing faces en‐
gine.
© satelettronica

3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 67
⇒ “3.2 Crankshaft dimensions”, page 68
⇒ “3.3 Measuring axial clearance of crankshaft”, page 68
⇒ “3.4 Measuring radial clearance of crankshaft”, page 68
⇒ “3.5 Renewing spur gear”, page 69
3.1 Exploded view - crankshaft
Note
When performing assembly work, secure engine to engine and gearbox support ⇒ page 27 .
1 - Bearing shell
❑ For cylinder block (with
oil groove)
© satelettronica
❑ Renew used bearing
shells
2 - Spur gear
❑ For balance shaft as‐
sembly
❑ Pulling spur gear off
crankshaft and shrink-
fitting new spur gear
⇒ page 69
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
❑ Use old bolts when
measuring radial clear‐
ance
❑ 65 Nm +90°
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
7 - Crankshaft
❑ Crankshaft dimensions ⇒ page 68
3. Crankshaft 67
❑ Measuring axial clearance ⇒ page 68

❑ Measuring radial clearance ⇒ page 68
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-
© satelettronica
♦ 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
3.4 Measuring radial clearance of crank‐

shaft

♦ Plastigauge
Procedure
– Remove bearing cap and clean bearing journal.
– Place a length of Plastigauge corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
• The Plastigauge must be positioned in the centre of the bear‐
ing shell.
– Fit bearing cap and tighten with old bolts. Do not rotate crank‐
shaft.
– Remove bearing cap again.
– Compare width of Plastigauge with measurement scale.
Radial clearance:
• New: 0.03 ... 0.08 mm.
• Wear limit: 0.17 mm.
– When carrying out final assembly, renew bolts.
3.5 Renewing spur gear
© satelettronica
♦ Fitting tool - 10 - 203-
♦ Puller - T10392-
3. Crankshaft 69
♦ Temperature gauge - VAS 6519-
♦ Hotplate (commercially available)
© satelettronica
Procedure
– Remove sealing flange (pulley end) ⇒ page 51 .
Note
♦ If the balance shaft assembly does not have to be renewed, it

is sufficient just to remove the idler gear.
♦ If the bolt for the idler gear for the balance shaft assembly has
been slackened or the spur gear on the crankshaft or the
crankshaft itself have been renewed, you must install a new
idler gear with the appropriate coating. Procedure for installa‐
tion
⇒ “4.1.2 Installing new balance shaft assembly”, page 151 .
– Remove idler gear ⇒ Item 13 (page 136) for balance shaft

assembly or remove balance shaft assembly ⇒ page 150 .
– Insert thrust piece -T10392/1- in end of crankshaft.

– Insert puller -T10392- into holes in spur gear, turn clockwise

-arrow- and screw in locating pins -A-.
– Counterhold crankshaft with ring spanner -A- and pull spur

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

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

the spur gear can become discoloured and distorted.
– Place the new spur gear flat on a commercially available hot‐

plate and heat it up to at least 200 °C, but not more than 240 °
C. Lettering faces 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 protective gloves for the following steps.
3. Crankshaft 71
– When the required temperature has been reached, pick up the

spur gear with pliers as illustrated.
Note
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.
– Install balance shaft assembly
Or
© satelettronica
– Install idler gear for balance shaft assembly
– Install sealing flange (pulley end) ⇒ page 51 .


⇒ “4.1 Exploded view - pistons and conrods”, page 73
⇒ “4.2 Removing and installing pistons”, page 75
⇒ “4.3 Measuring piston projection at TDC”, page 77
⇒ “4.4 Checking pistons and cylinder bores”, page 79
⇒ “4.5 Checking radial clearance of conrod bearings”,
page 80
4.1 Exploded view - pistons and conrods
Note
♦ All bearing and running surfaces must be oiled before assembling.

♦ Oil spray jet and pressure relief valve ⇒ page 75
1 - Bolt
© satelettronica
❑ Renew
ance
❑ Lubricate threads and
contact surface
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod
❑ Mark cylinder allocation
in colour -B-
❑ Installation position:
Markings -A- face to‐
wards pulley end
3 - Bearing shell
❑ Installation position
⇒ page 75
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material; refer to
⇒ Electronic parts cata‐
logue
❑ Check that it is securely
seated
4 - Conrod
❑ Only renew as a complete set

❑ With industrially cracked conrod bearing cap

❑ Separating parts of new conrod ⇒ page 75
❑ Mark cylinder allocation in colour -B-
❑ Installation position: Markings -A- face towards pulley end
❑ Axial clearance: wear limit: 0.37 mm
5 - Circlip
❑ 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 74
❑ Checking ⇒ page 79
❑ Install using piston ring clamp
© satelettronica
❑ Piston and cylinder dimensions ⇒ page 79
❑ Measuring cylinder bore ⇒ page 79
❑ Measuring piston projection at “TDC” ⇒ page 77
8 - Piston rings
❑ Compression rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Measuring ring gap ⇒ page 79
❑ Measuring ring-to-groove clearance ⇒ page 80
9 - Piston ring
❑ Oil scraper ring
❑ 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-.

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.
© satelettronica
– 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


♦ Pin - VW 222 A-
♦ Piston ring clamp, commercially available

Removing
• Engine secured to engine and gearbox support ⇒ page 27 .
– Remove cylinder head ⇒ page 98 .
– Remove balance shaft assembly ⇒ page 150 .
– Mark installation position and matching of conrod bearing caps
© satelettronica
to conrods for re-installation ⇒ Item 2 (page 73) .
– 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
Note
– Oil running surfaces of bearing shells.

– Install pistons using piston ring clamp.
Installation position:
• Pistons ⇒ page 74
• Bearing shells in conrods ⇒ page 75
– Install conrod bearing caps according to markings.
– Install balance shaft assembly ⇒ page 150 .
– Install cylinder head ⇒ page 98 .
Tightening torques
♦ ⇒ “4.1 Exploded view - pistons and conrods”, page 73

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

pistons or a short engine.

♦ Measuring bridge -VW 382/7- from measuring tool - VW 382-
© satelettronica
♦ Measuring plate -VW 385/17- from universal measuring tool -
VW 385-

Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
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
© satelettronica
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.

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
© satelettronica
points in transverse direction -A- and in longitudinal direction
-B-.
Cylinder bore ∅
Nominal dimension 81.01 mm
Measuring piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
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

Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
mm mm
4.5 Checking radial clearance of conrod

bearings
♦ Plastigauge
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
© satelettronica
journal.
– Fit conrod bearing cap and secure with old bolts
⇒ Item 1 (page 73) without rotating crankshaft.
– Remove conrod bearing cap again.
Radial clearance:
– Renew conrod bolts.


1 Toothed belt drive
⇒ “1.1 Exploded view - toothed belt”, page 81
⇒ “1.2 Removing and installing toothed belt”, page 83
1.1 Exploded view - toothed belt
1 - Toothed belt
chalk or felt-tip pen
❑ Check for wear
❑ Removing ⇒ page 83
❑ Installing (adjusting
valve timing)
⇒ page 87
© satelettronica
2 - Idler roller
3 - Nut
❑ Make sure that stud is
fitted securely
❑ 20 Nm
4 - Stud
❑ 15 Nm
5 - Nut
❑ Renew nut
❑ Make sure that stud is
fitted securely
❑ 20 Nm +45°
6 - Tensioning roller
7 - Stud
❑ 15 Nm
8 - Bolt
❑ 20 Nm
9 - Idler roller
10 - Bolt
❑ Renew
❑ 20 Nm +45°
11 - Camshaft sprocket
12 - Bolt
❑ Slacken and tighten with counterhold tool - T10051-
❑ 100 Nm
13 - Hub
❑ For camshaft
❑ Removing and installing ⇒ “3.5 Removing and installing camshaft”, page 118
1. Toothed belt drive 81

14 - Plug
15 - Toothed belt cover (rear)
16 - Bolt
❑ 9 Nm
17 - Hub
❑ For high-pressure pump
18 - Nut
❑ Tightening torque ⇒ Item 6 (page 262)
19 - High-pressure pump sprocket
20 - Bolt
21 - Idler roller
22 - Bolt
❑ Renew
❑ 50 Nm +90°
© satelettronica
23 - O-ring
❑ Renew
24 - Coolant pump
25 - Bolt
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

1.2 Removing and installing toothed belt
© satelettronica
equipment required
♦ 2x diesel injection pump locking pin - 3359-

♦ Crankshaft stop - T10050-

♦ Offset screwdriver - T10264-
♦ Bit XZN 10 - T10385- or bit M10
Removing
Caution


belt from alternator pulley and release tensioner.
© satelettronica
Note
Ignore -T40098- .
– Remove vibration damper ⇒ page 47 .

(top).


– Detach toothed belt cover (bottom).
© satelettronica
Caution
Irreparable damage can be caused if the toothed belt slips.

– Rotate crankshaft by turning bolt on crankshaft sprocket until

camshaft sprocket is positioned at “TDC”.
– Lock camshaft hub with diesel injection pump locking pin -
3359- .
Note
Disregard -arrows-.
– Lock crankshaft sprocket in position with crankshaft stop -

T10050- .
• The markings on the sprocket -2- and the crankshaft stop -1-
must align -arrow-. The pin of the crankshaft stop must engage
in the aperture in the 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 an M10 bit, loosen bolts -arrows- for toothed belt sprock‐
et on high-pressure pump by approx. 90°.
© satelettronica
– Slacken nut -1- for tensioning roller.
– Turn eccentric adjuster of tensioning roller with offset screw‐
driver - T10264- anti-clockwise -arrow- until tensioning roller
can be secured with locking tool - T10265- .

– Then use offset screwdriver - T10264- to turn eccentric ad‐

juster of tensioning roller clockwise -arrow- as far as stop and
tighten nut -1- by hand.
Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of toothed belt
with chalk or felt-tip pen for re-installation.
– Take off toothed belt first from idler roller and then from re‐
maining sprockets.
Installing (adjusting valve timing)
Note
Perform adjustments on toothed belt only when engine is cold.
© satelettronica
Caution

♦ 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-.
• Camshaft hub locked with diesel injection pump locking pin -

3359- .
• Renew bolts for camshaft sprocket one after the other.
• Loosely screw in new bolts -arrows-.
• 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.
© satelettronica
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.

– 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- .
© satelettronica
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.
• Initial tightening torque: 20 Nm

– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using offset screwdriver - T10264- until pointer -2-
aligns with centre of slot on base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.
– 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.
© satelettronica
– 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.

• 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 91 .
♦ If requirements are met, continue with procedure after adjust‐
ing valve timing correctly as described below ⇒ page 91 .
Re-adjusting valve timing:
– If camshaft hub cannot be locked, withdraw crankshaft stop -
T10050- until pin is clear of bore.
– 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.
© satelettronica
– 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 initially.
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 initially.
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 90 .

– If camshaft hub can now be locked, tighten camshaft sprocket

bolts -1- to final torque ⇒ Item 10 (page 81) .
– Tighten bolts -2- for high-pressure pump sprocket to final tor‐
que ⇒ Item 5 (page 262) .
Assembling
Note
♦ Renew seals and/or gaskets.


Tightening torques
♦ ⇒ “1.1 Exploded view - toothed belt”, page 81
© satelettronica

2 Cylinder head
⇒ “2.2 Exploded view - cylinder head cover”, page 95
⇒ “2.4 Removing and installing cylinder head cover”, page 107
⇒ “2.5 Removing and installing seals for injectors”, page 110
1 - Cylinder head gasket

❑ Renewing
⇒ “2.3 Removing and in‐
stalling cylinder head”,
page 98
❑ Identification of cylinder
head gasket
© satelettronica
⇒ page 95
coolant and engine oil
2 - Bolt
❑ For camshaft position
⇒ page 307
4 - Cylinder head
⇒ page 98
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
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
5 - Washer
6 - Bolt
❑ Renew
❑ Correct sequence when slackening ⇒ page 103
❑ Opening/closing pressure 0.3 ... 0.6 bar
2. Cylinder head 93

❑ 20 Nm
8 - Seal
❑ Renew (cut seal open to do so)
9 - Bolt
❑ 20 Nm
10 - Engine lifting eye
11 - Seal
❑ Renew
12 - Plug
❑ 20 Nm
13 - Gasket
❑ Renew
14 - Vacuum pump
❑ Removing and installing ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Removing and installing vacuum
pump
© satelettronica
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
18 - Seal
❑ Renew
19 - Bolt
❑ 20 Nm
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

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.

1- Part number
2- Holes
3- Ignore
Note
© satelettronica
Cylinder head gaskets of different thicknesses are fitted depend‐
ing on the amount of piston projection ⇒ page 77 . When renewing
only the cylinder head gasket, the new gasket should have the
same identification as the old one.
2.2 Exploded view - cylinder head cover
Caution
When installing a new base engine, it is essential that the

clamping pieces for the injectors are tightened to the specified
torque ⇒ page 236 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.
2. Cylinder head 95
1 - Gasket
❑ Renew if damaged or
leaking
2 - Cylinder head cover
⇒ page 107
3 - Bracket
❑ For vacuum lines and
electrical wiring
4 - O-ring
❑ Check and renew if nec‐
essary; if O-ring is not
available, renew hose
5 - Hose
❑ For crankcase breather
❑ Press release tabs to
detach
6 - Sealing bush
© satelettronica
❑ For fuel rail
leaking
7 - Grommet
8 - Clamping piece
9 - Bolt
10 - Fuel rail
❑ Observe rules for clean‐
liness ⇒ page 5
❑ Do not attempt to bend
high-pressure pipes to a
different shape
❑ Installing high-pressure pipes ⇒ page 250
11 - Bolt
12 - Bolt
13 - Fuel return line
14 - O-ring
❑ Renew
15 - Injector
❑ Observe rules for cleanliness ⇒ page 5
16 - O-ring
❑ Renew
17 - Copper seal
❑ Renew
18 - Seal
❑ For injector


19 - Filler cap
20 - Seal
❑ For filler cap
21 - Grommet
22 - Bolt
❑ Renew if seal is damaged
Cylinder head cover - tightening torque and sequence

– Tighten bolts for cylinder head cover in the sequence -1 ... 6-
to 9 Nm.
Note
Take care to keep cylinder head cover straight.
© satelettronica
2. Cylinder head 97

equipment required
© satelettronica
♦ Diesel injection pump locking pin - 3359-
♦ Puller - T10052-
♦ Bit XZN 10 - T10385-
Removing
– Remove coolant pipe (top left) ⇒ page 181 .


- G505- .
– Move clear electrical wiring harness -arrow-.

– Remove nuts -1- and detach bracket -2-.
© satelettronica
– Remove bolt and nut -arrows-.
– Press coolant pipe (rear right) to one side.
Note

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

- G62- .
Note
Disregard -item 1-.
– Unplug electrical connector -arrow- on oil pressure switch -

F1- .
© satelettronica
– 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 107 .
– Lift retaining clip -arrow- and disconnect coolant line.

– Loosen bolt -1- for turbocharger.
Note
Disregard -item 2-.
– Slacken clamp -arrows-.
© satelettronica
– Remove nuts -arrows- for turbocharger.
Note
– Move clear electrical wiring harness at cylinder head.
– Remove bolts -1- and detach camshaft sprocket.
2. Cylinder head 101

– 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.
© satelettronica
– Remove bolt -arrow- for toothed belt cover (rear).
– Remove bolt for Hall sender - G40- -arrow- and move Hall
sender - G40- to one side.

– 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
Risk of damage to glow plugs when putting down cylinder

head.
© satelettronica
♦ 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 A6 models with 2.0 ltr. 4-valve common rail TDI engine are
always equipped with steel glow plugs.
Installing

Note
♦ Use of impermissible abrasive materials can lead to subse‐

quent damage to the turbocharger, conrod bearings or similar.
♦ Do NOT use abrasive materials (sandpaper, sanding discs,
sanding pads, abrasive web, wire wool, etc.).
♦ Sealing surface (see photo) must not be raised.
♦ Dark discolouration (see photo) does not have to be removed.
♦ When removing sealant residue, make sure none of the resi‐
due enters the open channels of the engine.
♦ Ensure that nearby workspaces are kept clean and that the
abrasive materials listed above are not being used there.
– Sealant residue may only be removed from the cylinder head

and cylinder block using a commercially available blade scra‐
per.
• Sealing surfaces must NOT be damaged.
• No oil or coolant must be allowed to remain in the blind holes
© satelettronica
for the bolts.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• If a new cylinder head is installed, the contact surfaces be‐
tween the roller rocker fingers and the running surface of the
cam must be lubricated.
• Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
• Turn the crankshaft carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is operated.
• After fitting a new cylinder head or cylinder head gasket,
change the engine oil and the coolant in the entire cooling
system.
– Remove loose residue with a lint-free cloth.
– 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 for centring cylinder
block and cylinder head in cylinder block.

– 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 77 .
– Fit cylinder head gasket onto dowel sleeves -arrows- in cylin‐

der block.
© satelettronica
• 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 81 .


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

ing pin - 3359- .
Note
Disregard -item 1-.
© satelettronica

– 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 107 .
– Install turbocharger ⇒ page 203 .
– Install coolant pipe (rear) ⇒ page 185 .
– Install coolant pipe (rear right) ⇒ page 183 .
– Install coolant pipe (top left) ⇒ page 181 .
© satelettronica
– Change engine oil ⇒ Maintenance ; Booklet 411 .
– Fill cooling system with fresh coolant ⇒ page 164 .
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder head”, page 93
♦ ⇒ Fig. ““Cylinder head cover - tightening torque and se‐
quence”“ , page 97
♦ Dipstick guide tube
tem”, page 209

cover
Removing
– Remove injectors ⇒ page 246 .
– Remove fuel rail ⇒ page 251 .
(top).

– Unplug electrical connectors -2, 3, 4- and move electrical wir‐

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

– Release hose clips -2- and detach fuel hoses.
– Pull fuel lines upwards off cylinder head cover and press clear
to one side.
Note
© satelettronica
Disregard -item 4-.

- G505- .
– Press release tabs, disconnect crankcase breather hose -2-

and move hose clear -arrow-.
Note
Disregard -item 1-.


– Detach bracket -1- for vacuum lines and electrical wiring from
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.
© satelettronica
Installing
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 251 .
– Install injectors ⇒ page 246 .
– Bleed fuel system
Tightening torques
♦ ⇒ Fig. ““Cylinder head cover - tightening torque and se‐
© satelettronica
2.5 Removing and installing seals for injec‐
tors
♦ Pliers -VAS 211 007- (not illustrated)
♦ Carrier - 3390-
Procedure
– Remove corresponding injector
⇒ “5.7 Removing and installing injectors”, page 246 .
– Pull off seal -1- using pliers -VAS 211 007- -arrow-.

– Use suitable thrust piece (e.g. carrier - 3390- ) and short ex‐
tension -1- to press new injector seal in from above -arrow- as
far as stop.

♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/8-
© satelettronica
Procedure
• Engine oil temperature at least 30 ℃
• 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 305 .

– 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 305 .
© satelettronica
– Erase any entries in event memory resulting from testing ⇒ Ve‐
hicle diagnostic tester, Guided Functions , then Interrog-
ate event memory .

3 Valve gear
⇒ “3.2 Measuring axial clearance of camshaft”, page 114
⇒ “3.3 Measuring radial clearance of camshaft”, page 115
⇒ “3.4 Removing and installing camshaft oil seal”, page 116
1 - Valve
❑ Must not be machined;
only grinding-in is per‐
missible
❑ Mark installation posi‐
tion for re-installation
© satelettronica
❑ Valve dimensions
⇒ page 134
❑ Checking valve guides
⇒ page 133
2 - Cylinder head
3 - Valve stem oil seal
❑ Renewing with cylinder
head installed
⇒ page 125
head removed
⇒ page 129
4 - Valve spring
5 - Valve spring plate
6 - Valve cotters
7 - Sealing cap
❑ Renew
❑ Removing sealing cap
with retaining frame in‐
stalled: pierce on one
side with an awl and pry
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 113

10 - Bolt
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
© satelettronica
15 - Hydraulic compensation element
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


© satelettronica
Procedure
– Remove retaining frame
⇒ “3.5 Removing and installing camshaft”, page 118 .
– 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.
– 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

♦ Plastigauge
Procedure
– Remove roller rocker fingers
– Clean bearings and bearing journals.
bearing on the bearing journal or bearing shell to be measured.
ing.
– Fit retaining frame and tighten to 10 Nm without rotating cam‐
shafts ⇒ page 114 .
– Remove retaining frame again.
3. Valve gear 115


• Radial clearance: 0.035 ... 0.085 mm
3.4 Removing and installing camshaft oil

seal
Note
♦ A modified oil seal is being phased in.

♦ The “old” version oil seal -item A- forms a continuous surface
between the camshaft and the cylinder head.
♦ The “new” version oil seal -item B- has a shoulder between the
camshaft and the cylinder head.
© satelettronica
♦ Fitting tool - 10 - 203-
♦ Oil seal extractor - 3240- for “old” version oil seal

♦ Puller - T10443- for “new” version oil seal
♦ Bolt M12x1.5x75
Procedure
– Remove camshaft sprocket and hub
“Old” version oil seal:
– Insert thrust piece -3240/1- in camshaft.
© satelettronica
– Screw inner section of oil seal extractor -3240- two turns out
of outer section (approx. 3 mm) and lock with knurled screw.
pressure).
– Loosen knurled screw and turn inner section against camshaft
until oil seal is pulled out.
oil seal.
“New” version oil seal:
Caution
♦ If the grub screw is unscrewed too far the thrust plate in‐
side the puller -T10443- will come loose from the thrust
bolt. If this happens, the thrust plate must be pushed back
onto the thrust bolt.
– Carefully unscrew grub screw -arrow- of puller -T10443- until

slight resistance is felt.
3. Valve gear 117

– Apply puller - T10443- in a straight line, as shown in illustration,

and lock by screwing in grub screw.-A-.
– Screw in thrust bolt -B- until oil seal is pulled out.
All types of oil seal (continued):
– Clean contact surface and sealing surface.
Note
The sealing lip of the oil seal must not be additionally oiled or
greased.
– Apply guide sleeve of fitting tool - 10 - 203- to camshaft as

– Carefully push oil seal -1- over guide sleeve and onto cam‐
shaft.
© satelettronica
– Press in oil seal onto stop using thrust piece of fitting tool - 10
- 203- and bolt M12×1.5×75.
– Install camshaft sprocket and hub


equipment required
© satelettronica
♦ Puller - T10052-
♦ Camshaft fitting tool - T40094-
♦ Clamping tool -T40096/1- for vehicles with two-piece camshaft
gear
♦ Safety goggles
Removing
• Cylinder head installed.
– Take toothed belt off camshaft sprocket and high-pressure
pump sprocket ⇒ page 83 .
3. Valve gear 119

– Press release tabs and detach crankcase breather hose -2-.

– Loosen hose clip -1- and remove air hose.
– Remove cylinder head cover ⇒ page 107 .
– Remove bolts -1, 3-; exhaust gas recirculation cooler remains

installed.
© satelettronica
– Remove bolts -1- and detach camshaft sprocket.
– 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
© satelettronica
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.
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.
– Oil running surfaces of both camshafts.
3. Valve gear 121

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-.
© satelettronica
– 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,
Vehicles with two-piece camshaft gear:
– 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.
© satelettronica
• 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- .
Note

2 mm).
3. Valve gear 123

Caution
Make sure excess sealant does not contaminate camshaft

bearings.
♦ The sealant beads 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
© satelettronica
tool - T40095- and, if necessary, clamping tool -T40096/1- out
of camshaft fitting tool - T40094- and insert components care‐
fully into cylinder head.

– 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 114 .
– Remove camshaft fitting tool - T40095- and, if necessary,
clamping tool -T40096/1- .
note the following:
– Install camshaft oil seal ⇒ page 116 .
– Drive new sealing cap ⇒ Item 7 (page 113) 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 .
– Install cylinder head cover ⇒ page 107 .
Caution
© satelettronica
Risk of 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.
Tightening torques
♦ ⇒ Fig. ““Retaining frame - tightening torque and sequence”“ ,
page 114
♦ ⇒ “3.1 Exploded view - valve gear”, page 113

seals
⇒ “3.6.1 Removing and installing valve stem oil seals (cylinder
head installed)”, page 125
head removed)”, page 129
3.6.1 Removing and installing valve stem oil

seals (cylinder head installed)
3. Valve gear 125

♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
© satelettronica
♦ Removal and installation device for valve cotters - VAS 5161
A- with guide plate for 3.0 ltr. TDI engine - VAS 5161/23- and
sleeve -VAS 5161/23-1-
♦ Bolt, M6x30 (2x)

Procedure
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Set piston of appropriate cylinder to “bottom dead centre”.

– Fit guide plate for 3.0 ltr. TDI engine - VAS 5161/23- onto cyl‐
inder 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.
© satelettronica
– 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 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.
3. Valve gear 127

– Pull off valve stem oil seal with valve stem seal puller - 3364- .
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.
© satelettronica
– 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 for 3.0 ltr. TDI engine
- 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 118 .
3.6.2 Removing and installing valve stem oil seals (cylinder head removed)
© satelettronica
equipment required
3. Valve gear 129


A- with guide plate for 3.0 ltr. TDI engine - VAS 5161/23- and
sleeve -VAS 5161/23-1-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Bolt, M6x30 (2x)
Procedure
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
© satelettronica
– Connect cylinder head tensioning device to compressed air
supply.
– 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.
– Fit guide plate for 3.0 ltr. TDI engine - VAS 5161/23- onto cyl‐
inder 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.


– Slide sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
© satelettronica
Caution
ling.


3. Valve gear 131

– Insert assembly cartridge in guide plate for 3.0 ltr. TDI engine
- VAS 5161/23- again.
cotters.
tion.
Assembling
© satelettronica


⇒ “4.1 Machining valve seats”, page 133
⇒ “4.2 Checking valve guides”, page 133
⇒ “4.3 Checking valves”, page 134
⇒ “4.4 Valve dimensions”, page 134
4.1 Machining valve seats
Note
Valve seats may not be machined due to the very small toleran‐
ces.
4.2 Checking valve guides

© satelettronica
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.

– Attach dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder head.
– Insert valve into guide.
• End of valve stem must be flush with 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.
© satelettronica
– Renew valve if scoring is clearly visible.
4.4 Valve dimensions
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

17 – Lubrication
1 Sump/oil pump
⇒ “1.3 Removing and installing sump”, page 139
er G266 ”, page 143
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 further damage, the following steps
are required after completion of repair work: clean the oil passages carefully and renew the oil spray jets,
© satelettronica
engine oil cooler and oil filter.
♦ Oil spray jet and pressure relief valve ⇒ page 75
1. Sump/oil pump 135

1 - Seal
❑ Renew
2 - Oil drain plug
❑ 30 Nm
3 - Sump
⇒ page 139
4 - Bolt
❑ 9 Nm
5 - Suction pipe
❑ Clean strainer if dirty
6 - O-ring
❑ Renew
7 - Oil pump
⇒ page 142
❑ Before installing, check
© satelettronica
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
❑ For balance shaft
11 - Bolt
❑ Renew
❑ 20 Nm +90°
12 - Thrust washer
❑ For idler gear
❑ Renew
❑ When installing idler gear, apply grease to hold washer on balance shaft assembly
13 - Idler gear
❑ For balance shaft assembly
❑ If the bolt for the idler gear has been slackened or the spur gear on the crankshaft or the crankshaft itself
have been renewed, you must install a new idler gear with the appropriate coating. Procedure for instal‐
lation ⇒ “4.1.2 Installing new balance shaft assembly”, page 151
❑ 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 138
14 - Bolt
❑ With washer
❑ Renew

❑ If the bolt for the idler gear has been slackened or the spur gear on the crankshaft or the crankshaft itself
have been renewed, you must install a new idler gear with the appropriate coating. Procedure for instal‐
lation ⇒ “4.1.2 Installing new balance shaft assembly”, page 151
❑ 90 Nm +90°
15 - Hub
❑ For idler gear
❑ Renew
16 - Crankshaft gear
17 - Cover
❑ Installation position for cover of oil level and oil temperature sender - G266- ⇒ page 138
18 - Dowel sleeves
19 - Balance shaft assembly
❑ Removing ⇒ page 150
❑ Before installing, check that the two dowel sleeves for centring balance shaft assembly are fitted on
cylinder block
❑ Installing new balance shaft assembly ⇒ page 151
❑ Re-installing "old" balance shaft assembly ⇒ page 155
20 - Bolt
© satelettronica
❑ Renew
21 - Dowel sleeves
22 - Bolt
❑ 9 Nm
23 - Oil intake pipe
24 - Bolt
❑ 9 Nm
25 - Seal
❑ Renew
27 - Cover
❑ For oil level and oil temperature sender - G266-
28 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
29 - Bolt
❑ Renew

Installation position for cover of oil level and oil temperature send‐
er
– Clip in cover for oil level and oil temperature sender -arrow-,
Note
For greater clarity, item -1- shows oil level and oil temperature
sender .
Sump - tightening torque and sequence
© satelettronica
– Tighten bolts in stages:
1. -1 … 20- 5 Nm in diagonal sequence
2. -Arrows- ⇒ Rep. gr. 34 ; Removing and instal‐
ling gearbox; Tightening torques for
gearbox or ⇒ Rep. gr. 37 ; Removing
and installing gearbox; Tightening tor‐
ques for gearbox
3. -1 … 7-, Tighten in stages and in diagonal se‐
-9, 10-, quence; final torque 13 Nm
-12 … 20-
4. -8, 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.

Balance shaft assembly - tightening torque and sequence
Note

2. -1 … 6- 6 Nm
3. -5- and -6- 13 Nm
4. -1 … 4- 20 Nm
5. -1 … 4- Turn 90° further
1.2 Engine oil
© satelettronica
Oil capacities, oil specifications and viscosity grades ⇒ Mainte‐
nance tables .
1.3 Removing and installing sump

♦ Socket - T10058-
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 411
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Removing and installing subframe with steer‐
ing rack .
– Unplug electrical connector -2- at oil level and oil temperature
sender - G266- .
Note
Disregard -item 1-.
– Remove torque reaction support ⇒ page 38 .


side.
Note
– Remove bolts securing sump to gearbox -arrows-.

– Slacken bolts -1 ... 20- in diagonal sequence and remove.
– Carefully release oil sump from bonded joint and detach.
Installing
Caution
© satelettronica
tion.
WARNING
Risk of eye injury.

– Remove sealant residue from sump and cylinder block using

rotating plastic brush or similar.

Note

2 mm).
Caution

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

lustrated.
• Thickness of sealant bead: 2 ... 3 mm.
Note
© satelettronica
♦ 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 138 .
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, sealant must dry for approx. 30 minutes.
Then (and only then) fill the engine with engine oil.
– Install torque reaction support ⇒ page 38 .

– Install ATF cooler ⇒ Rep. gr. 37 ; ATF circuit; Removing and
installing ATF cooler .
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Removing and installing subframe with steer‐
ing rack .
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
411 .
Tightening torques
♦ ⇒ Fig. ““Sump - tightening torque and sequence”“ , page 138


♦ Circlip pliers (commercially available)
♦ M3 bolt
Removing
– Remove bolt -arrow- and detach suction pipe from oil pump.
– Remove circlip -1- using circlip pliers.

– Pull drive shaft -2- out of oil pump using a magnet -arrow-.
© satelettronica
– 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.
Tightening torques
♦ ⇒ “1.1 Exploded view - sump/oil pump”, page 135


Removing
– Remove bolts -1- and detach oil level and oil temperature
sender - G266- -item 4-.
Installing
Note
Renew seal -2- and self-locking bolts -1-.
411 .
Tightening torques
© satelettronica

2 Engine oil cooler

⇒ “2.1 Removing and installing engine oil cooler”, page 144
2.1 Removing and installing engine oil cool‐

er
Removing
Note
Place a cloth underneath to catch escaping coolant and engine

oil.
– On vehicles with multitronic gearbox: Release hose clip -1-

and detach coolant hose.
– Unscrew bolts -arrows- and detach engine oil cooler.
© satelettronica
Installing
Note

Tightening torques
♦ ⇒ “3.1 Exploded view - oil filter”, page 145


⇒ “3.1 Exploded view - oil filter”, page 145
⇒ “3.2 Removing and installing oil pressure switch F1 ”,
page 146
⇒ “3.3 Removing and installing oil filter housing”, page 146
⇒ “3.4 Checking oil pressure”, page 149
3.1 Exploded view - oil filter
1 - Sealing cap
❑ 25 Nm
2 - O-ring
❑ Renew
3 - O-ring
❑ Renew
4 - O-ring
© satelettronica
❑ Renew
5 - Oil filter element
❑ See note ⇒ page 135
let 411
❑ Connection diagram -
coolant hoses
⇒ page 157
⇒ page 144
❑ If renewed, refill system
with fresh coolant
7 - Bolt
❑ 11 Nm
8 - Gaskets
❑ Renew
9 - Bolt
❑ Renew
10 - Oil filter bracket
❑ With integrated oil retention valve
11 - Gaskets
❑ Renew

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-
© satelettronica
Removing
– 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
– Renew seal for oil pressure switch - F1- after removal.
– Cut seal open to renew.
If seal is not available separately, refer to ⇒ Electronic parts
catalogue ; renew oil pressure switch after removal
– Install coolant pipe (rear right) ⇒ page 183 .
Tightening torques
3.3 Removing and installing oil filter housing


© satelettronica
♦ Used oil collection and extraction unit - VAS 6622A-

Removing
– Remove oil filter element ⇒ Maintenance ; Booklet 411 .
– Remove coolant pipe (top left) ⇒ page 181 .
– Remove pump for exhaust gas recirculation cooler - V400-
⇒ page 170 .
– 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.
tion.
© satelettronica
– On vehicles with multitronic gearbox: Release hose clip -1-
and detach coolant hose.
– Position used oil collection and extraction unit - V.A.G 1782-
below engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
Note

♦ Renew seal.
– Install pump for exhaust gas recirculation cooler - V400-

⇒ page 170 .
– Install coolant pipe (top left) ⇒ page 181 .
– Install oil filter element, fill up with engine oil and check oil level
⇒ Maintenance ; Booklet 411 .
Note

Tightening torques
♦ ⇒ Fig. ““Oil filter bracket - tightening torque and sequence”“ ,
page 146
♦ Dipstick guide tube

3.4 Checking oil pressure

♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK
– Remove oil pressure switch - F1- ⇒ page 146 .
© satelettronica
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure switch.
– 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
0.6 bar.
If specification is not obtained, switch off engine immediately and
check oil pump drive; renew oil pump if necessary
⇒ “1.4 Removing and installing oil pump”, page 142 .
If specification is obtained, let engine warm up.
• Oil pressure specification at operating temperature and 2000
rpm: at least 1.0 bar.
Assembling
– Install oil pressure switch - F1- ⇒ page 146 .

4 Balance shaft assembly

⇒ “4.1 Removing and installing balance shaft assembly”,
page 150
4.1 Removing and installing balance shaft

assembly
⇒ “4.1.1 Removing balance shaft assembly”, page 150
⇒ “4.1.2 Installing new balance shaft assembly”, page 151
⇒ “4.1.3 Installing used balance shaft assembly”, page 155
4.1.1 Removing balance shaft assembly

© satelettronica
Procedure
– 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”.


(top).
Caution

© satelettronica
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 151 .

♦ Re-installing a used balance shaft assembly ⇒ page 155 .
4.1.2 Installing new balance shaft assembly

4. Balance shaft assembly 151

♦ Bits - T10099-
© satelettronica
♦ Open end spanner insert, AF 14 - T10393-

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 specified backlash.
♦ To achieve the correct backlash, a coating is already applied
to the new idler gear.
♦ The coating is worn down rapidly and the backlash is then
correct.
♦ Therefore, a new balance shaft assembly must always be in‐
stalled in conjunction with a new idler gear which has the
correct coating.
Caution
© satelettronica
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 138
– 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.

– Tighten bolts securing balance shaft assembly ⇒ page 139 .
– Lock balance shaft with locking tool - T10255- , turning bal‐

ance shaft as required.
© satelettronica
• 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, you must turn the gear some teeth
further as required and then fit it again.
– Tighten bolts -arrows- for balance shaft gear.

– Remove locking tool - T10255- .

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.
© satelettronica
note the following:
Tightening torques
4.1.3 Installing used balance shaft assembly


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
– Lock balance shaft with locking tool - T10255- , turning bal‐

ance shaft as required.
© satelettronica
• 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.
– Attach balance shaft assembly to cylinder block.
• 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 139 .

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

19 – Cooling

⇒ “1.1.1 Connection diagram - coolant hoses, vehicles with man‐
ual gearbox and without auxiliary heater”, page 157
iliary heater and multitronic gearbox”, page 159
© satelettronica
Note
♦ Blue = Large coolant circuit

♦ Red = Small coolant circuit
♦ Orange = Coolant circuit for exhaust gas recirculation.

1 - Not fitted
2 - Radiator
with fresh coolant
3 - Coolant pump
block
with fresh coolant
5 - Exhaust gas recirculation
cooler
with fresh coolant
⇒ page 177
er - G62-
© satelettronica
⇒ page 176
V50-
❑ On vehicles with start/
stop system only
❑ Depending on vehicle
version, different cool‐
ant shut-off valves are
installed.
❑ For a detailed descrip‐
tion, refer to ⇒ Heating,
air conditioning; Rep. gr. 87 ; Coolant circuit; Overview of fitting locations - coolant circuit
10 - Bleeder hole
❑ 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
❑ Checking cooling system for leaks ⇒ page 160
17 - Pump for exhaust gas recirculation cooler - V400-
18 - 4/2-way valve with thermostat

1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater and
multitronic gearbox
Note

♦ Orange = Coolant circuit for exhaust gas recirculation.
♦ Green = Coolant circuit for automatic gearbox.
1 - Radiator
with fresh coolant
2 - Coolant pump
© satelettronica
block
with fresh coolant
cooler
with fresh coolant
⇒ page 177
er - G62-
⇒ page 176
8 - Bleeder hole
with fresh coolant
valve - N279-
❑ Connection diagram, re‐
moving and installing ⇒
Heating, air condition‐
ing; Rep. gr. 87 ; Cool‐
ant circuit; Overview of
fitting locations - coolant circuit
11 - Gearbox oil cooling valve - N509-
❑ Only for vehicles with multitronic
12 - Auxiliary ATF cooler
❑ Only for vehicles with multitronic

13 - Thermostat
❑ For exhaust gas recirculation cooler
❑ Arrow points in direction of through-flow
15 - Filler cap
❑ For coolant expansion tank
❑ Checking cooling system for leaks ⇒ page 160
19 - 4/2-way valve with thermostat
© satelettronica
♦ Cooling system tester - V.A.G 1274 B-

Checking cooling system for leaks

• Engine must be warm.
WARNING
© satelettronica
is hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.
– 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. 1.5 bar.
• The pressure should not drop more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops more than 0.2 bar, locate leak and elim‐
inate fault.
Note
The drop in pressure of 0.2 bar within 10 minutes is caused by

the decrease in coolant temperature. The colder the engine is,
the less the pressure will fall. If necessary, check again when the
engine is cold.

Checking pressure relief valve in filler cap

– 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.

© satelettronica

♦ Coolant collecting system - VAS 5014- or drip tray for work‐

shop hoist - VAS 6208-
© satelettronica
♦ Safety goggles
Draining
WARNING

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

– Remove front noise insulation -1- ⇒ General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
© satelettronica
gine.
– Remove drain plug -1- at connection and drain off coolant.

– Release hose clip -arrow-, disconnect coolant hose and drain
off coolant.
Filling
Caution
To ensure optimal corrosion protection, only distilled water

may be mixed with coolant additives.

Note
♦ The effectiveness of the coolant is greatly influenced by the

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . If you use other coolant additives, this can
significantly impair in particular the corrosion protection effect.
The resulting damage could lead to loss of coolant and con‐
sequently to serious engine damage.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
reliability under heavy loads, particularly in countries with trop‐
© satelettronica
ical climates.
♦ Refractometer - T10007A- or refractometer - T10007B- MUST
be used to determine the current level of frost protection.
♦ Scale -1- on the refractometer applies to coolant additives G12
++ and G12evo.
♦ Scale -2- on the refractometer applies to coolant additive G13.
tection.
♦ The mixture must guarantee frost protection down to at least
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ The temperature indicated on the refractometer corresponds
to the temperature at which the first ice crystals can form in
the coolant.
ses.

• Coolant (40 %) and water (60 %) for frost protection to -25 °C
• Coolant (50 %) and water (50 %) for frost protection to –35 °
C
• Coolant additive ⇒ Electronic parts catalogue

Procedure
– Close drain plug -1-.

– Connect coolant hose using hose clip -arrow-.
© satelettronica
– Fill reservoir of -VAS 6096- with at least 8 litres of premixed
coolant (according to recommended ratio):
V.A.G 1274/8- .
Note

rection of flow).


zone.
in the green zone.
sequent filling.
• If the needle does not reach the green zone, repeat the proc‐
ess.
• Check cooling system for leaks if the vacuum is not main‐
© satelettronica
tained.
– Open valve -A-.
is then filled.
– Fit pipe for cooling system tester - V.A.G 1274/10- onto adapt‐
er for cooling system tester - V.A.G 1274/8- .
coolant.
chamber cover .


– Fill up with coolant until it comes out at bleeder hole in coolant
hose.
– Detach pipe for cooling system tester - V.A.G 1274/10- and
close filler cap on coolant expansion tank.
– Start engine.
Time period Engine speed Air conditioner/heater setting

3 minutes 2000 rpm • Air conditioning system “OFF”, LED in AC button
not lit
• Heating at “HI”, select lowest possible blower
speed (= 0)
Until both large coolant Idling • Air conditioning system “OFF”
© satelettronica
hoses at radiator be‐
come warm • Heating at “HI”
1 minute 2000 rpm • Air conditioning system “OFF”

• Heating at “HI”

tion .
WARNING

The cooling system is under pressure when the power unit is
hot.
Cover filler cap on coolant expansion tank with a cloth and
– Check coolant level.

gine is cold.
engine is warm.
– Top up with coolant again if necessary.
– Fill up coolant to approx. 5 mm above max. marking when en‐
gine is cold.
– Install engine cover panel.
– Erase event memory ⇒ Vehicle diagnostic tester.


page 170
⇒ “2.5 Checking thermostat”, page 173
⇒ “2.6 Removing and installing 4/2-way valve with thermostat”,
page 173
”, page 176
2.1 Exploded view - coolant pump/thermostat
© satelettronica
1 - Coolant pump
⇒ page 173
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 173
6 - Bolt
❑ 15 Nm

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 170
© satelettronica
pump
♦ Hose clamps up to 25 mm - 3094-

Removing
© satelettronica

WARNING

is hot.
– Remove nuts -2- and pull pump for exhaust gas recirculation
cooler - V400- off engine.
– Remove bolts -3- and detach pump for exhaust gas recircula‐
tion cooler from bracket.
Installing
© satelettronica
Note

Tightening torques
tem”, page 209


Removing
– Unscrew bolts -1- and remove coolant pump -2-.
– Detach O-ring -3-.
Installing
Note
Fit new O-ring.
– Clean and smoothen sealing surface for O-ring.

– Lightly lubricate O-ring -3- with coolant.
– Fit coolant pump -2-.
© satelettronica
• Installation position: Sealing plug in housing faces down‐
wards.
Note

Tightening torques
♦ ⇒ “2.1 Exploded view - coolant pump/thermostat”, page 169
2.5 Checking thermostat

– Remove thermostat and heat it in a water bath.
Starts to open Fully open Opening travel
approx. 92 °C approx. 107 °C1) at least 7 mm
• 1) Cannot be tested.
2.6 Removing and installing 4/2-way valve

with thermostat

♦ Articulated wrench, 10 mm - 3185-
© satelettronica
Removing
– Move electrical connector -2- with bracket 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.
– Remove bolt -1- and pull coolant pipe (bottom left) off 4/2-way
valve.
© satelettronica


– Release hose clips -3-, lift retaining clip -1- and detach coolant
hoses.
– Detach 4/2-way valve with thermostat.
Installing
Note
♦ Fit new O-ring.

– Install dipstick guide tube.

– Install coolant pipe (bottom left) ⇒ page 182 .
© satelettronica
Note

Tightening torques

ature sender - G62-
Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
-arrow- on coolant expansion tank briefly and then close cap
again (it should click into place).


– Pull off retaining clip -1- and pull out coolant temperature
sender - G62- .
Installing
Note
♦ Fit new O-ring.

♦ Insert new coolant temperature sender - G62- immediately in‐
to connection to avoid loss of coolant.

© satelettronica
Removing
• Engine cold.
Note
– Unscrew radiator outlet coolant temperature sender - G83-

-item 1-.
Installing
Note

♦ Insert new radiator outlet coolant temperature sender - G83-
immediately into threaded hole to avoid loss of coolant.

Tightening torques


Removing
noise insulation .
Note
Place a cloth under gearbox oil cooling valve to catch escaping

coolant.
– Release hose clips -1, 2- and disconnect coolant hoses.

– Remove gearbox oil cooling valve.
Installing
© satelettronica
Note

Tightening torques
♦ 9 Nm

3 Coolant pipes

Coolant pipes on engine
1 - Bolt
❑ 9 Nm
2 - Coolant pipe (bottom left)
⇒ page 182
3 - O-ring
❑ Renew
4 - Thermostat
❑ For exhaust gas recircu‐
lation cooler
© satelettronica
5 - Coolant pipe (rear right)
⇒ page 183
6 - Bolt
❑ 9 Nm
7 - Nut
❑ 9 Nm
8 - Retaining clip
er - G62-
⇒ page 176
10 - O-ring
❑ Renew
11 - Gasket
❑ Renew
12 - Bolt
❑ 9 Nm
13 - Connection
❑ For coolant hoses
❑ 2 Nm
15 - O-rings
❑ Different diameters
❑ 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)
Coolant pipes on multitronic gearbox
1 - Bolt
❑ 9 Nm
2 - Gearbox oil cooling valve -
© satelettronica
N509-
⇒ page 178
3 - Bolt
❑ 20 Nm
4 - Bracket
❑ For gearbox oil cooling
valve - N509-
5 - Bolt
❑ 9 Nm
6 - Coolant pipe
⇒ page 187
7 - Bolt
❑ 20 Nm


⇒ “3.2.1 Removing and installing coolant pipe (top left)”,
page 181
⇒ “3.2.2 Removing and installing coolant pipe (bottom left)”, page
182
⇒ “3.2.3 Removing and installing coolant pipe (rear right)”,
page 183
⇒ “3.2.4 Removing and installing coolant pipe (rear)”, page 185
⇒ “3.2.5 Removing and installing coolant pipe on multitronic gear‐
box”, page 187

(top left)
© satelettronica
Removing
Note
Disregard -item 1-.


from coolant pipe (top left).
Installing
Note

Tightening torques
tem”, page 209
© satelettronica
(bottom left)
Removing
Note
Disregard -item 1-.

hoses.
– Remove bolt -1- and pull coolant pipe (bottom left) off 4/2-way
valve.
Installing
Note
♦ Fit new O-ring.

– Install air hoses with screw-type clips

⇒ “2.2 Exploded view - hose connections for charge air sys‐
tem”, page 209 .
© satelettronica
Tightening torques

(rear right)
Removing

Caution

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

– Install Lambda probe - G39- ⇒ page 266 .
© satelettronica
Note

Tightening torques

(rear)
Removing


- G505- .
– Move clear electrical wiring harness -arrow-.

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


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

Tightening torques

multitronic gearbox

Removing
noise insulation .
– Place drip tray for workshop hoist - VAS 6208- beneath gear‐
box.
© satelettronica
hose clips -1, 2- and disconnect coolant hoses.
– Detach coolant pipe.
Installing
Note

Tightening torques

4 Radiator/radiator fan(s)
⇒ “4.1 Exploded view - radiator/radiator fan(s)”, page 189
⇒ “4.2 Exploded view - radiator cowl and radiator fan”,
page 191
4.1 Exploded view - radiator/radiator fan(s)
1 - Air duct
2 - Coolant hose
tach
❑ Connecting
⇒ page 190
3 - O-ring
© satelettronica
4 - Radiator
⇒ page 192
5 - Coolant hose
tach
❑ Connecting
⇒ page 190
6 - O-ring
7 - Coolant pipe
tank
tach
❑ Connecting
⇒ page 190
8 - O-ring
9 - Rubber bush
❑ For radiator
10 - Retaining pin
11 - Air duct
12 - Bolt
❑ 2.5 Nm
4. Radiator/radiator fan(s) 189

13 - Condenser
14 - Air duct
❑ For radiator
17 - Bolt
❑ 5 Nm
18 - Support
19 - Bolt
❑ 4.5 Nm

• If damaged, renew retaining clip -4-.
– If damaged, renew O-ring. To do so, remove O-ring -2- from
© satelettronica
plug-in connector -3- using a suitable tool (do not use a sharp
tool). Take care not to damage the plug-in connector or the
surface on which the O-ring is seated.
ant hose.
bly.

4.2 Exploded view - radiator cowl and radi‐

ator fan
⇒ “4.2.1 Exploded view - radiator cowl and radiator fan, vehicles
⇒ “4.2.2 Exploded view - radiator cowl and radiator fans, vehicles
4.2.1 Exploded view - radiator cowl and radiator fan, vehicles with manual gear‐
box
1 - Radiator fan control unit -

J293-
⇒ page 200
2 - Bolt
❑ 4.5 Nm
3 - Bolt
❑ 5 Nm
© satelettronica
4 - Radiator cowl
⇒ page 199

4.2.2 Exploded view - radiator cowl and radiator fans, vehicles with multitronic
gearbox

⇒ page 200
2 - Bolt
❑ 3.5 Nm
3 - Bolt
❑ 5 Nm
4 - Radiator cowl
⇒ page 195
© satelettronica
⇒ page 200
⇒ page 200
7 - Bolt
❑ 5 Nm
Note
Radiator and radiator cowl are removed together.

© satelettronica
Removing
– Remove noise insulation (front) -1- ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Removing and instal‐
ling noise insulation .


impact absorber .
– Remove condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; Removing and installing condenser .
gine.
© satelettronica
– Open drain plug -1- at connection and drain off coolant.
– Then lift retaining clip and detach connection -2- from radiator.
WARNING

♦ Unplug electrical connectors before working in vicinity of
radiator cowl.
diator.

upwards -arrows-.

– Remove radiator with radiator cowl.
© satelettronica
Installing
Note
If there are slight impressions on the fins, refer to ⇒ page 8 .
Note

Tightening torques
♦ ⇒ “4.1 Exploded view - radiator/radiator fan(s)”, page 189
♦ Condenser ⇒ Heating, air conditioning; Rep. gr. 87 ; Air con‐
ditioner compressor; Detaching and attaching air conditioner
♦ Impact bar ⇒ General body repairs, exterior; Rep. gr. 63 ;
Bumper (front); Removing and installing attachments
♦ Noise insulation ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation; Exploded view - noise insulation


Removing
– Remove lock carrier cover -3- ⇒ General body repairs, exte‐
bumper cover .
© satelettronica

– Remove front noise insulation -1- ⇒ Rep. gr. 66 .
– Remove closure plate for bumper cover -3- ⇒ General body

repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing and
© satelettronica
– Release catches -arrows A-, swivel air duct -1- on left and right
to centre of vehicle -arrow B- and detach.


– Open drain plug -1- at connection and drain off coolant.
– Then lift retaining clip and detach connection -2- from radiator.

© satelettronica
radiator.
– Release retaining pins for radiator on both sides -arrow A- and

pull out upwards -arrow B-.


– Press radiator slightly towards front -arrow-.
Installing
– Install air duct ⇒ page 226 .
– Install lock carrier cover and closure plate for bumper cover
(front) ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper
© satelettronica
(front); Removing and installing bumper cover .
Note

V7-
⇒ “4.5.1 Removing and installing radiator fan V7 ”, page 199
⇒ “4.5.2 Removing and installing radiator fans V7 / V177 - vehi‐
cles with multitronic gearbox”, page 200
⇒ “4.5.3 Removing and installing radiator fan control unit J293 /
J671 ”, page 200
4.5.1 Removing and installing radiator fan -

V7-
Removing
Note
– Remove radiator with radiator cowl ⇒ page 192 .


– Unscrew bolts -arrows- and remove radiator fan - V7- .
Installing
– Install radiator with radiator cowl ⇒ page 192 .
Tightening torques
♦ ⇒ “4.2 Exploded view - radiator cowl and radiator fan”,
page 191

V7- / -V177- - vehicles with multitronic
gearbox
Removing
Note
© satelettronica


side).
Installing
Tightening torques
♦ ⇒ “4.2.2 Exploded view - radiator cowl and radiator fans, ve‐
hicles with multitronic gearbox”, page 192

Removing
noise insulation .

– Move electrical wiring harness going to radiator fan control unit
clear.

Installing
Tightening torques
♦ ⇒ “4.2 Exploded view - radiator cowl and radiator fan”,
© satelettronica
page 191

1 Turbocharger
1 - Air hose
2 - Pulsation damper
3 - Oil return line
4 - Bolt
❑ Renew
❑ 9 Nm
5 - Gasket
❑ Renew
© satelettronica
6 - Threaded connection
❑ 40 Nm
7 - Gasket
❑ Renew
8 - Bolt
❑ 20 Nm
9 - Turbocharger
❑ Can only be renewed to‐
gether with vacuum unit
❑ Adaption must be per‐
formed after renewing
this component
❑ Select 01 - Engine
electronics, func-
tions and perform Gui‐
ded Function 01 -
Adaption after re-
placing positioner
⇒ page 203
10 - Gasket
❑ Renew
11 - Nut
❑ Renew
❑ Coat thread with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 24 Nm
12 - Particulate filter
13 - Exhaust gas temperature sender 1 - G235-

14 - Banjo bolt
❑ 30 Nm
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
19 - Nut
❑ Renew
❑ 24 Nm
20 - Vacuum hose
© satelettronica
21 - Hose
❑ Optional equipment for countries with cold climates: with heater element for crankcase breather - N79-
22 - Air pipe
23 - Support
❑ For turbocharger
24 - Bolt
❑ 24 Nm
25 - Bolt
❑ 9 Nm

Removing
Note
Observe rules for cleanliness ⇒ page 5 .
1. Turbocharger 203
Caution
If the turbocharger has suffered mechanical damage (e.g.

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check air cleaner housing, air filter element and air hoses
for dirt and foreign particles.
♦ Check the entire charge air system (including the charge
air cooler) for foreign matter.
♦ If foreign matter is found in the charge air system, clean
all relevant ducts and hoses and renew charge air cooler
if necessary.

© satelettronica
noise insulation .
– 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-.
Note
Disregard -arrows-.
© satelettronica
one side.
– Remove bolts -1- and -2- and take out support for turbocharg‐
er.
1. Turbocharger 205

– Detach electrical connector -3- for exhaust gas temperature
sender 1 - G235- from bracket, unplug connector and move
electrical wiring clear.
Note
Disregard -item 1-.
– Remove both nuts -bottom arrows-.
© satelettronica
Note
Nut -top arrow- is removed later.
– Remove union nut -1-.

– Unplug electrical connector -3- for position sender for charge
pressure positioner - G581- .
– Remove nut -4- securing turbocharger to exhaust manifold.
– Remove nuts -1-, pull turbocharger and particulate filter off

studs and swivel to side as far as possible.

– Remove nut -top arrow- and disconnect turbocharger from

particulate filter.
Caution
Risk of damage to oil supply line.

♦ Do not attempt to bend oil supply line to a different shape.
– Seal off open pipes/lines and connections with clean plugs

from engine bung set - VAS 6122- .
Installing
Note
♦ Renew gasket/seal, nuts and O-ring.

♦ Fill turbocharger with engine oil at connection for oil supply
line.
© satelettronica
♦ 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.

tion .
– Adaption must be performed after renewing this component:
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and then Start diagnosis .
– Choose Select own test tab and select following options
one after the other:
♦ Drive train
♦ Select engine code and engine
♦ 01 - Self-diagnosis compatible systems
♦ 01 - Engine electronics
♦ 01 - Engine electronics, functions
♦ 01 - Adaption after replacing positioner
Tightening torques
♦ ⇒ “1.1 Exploded view - turbocharger”, page 202
tem”, page 209
1. Turbocharger 207
2 Charge air system

page 209
page 211

⇒ page 209
2 - Hose clip
3 - Air hose
❑ To turbocharger
© satelettronica
4 - Hose clip
5 - Hose clip
6 - Air hose
7 - Hose clip
8 - O-ring
❑ Renew
G31- / intake air temperature
sender - G42-
⇒ page 211
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

19 - Hose clip
20 - Bolt
❑ 7 Nm
21 - Resonator
22 - Rubber grommet
23 - Hose clip
24 - Air hose
❑ To resonator

charge air system
Note
© satelettronica
♦ The screw sections of used screw-type clips must be sprayed
with rust remover prior to fitting so that the air hoses can be
attached securely to the hose connections.
Tightening torque for

1- Hose clip with width -a- = 13 mm: 5.5 Nm
2- Hose clip with width -b- = 9 mm: 3 Nm

er
Removing
ments .

cooler.
© satelettronica
cooler.
Installing
Note
– Install lock carrier cover and closure plate at bumper cover ⇒

Exploded view - bumper cover .
Tightening torques
tem”, page 209


sure sender - G31-
Removing
Installing
Note
Fit new O-ring.
Tightening torques
© satelettronica
♦ Charge air system tester - V.A.G 1687-
Procedure
Note
Check that all air pipes and hoses and vacuum lines are correctly
fitted and that there are no leaks before carrying out tests or re‐
pairs.

noise insulation .


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.
© satelettronica
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-.

– 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
© satelettronica
felt with the hand; apply commercially available leak detection
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.
– Install air hoses with screw-type clips

⇒ “2.2 Exploded view - hose connections for charge air sys‐
tem”, page 209 .
tion .


1 Injection system
⇒ “1.1 Overview - fuel system”, page 214
page 216
⇒ “1.3 Filling and bleeding fuel system”, page 222
1.1 Overview - fuel system
Caution

© satelettronica
fuel system must be bled
♦ If the high-pressure pump is removed or renewed, the first
fuel filling operation must be performed before the engine
is started for the first time
Note
The high-pressure pump will be damaged if the first fuel filling

operation is not performed.

1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
2 - Fuel filter
❑ Exploded view ⇒ Fuel
supply system, diesel
engines; 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‐
© satelettronica
agnostic tester
❑ Exploded view
⇒ page 262
7 - Fuel metering valve - N290-
❑ Do not unscrew
8 - Fuel pressure regulating
valve - N276-
❑ Exploded view
⇒ page 236
9 - Fuel rail
G247-
11 - Restrictor
12 - Injector


⇒ page 261
2 - Electrical connectors
❑ For Lambda probe -
G39-
❑ For exhaust gas tem‐
perature sender 3 -
G495-
⇒ page 220
3 - Lambda probe - G39- with
⇒ page 220
❑ Exploded view
⇒ page 266
© satelettronica
4 - Exhaust gas temperature
sender 1 - G235-
⇒ page 222
control motor - V338- with ex‐
haust gas recirculation poten‐
tiometer - G212-
❑ Integrated into exhaust
❑ Checking exhaust gas
recirculation cooler
change-over
⇒ page 293
exhaust gas recircula‐
tion cooler ⇒ page 291
8 - Pressure differential sender - G505-
9 - Coolant circulation pump - V50-
❑ Vehicles with start/stop system only
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit; Overview of fitting
locations - coolant circuit

12 - Fuel pressure regulating valve - N276-

❑ With clutch pedal switch for engine start - F194- and clutch pedal switch - F36-
❑ Only on vehicles with manual gearbox
© satelettronica
19 - Charge pressure sender - G31- / intake air temperature sender - G42-
20 - Throttle valve module - J338- with throttle valve potentiometer - G69-
22 - Fuel temperature sender - G81-
23 - Glow plugs
❑ Glow plug 1 - Q10-
26 - Injectors
❑ Injector, cylinder 1 - N30-


28 - Position sender for charge pressure positioner - G581-
29 - Exhaust gas recirculation cooler change-over valve - N345-
❑ Electrical connector for exhaust gas temperature sender 1 - G235-
❑ Removing and installing exhaust gas recirculation cooler ⇒ page 291

♦ In electronics box in plenum chamber (left-side)
Removing and installing ⇒ page 269
© satelettronica
Fitting location: accelerator position sender - G79- and accelera‐
tor position sender 2 - G185-
♦ In accelerator pedal module
Note

Removing and installing ⇒ Fuel supply system, diesel engines;

Rep. gr. 20 ; Accelerator mechanism; Removing and installing
accelerator pedal module with accelerator position sender -G79-/-
G185- .
Fitting location of brake light switch - F- / clutch position sender -

G476-
2- Clutch position sender - G476- with clutch pedal switch for
engine start - F194- and clutch pedal switch - F36- (manual
gearbox only)
Removing and installing ⇒ Brake system; Rep. gr. 45 ; Sensors;
Removing and installing brake light switch

Fitting locations
Fuel metering valve - N290- -arrow-
© satelettronica
Fitting location of pump for exhaust gas recirculation cooler -
V400-
4 - Electrical connector for pump for exhaust gas recirculation
cooler - -
♦ At rear left of engine
Fitting location of coolant temperature sender - G62-

2 - Electrical connector for coolant temperature sender - G62-
♦ At rear of engine


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

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

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- with intake air

1- Electrical connector for charge pressure sender - G31- with
intake air temperature sender - G42-
♦ In engine compartment (front left)
© satelettronica
Fitting location of position sender for charge pressure positioner
- G581-
1- Electrical connector for position sender for charge pressure
positioner - G581-
♦ On turbocharger on right side of engine
Fitting location of charge pressure control solenoid valve - N75-

♦ At front right of engine -arrow-

Electrical connectors
Exhaust gas temperature sender 1 - G235- -1-
© satelettronica
Exhaust gas temperature sender 4 - G648- -1-
1.3 Filling and bleeding fuel system

If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled.
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.

Proceed as follows to fill high-pressure pump with fuel.

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
♦ Drive train
♦ Activate fuel pump
♦ Press Carry out check
♦ Select 120 seconds.
© satelettronica
– The fuel pump must run for 120 seconds to ensure that the
fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Check fuel system for leaks.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section again for leaks.

– Allow engine to run for several minutes at moderate rpm.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Then inspect high-pressure section of fuel system again for
leaks.

2 Vacuum system
⇒ “2.1 Connection diagram - vacuum system”, page 224
⇒ “2.2 Checking vacuum system”, page 224
2.1 Connection diagram - vacuum system
Caution
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.
1 - Charge pressure control

solenoid valve - N75-
2 - Turbocharger with vacuum
unit
❑ With position sender for
© satelettronica
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
❑ With vacuum reservoir
cooler change-over valve -
N345-
tion
2.2 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
♦ Porous or leaking lines
© satelettronica
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check the vacuum lines
leading to the relevant component and also check the remain‐
ing vacuum lines in the system.
– 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.
2. Vacuum system 225

3 Air cleaner
1 - Air duct
2 - Sealing element
3 - Mounting
⇒ page 227
© satelettronica
parts catalogue
Maintenance tables
let 411
6 - Cover
its or dirt
7 - Housing for air mass meter
- G70-
8 - Bolt
10 - Air duct
11 - Air pipe
❑ Tightening torque for screw-type clips ⇒ page 209
12 - Air duct
13 - Bolt
❑ 1.5 Nm


housing
Removing
ments .
Note
Disregard -item 1-.
© satelettronica
3. Air cleaner 227


meter - G70- .
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.
Note

© satelettronica
take side).
– Re-install air cleaner housing.
– Make sure that air hose is correctly seated at air mass meter
- G70- .
quence.
ments .

4 Intake manifold
233
⇒ “4.4 Cleaning throttle valve module J338 ”, page 233
1 - Guide tube
❑ For oil dipstick
2 - Seal
❑ Renew
3 - Gasket
❑ Renew
4 - Bolt
© satelettronica
❑ 8 Nm
❑ Version fitted in vehicle
may differ from illustra‐
tion
6 - Bolt
❑ 9 Nm
7 - Intake manifold
⇒ page 230
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 - Pipe connection
❑ For exhaust gas recirculation
❑ Opening must face cylinder head when installing; it may be necessary to rework pipe connection
⇒ page 230
16 - Bolt
❑ 9 Nm
17 - Seal
❑ Renew


❑ With throttle valve potentiometer - G69-
❑ Cleaning ⇒ “4.4 Cleaning throttle valve module J338 ”, page 233
❑ Removing and installing ⇒ “4.3 Removing and installing throttle valve module J338 ”, page 233
19 - Bolt
❑ 8 Nm
20 - Bolt
❑ 9 Nm
21 - Clip
Pipe connection must be installed rotated through 180°. Opening

of pipe connection faces cylinder head.
– Using a suitable file, create a new recess opposite existing
recess in support plate of pipe connection.
© satelettronica
♦ Ratchet - V.A.G 1331/1-

♦ Socket Torx T30 - T10405-
♦ Socket - T40055-
© satelettronica
Removing
Caution
♦ Observe ⇒ “3.1 Rules for cleanliness”, page 5 .

♦ Risk of malfunctions caused by dirt.

– Unplug electrical connectors on glow plugs ⇒ page 305 .
– Remove bolt -2- and union nuts -1 and 3- and detach high-
pressure pipe.

– Unplug electrical connectors -2 and 3-.

– Remove bolt -arrow- and push wiring retainer to the side.
Note
Disregard -item 1-.
– Remove bolts -1 and 3-.

– Release hose clips -2 and 4- and detach fuel hoses.
to one side.
Note
© satelettronica
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-.

J338- .

– 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 250 .
Tightening torques
♦ ⇒ “4.1 Exploded view - intake manifold”, page 229

module - J338-
© satelettronica
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.
Tightening torques
4.4 Cleaning throttle valve module - J338-

♦ Acetone (commercially available)
♦ Safety goggles

♦ Ultrasonic cleaning unit - VAS 6418-

♦ Cleaning solution -D 600 200 A2- : refer to ⇒ ETKA
Procedure
– Remove throttle valve module - J338-
⇒ “4.3 Removing and installing throttle valve module J338 ”,
page 233 .
WARNING
Risk of injury caused by acetone. Acetone is highly flammable

and can cause irritation to the eyes and skin.
– Pre-clean throttle valve housing, especially around throttle

valve -arrows-, using commercially available acetone and a
plastic scraper.
• Take care not to scratch the throttle valve housing when clean‐
© satelettronica
ing it.
Cleaning throttle valve module - J338- using ultrasonic cleaning

unit - VAS 6418- :
– Close drain tap -arrow- on ultrasonic cleaning unit - VAS 6418-
(located on right side of housing).
– Fill ultrasonic cleaning unit - VAS 6418- with approx. 1800 ml
of hot tap water and 200 ml of cleaning solution -D 600 200
A2- .
– Switch on cleaning unit by pressing on/off button -C-.

– Turn rotary temperature control -B- until LED for heating tem‐
perature is at 60 °C.
– Turn rotary control for operating time -A- to -arrow- (continu‐
ous operation).
– Press ► -D- button to start unit running.

– Immerse throttle valve module -1- until only throttle valve is

covered by cleaning fluid and fix in position using workshop
materials.
– The electronics must not come into contact with the cleaning
fluid.
– Once ultrasonic cleaning unit - VAS 6418- has reached 60 °C,
clean throttle valve module for approx. 30 minutes on contin‐
uous ultrasonic cleaning setting.
– Remove softened remaining deposits with a brush or cloth.
– There must not be any moisture in connector (blow out with
compressed air if necessary).
– Before installing throttle valve module, check it is functioning
properly; to do so connect electrical connector to throttle valve
module.
– Start engine briefly and then turn it off again immediately. If
throttle valve closes and opens after switching off engine,
throttle valve module is functioning properly.
– If throttle valve module is OK, install throttle valve module
page 233 .
© satelettronica

5 Injectors/high-pressure reservoir
(rail)
⇒ “5.1 Exploded view - injectors”, page 236
⇒ “5.2 Performing adaption of correction values for injectors”,
page 239
⇒ “5.3 Checking injectors”, page 239
⇒ “5.4 Checking return flow rate of injectors with engine running”,
page 240
⇒ “5.5 Checking return flow rate of injectors at starter cranking
speed”, page 243
⇒ “5.6 Checking for injectors sticking open”, page 244
⇒ “5.8 Removing and installing high-pressure pipes”, page 250
⇒ “5.9 Removing and installing high-pressure reservoir (rail)”,
page 251
5.1 Exploded view - injectors
© satelettronica
When installing a new base engine, you must check whether
there is a sticker on the cylinder head cover.
If a sticker is attached which states Spannpratzen auf vor-
geschriebenes Drehmoment angezogen (clamping pieces tight‐
ened to specified torque), the clamping pieces have already been
tightened to the specified final torque at the factory.
If no sticker is attached, it is essential that the clamping pieces for
the injectors are tightened to the specified torque
⇒ Item 7 (page 237) after installing the high-pressure pipes. If
these instructions are not observed, the engine could be dam‐
aged.

1 - Seal
❑ In cylinder head cover
❑ Renew if leaking
⇒ page 110
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
© satelettronica
❑ 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 246
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 line for leaks
7 - Bolt
❑ Renew
❑ Tighten initially to 2 Nm, then screw on union nuts for high-pressure pipes hand-tight and align injectors
❑ 8 Nm + 270° (3x 90° further)
8 - Clamping piece
❑ Use a coloured pen to mark injectors and corresponding clamping piece and cylinder for re-installation;
pay attention to markings when installing
❑ The clamping pieces can be re-used when installing new injectors
9 - High-pressure pipe
❑ Between fuel rail and injectors
5. Injectors/high-pressure reservoir (rail) 237

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
© satelettronica
12 - Fuel return hose
❑ Always renew after removing
❑ Checking ⇒ “6.2 Checking fuel pressure regulating valve N276 ”, page 257
⇒ “6.1 Removing and installing fuel pressure regulating valve N276 ”, page 255
❑ 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
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
lowing checks:
♦ Check taper seats of high-pres‐
sure pipes for deformation and
cracks.
damaged.
used again.
❑ 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.
© satelettronica
5.2 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 - Adaption value (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
(and in the Guided Functions). Use ⇒ Vehicle diagnostic tester
5.3 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 239
• Checking for injectors sticking open ⇒ page 244

• Checking return flow rate of injectors with engine running

⇒ page 240
• Checking return flow rate of injectors at starter cranking speed
⇒ page 243
Perform the following tests first if the engine does not start at all:
♦ Checking for injectors sticking open ⇒ page 244
♦ Checking return flow rate of injectors at starter cranking speed
⇒ page 243
♦ Checking fuel pressure regulating valve - N276- ⇒ page 257
5.4 Checking return flow rate of injectors

with engine running
Checking return flow rate of all injectors
Caution

© satelettronica
– 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

♦ Return flow meter - VAS 6684-
© satelettronica
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.
– Dry all components after cleaning.
– Clamp off fuel return hose -arrow- using a hose clamp -3094- .

– 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 hoses of return flow meter - VAS 6684- to return line
connections of all three 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.
– 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.
1- Injectors OK. Return flow rate approx. identical on all injec‐
tors.
© satelettronica
2- Injector for cylinder 3 not OK. Return flow rate greater than
three times the volume of smallest measured return flow
rate.
Note
There is a mechanical fault at the injector if the return flow rate is

greater than three times the volume of the smallest measured
return flow rate.
– If one injector has a significantly higher return flow rate than

the others it must be renewed ⇒ page 246 .
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 onto injectors. The

catch should engage audibly. Then press release pin down
carefully.
– Erase entry in event memory using ⇒ Vehicle diagnostic test‐
er.
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.

5.5 Checking return flow rate of injectors at

starter cranking speed
Only perform this test if the engine does not start at all.
Caution
© satelettronica
Procedure
– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.


-arrow-.
– Connect hoses of return flow meter - VAS 6684- to return line
connections of all four injectors.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
• Specification of return flow rate: 0 ml
– If fuel comes out of an injector, that injector must be renewed.
deformation.
Note
© satelettronica
– Push return line connections carefully onto injectors. The
catch should engage audibly. Then press release pin down
carefully.
er.
Note
5.6 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.

♦ Use a return line to make an -adapter-.
Caution

© satelettronica
er.
– 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.

Start with cylinder No. 1.
-arrow-.
– Connect adapter to return line connection of injector to be tes‐
ted after adapter has been cleaned and blown out.

– Generate a vacuum of -500 mbar using the hand vacuum

pump - VAS 6213- .
If the vacuum reading remains the same for 30 seconds, the 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 246 .
deformation.
Note
© satelettronica
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
pin down carefully.
Note

♦ Cleaning kit - VAS 6811-

♦ Puller - T10055-
♦ Assembly sleeve - T10377-
© satelettronica
♦ 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.
♦ Plug open connections with suitable sealing caps imme‐
diately.

-arrow-.
© satelettronica
– Unplug electrical connectors -arrows- at injectors.
– Loosen union nuts of high-pressure pipes -1 to 4-.

– 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 piece.
– Apply puller - T10055- with puller - T10415- as shown in illus‐

tration, and pull out injector upwards.
Note
© satelettronica
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
♦ 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.

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- .
– Renew O-ring for injector bore using assembly sleeve -

T10377- .
Note
If injector seals in cylinder head cover are damaged, they must

be renewed ⇒ page 110 .
– Install injectors.
– Slide clamping piece onto injectors; observe installation posi‐
tion.
© satelettronica
– 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.
– 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.
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 are already stored in the engine
control unit.
After renewing one or more injectors, the learnt values for the fuel
pressure regulating valve - N276- must be re-adapted; refer to
“Guided Functions” on ⇒ Vehicle diagnostic tester.
Note
Tightening torques
♦ ⇒ “5.1 Exploded view - injectors”, page 236
5.8 Removing and installing high-pressure

pipes

Procedure
Note

© satelettronica
following checks:
cracks.
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).
– 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 223 .
Tightening torques

reservoir (rail)

♦ Socket - T40055-
© satelettronica
Removing
Caution


– Unplug electrical connector -arrow- at fuel pressure regulating
valve - N276- .

pressure pipe.
– Release hose clip -arrow- and detach fuel return hose from
fuel rail.
– Seal off open fuel return hose with a clean plug.
© satelettronica
Note
– Unplug electrical connectors on glow plugs ⇒ page 305 .

– Remove bolt -arrow- and move wiring retainer with electrical
wiring harness clear and press to one side.
– Loosen union nuts for high-pressure pipes using socket -
T40055- .

– 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 so they are free of stress.
Note

following checks:
cracks.
erwise damaged.
© satelettronica
Tightening torques


⇒ “6.1 Removing and installing fuel pressure regulating valve
N276 ”, page 255
⇒ “6.2 Checking fuel pressure regulating valve N276 ”,
page 257
258

regulating valve - N276-
♦ Open-end spanner insert, 30 mm - T10553-
♦ Torque wrench
© satelettronica

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
© satelettronica
– Remove fuel rail ⇒ page 251 .

– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using commercial cleaning solution
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- .

– Loosen union nut using open-end spanner insert, 30 mm -
T10553- (at the same time, 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.
– 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 holding hexagon flats
on housing of regulating valve with open-end spanner or pliers
(water pump pliers or similar).
– Tighten union nut using open-end spanner insert, 30 mm -
housing).
Tightening torques
– Install fuel rail ⇒ page 251 .
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Interrogate event memory.
After renewing high-pressure pump or fuel pressure regulating
valve - N276- , learnt values must be re-adapted; see “Guided
© satelettronica
Functions” in ⇒ Vehicle 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.
– Interrogate event memory again.
6.2 Checking fuel pressure regulating valve

- N276-
♦ Fuel-resistant measuring container
Caution


– 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, start engine and increase engine speed
to ≥ 2000 rpm.
• Fuel is still discharged in the first few seconds after the engine
is started
• Specification after a few seconds: return flow rate = 0 ml
• Drip leaks are permissible
© satelettronica
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
3) If engine can no longer be started
Perform check at cranking speed.
• Drip leaks are permissible
• If specification is not obtained, fuel pressure regulating valve
- N 276- is defective.

sender - G247-
♦ Socket (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

© satelettronica
– Before removal, clean area around thread for fuel pressure
sender - G247- using e.g. commercial cleaning solution.
• Make sure no dirt gets into opening in high-pressure reservoir.
• Clean carefully; cleaning solution must not enter the electrical
connector.
– Dry off fuel pressure sender - G247- .


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.
– Seal off opening in high-pressure reservoir with a plug.
Installing
Note
♦ Fuel pressure sender - G247- must always be renewed after

it has been removed.
© satelettronica
♦ Also check sealing surface at opening in high-pressure reser‐
voir.
♦ Check that the deformable sealing lip and the thread on the
new fuel pressure sender - G247- are not damaged.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure sender - G247- must be coated with diesel
fuel.
– Screw in fuel pressure sender - G247- by hand.

– Then tighten fuel pressure sender - G247- to specified torque.
Tightening torques
– After installing fuel pressure sender - G247- , leave engine
running at moderate speed for a few minutes when bleeding
fuel system and then switch off again.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.

– Carefully check the entire fuel system for leaks.
– Renew affected component if leakage still occurs after tight‐
ening to correct torque.

Note
– After road test, interrogate event memory again.

- G70-
Removing
meter - G70- .
– Unscrew both bolts from air mass meter - G70- .
– Then carefully pull air mass meter - G70- out of guide on air
cleaner housing.
© satelettronica
Installing
To ensure that the air mass meter -G70- functions correctly, it is
important to observe the following notes and procedures.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter and falsify the detected air mass
values. This will cause a loss of power as the calculated in‐
jection quantities will be too low.
– Check air mass meter and air hose (engine intake side) for salt
residue, dirt and leaves.
– Check intake duct as far as air filter element for dirt. 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 227 .
quence.

⇒ “7.1 Exploded view - high-pressure pump”, page 262
⇒ “7.2 Removing and installing high-pressure pump”, page 263
7.1 Exploded view - high-pressure pump
1 - Bracket for ancillaries

⇒ page 48
2 - Bolt
❑ 2x
❑ Renew
❑ 20 Nm + 180°
3 - Hub
❑ Use counterhold tool -
T10051- when loosen‐
ing and tightening
© satelettronica
❑ To remove, use puller -
T40064-
sprocket
5 - Bolt
❑ 20 Nm
6 - Nut
❑ 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 222
❑ 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
❑ Between high-pressure pump and fuel rail
Note
♦ The high-pressure pipes can be

lowing checks:

♦ Check taper seat for deformation

and cracks.
damaged.
used again.
❑ 25 Nm

pump
Caution
Risk of malfunctions caused by dirt.
© satelettronica
Running when dry causes irreparable damage to high-pres‐
sure pump.
♦ If the high-pressure pump has been removed or renewed,
it is important to fill and bleed the fuel system before the
engine is started for the first time
Removing
– Remove toothed belt from camshaft and high-pressure pump
⇒ page 83 .
pressure pipe.
– Remove bolts -1 and 3-.

– 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 an M10 bit, remove bolts -arrows- for toothed belt

sprocket on high-pressure pump.
© satelettronica
– 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
– Install toothed belt for high-pressure pump ⇒ page 83 .
Caution

sure pump.
♦ If the high-pressure pump has been removed or renewed,
it is important to fill and bleed the fuel system before the
engine is started for the first time
– Reset learnt values after renewing high-pressure pump ⇒ Ve‐

hicle diagnostic tester, Guided Functions , 01 - Reset
© satelettronica
learnt values .
Tightening torques
♦ ⇒ “7.1 Exploded view - high-pressure pump”, page 262

8 Lambda probe
1 - Turbocharger
❑ With position sender for
charge pressure posi‐
tioner - G581-
⇒ page 266
❑ New Lambda probes
are coated with an as‐
sembly paste
❑ If you are re-using
Lambda probe, coat on‐
© satelettronica
ly thread with high-tem‐
perature paste; refer to
logue for high-tempera‐
ture paste
❑ The assembly paste/
high-temperature paste
must not get into the
slots on the Lambda
probe body
❑ 55 Nm
sender 3 - G495-
⇒ page 286
4 - Pressure differential sender
- G505-
⇒ page 282
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
❑ Tighten bolt to 4.5 Nm
❑ Adaption must be performed after renewing particulate filter. Use ⇒ Vehicle diagnostic tester


Removing
WARNING
When working on all parts of the exhaust system:

♦ Observe safety precautions when working on the exhaust
system
⇒ “2.6 Safety precautions when working on the exhaust
© satelettronica
system”, page 4 .

– Unplug electrical connector -3- for Lambda probe - G39- and
– Unscrew Lambda probe - G39- -item 1- using a tool from
Lambda probe open ring spanner set - 3337- .
Note
Installing
Note

body.
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Electronic parts catalogue
Tightening torques
♦ ⇒ “8.1 Exploded view - Lambda probe”, page 266
8. Lambda probe 267


page 269

♦ Adapter cable - V.A.G 1598/39-1-
© satelettronica
♦ Test box - V.A.G 1598/42-

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-pin wiring
harness connector ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
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‐
© satelettronica
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 269 .

– Connect the 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.
Perform the following after reconnecting engine control unit:
– Interrogate event memory and erase if necessary.



Note

© satelettronica
♦ 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.
Removing
– If the engine control unit - J623- is renewed, the adaption val‐
ues must be read out and stored before the engine control unit
- J623- is removed.
♦ Drive train
♦ 01 - Replace control unit
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
• If the adaption values of the injectors cannot be read out of the
old (defective) engine control unit, the adaption values must
be entered into the new engine control unit manually and the
adaption procedure must be performed accordingly.
chamber cover .


-item 1-.
Note
Disregard -item 2-.
© satelettronica
air blower.

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.



in illustration).
heated.
nectors.
© satelettronica
Installing
– After the engine control unit - J623- has been renewed, the
“Injector delivery calibration” and the “Injector voltage calibra‐
tion” must also be re-adapted in the engine control unit (these
functions influence engine power and exhaust emissions).
– On vehicles with particulate filter the current mileage (km)
reading must be stored in the engine control unit - J623- via
an adaption procedure.
must be performed:
– Activate engine control unit using ⇒ Vehicle diagnostic tester
in Guided Functions mode, function 01 - Replace con-
trol unit .

⇒ “1.2 Removing and installing front exhaust pipe”, page 275
⇒ “1.4 Renewing tailpipes”, page 278
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
© satelettronica
clearance is maintained to the body at all points and the mountings are evenly loaded.
1 - Bolt
❑ 23 Nm
2 - Bracket
3 - Centre silencer
be renewed separately
for repair purposes
❑ Cutting point between
centre silencer and rear
silencer ⇒ page 276
⇒ page 279
4 - Bolt
❑ 23 Nm
5 - Mounting
❑ Check preload
tem”, page 279
6 - Nut
❑ Renew
❑ 23 Nm
7 - Gasket
❑ Renew
❑ With catalytic converter
❑ With pressure line for

pressure differential
sender - G505-
❑ Mounting components ⇒ page 275
❑ After renewing, perform Adaption in Guided Functions ⇒ Vehicle diagnostic tester
9 - Gasket
❑ Renew
10 - Nut
❑ Renew
❑ 23 Nm
11 - Bolt
❑ 23 Nm
12 - Mounting
13 - Front exhaust pipe
❑ With flexible joint; do not bend flexible joint more than 10° – otherwise it can be damaged
© satelettronica
❑ Protect against knocks and impact
14 - Clamp (front)
15 - Nut
❑ 23 Nm
16 - Clamp (rear)
17 - Nut
❑ 23 Nm
19 - Tailpipe
❑ Can be renewed separately for repair purposes ⇒ page 278
20 - Rear silencer
❑ Combined as one unit with centre silencer and tailpipes as original equipment Can be renewed separately
for repair purposes
❑ Renewing tailpipes ⇒ page 278


tom of clamp.
• Bolted connection faces to left.

bottom of clamp.
© satelettronica
Components of mountings for particulate filter
1- Nut
2- Spacer sleeve
3- Bracket
5- Washer
6- Bolt, 23 Nm
7- Bolt, 23 Nm
8- Spacer sleeve
9- Buffer
10 - Bolt, 23 Nm
11 - Bracket
1.2 Removing and installing front exhaust

pipe
Removing
noise insulation .

WARNING

system
system”, page 4 .
– Remove bolts -1- and nuts -arrows-.
© satelettronica
Caution

10°.
– Loosen bolts -arrows-, push back clamp and detach front ex‐
haust pipe.
Installing
Note
Renew gasket and nuts.

Tightening torques

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.

Procedure
WARNING

system
© satelettronica
system”, page 4 .
– Cut through exhaust pipe at right angles at the position marked

-arrow- using chain pipe cutter - VAS 6254- .
– Position centre of clamps -arrow- over cutting location.


tom of clamp.
Tightening torques
1.4 Renewing tailpipes

♦ The tailpipes can be cut through at the point marked so that
the tailpipes can be renewed separately.
ference of the tailpipe.
© satelettronica
Procedure
– Cut through tailpipe at right angle at the position marked by
-arrows- using chain pipe cutter - VAS 6254- .
– Fit tailpipes.
– Check clearance between tailpipes and bumper:

– Tighten bolt connections on clamps.
Tightening torques


Procedure
er
– Loosen bolted 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.

– Tighten bolt connections on clamp evenly.
© satelettronica
Vehicles with clamps between centre silencer and rear silencer
– Push centre silencer towards front of vehicle -arrow- until
mounting for centre silencer is preloaded by -a- = 6 ... 10 mm.
– 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.


Tightening torques

– 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.
© satelettronica
– Rectify any leaks that are found.


⇒ “2.1 Removing and installing particulate filter”, page 281
⇒ “2.2 Removing and installing pressure differential sender G505
”, page 282
2.1 Removing and installing particulate filter

♦ Tool set - T10395 A-
© satelettronica
Removing
WARNING

system
system”, page 4 .
– Remove front exhaust pipe ⇒ page 275 .

– Unscrew exhaust gas temperature sender 4 - G648- -item 1-
using a tool from tool set - T10395 A- .
Note
– Remove coolant pipe (rear right) ⇒ page 183 .

– Remove exhaust gas recirculation cooler ⇒ page 291 .
– Remove turbocharger ⇒ page 203 .

– Remove bolts -2- and detach exhaust gas recirculation pipe.
Note
Disregard -item 1-.

– Remove bolt -1- and nut -2- and push rear coolant pipe clear
to one side.
Note
Disregard -arrows-.
© satelettronica
– Remove particulate filter forwards.
Installing
Note
Renew gaskets and nuts.
– Secure coolant pipe (rear) ⇒ page 185 .

– Install exhaust gas recirculation pipe ⇒ page 290 .
– Install exhaust gas recirculation cooler ⇒ page 291 .
– After renewing particulate filter, perform Adaption in Guided
Functions ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ “3.1 Exploded view - exhaust gas temperature control”, page
284
2.2 Removing and installing pressure differ‐

ential sender - G505-
Note
The pressure differential sender - G505- detects the amount of

deposits in the particulate filter.


Removing
– Unscrew bolt -2- and detach pressure differential sender -
G505- .
– Before disconnecting, spray the hoses for the pressure differ‐
ential sender - G505- 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
Note
♦ Before installing, blow out pressure pipes from pressure dif‐

ferential sender - G505- to particulate filter towards particulate
© satelettronica
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 were loosened on particulate filter, tighten
pressure pipe connections ⇒ page 266 .
– “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.
Tightening torques

3 Exhaust gas temperature control

⇒ “3.1 Exploded view - exhaust gas temperature control”,
page 284
⇒ “3.2 Removing and installing exhaust gas temperature sender”,
page 285
3.1 Exploded view - exhaust gas temperature control

sender 1 - G235-
⇒ page 285
❑ Coat thread with high-
temperature paste; for
parts catalogue
❑ 45 Nm
2 - Turbocharger
© satelettronica
⇒ page 266
sender 3 - G495-
⇒ page 286
❑ The thread of the ex‐
haust gas temperature
sender is coated; it must
not additionally be
greased with high-tem‐
perature paste
❑ 60 Nm
- G505-
⇒ page 282
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
high-temperature paste refer to ⇒ Electronic parts catalogue
❑ The thread of the exhaust gas temperature sender is coated; it must not additionally be greased with
❑ 60 Nm

3.2 Removing and installing exhaust gas

temperature sender
⇒ “3.2.1 Removing and installing exhaust gas temperature send‐
er 1 G235 ”, page 285
er 3 G495 ”, page 286
er 4 G648 ”, page 288
3.2.1 Removing and installing exhaust gas

temperature sender 1 - G235-
© satelettronica
Removing
Note
WARNING

system
system”, page 4 .

noise insulation .
3. Exhaust gas temperature control 285

– Unplug electrical connector -3- for exhaust gas temperature

sender 1 - G235- and unclip at bottom.
– Remove bolts -1, 2- and detach exhaust gas recirculation pipe.
© satelettronica
using a tool from tool set - T10395 A- and unclip electrical wire
-arrow-.
Installing
Tightening torques
284


Removing
Note
© satelettronica
WARNING

system
system”, page 4 .

– Detach electrical connector -3- from bracket.
– Unplug electrical connector -4- and move clear.
Note
Disregard -item 1-.
Installing
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.
Tightening torques
284


Removing
© satelettronica
– Unclip electrical connector -C- from bracket -B- and unplug.
Note
Disregard -item A- and -arrows-.
WARNING

system
system”, page 4 .



– Unclip electrical connector -2- from bracket and unplug.
Installing
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 coat them additionally with high-temperature paste
and that you tighten them to the specified torque.
– Install front exhaust pipe ⇒ page 275 .

Tightening torques
© satelettronica
284

4 Exhaust gas recirculation

⇒ “4.1 Exploded view - exhaust gas recirculation system”,
page 290
⇒ “4.2 Removing and installing exhaust gas recirculation cooler”,
page 291
⇒ “4.3 Checking exhaust gas recirculation cooler change-over”,
page 293
⇒ “4.4 Cleaning exhaust gas recirculation system”, page 294
4.1 Exploded view - exhaust gas recirculation system
1 - Gasket
❑ Renew
2 - Bolt
❑ 9 Nm
pipe
© satelettronica
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 293
⇒ page 291
❑ After renewing exhaust
gas recirculation control
motor - V338- , learnt
ted; see Guided Func-
tions of ⇒ Vehicle di‐
agnostic tester, 01 -
Adaption elec. ad-
juster with checkback
9 - Coolant hose
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 23 Nm
12 - Gaskets
❑ Renew

13 - Exhaust gas recirculation pipe

14 - Bolt
❑ 23 Nm
4.2 Removing and installing exhaust gas re‐

circulation cooler
© satelettronica
Removing

Note
4. Exhaust gas recirculation 291

– Remove bolts -2- for exhaust gas recirculation pipe.
Note
Disregard -item 1-.
Note
Disregard -item 2-.
© satelettronica
ing clear.
– Move fuel hoses clear at exhaust gas recirculation cooler.

– Remove bolts -1, 3- and detach exhaust gas recirculation
cooler.
Installing
Note
♦ Renew gaskets and O-ring.


– Attach coolant hose and secure with hose clip -3-.

– Tighten bolt and nut -arrows- to secure coolant pipe.
Note

– After renewing exhaust gas recirculation control motor -
V338- , learnt values must be re-adapted; see Guided Func-
tions of ⇒ Vehicle diagnostic tester, 01 - Adaption elec.
adjuster with checkback .
Tightening torques
♦ ⇒ “4.1 Exploded view - exhaust gas recirculation system”,
page 290
© satelettronica
tem”, page 209
4.3 Checking exhaust gas recirculation

cooler change-over
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 cooler change-
over should move -arrows-.
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.

4.4 Cleaning exhaust gas recirculation sys‐

tem
Note
♦ The cleaning process is only worthwhile for exhaust gas re‐

circulation coolers from part number 03L 131 512 DT onwards.
♦ Check the part number before starting work.
Explanation:
Certain extreme driving modes (e.g. short distances) may result
in varnish formation/carbon deposits inside the exhaust gas re‐
circulation cooler. In this case, the exhaust emissions warning
lamp in the instrument cluster lights up and the following code
appears in the event memory:
♦ P401 EGR system throughput too low
In these cases, these carbon deposits can be removed by carry‐
ing out the rinsing/cleaning procedure described below.
© satelettronica
♦ Cooler rinsing system for exhaust gas recirculation - VAS 542
007-
♦ Adapter - VAS 542 007/4-1-

Starting cleaning procedure for exhaust gas recirculation system

– Remove air cleaner housing and air hose

⇒ “3.2 Removing and installing air cleaner housing”,
page 227 .
– Remove bolt and nut -arrows- from coolant pipe.
© satelettronica
– Remove bolts -1 and 2- for connecting pipe for exhaust gas
recirculation. It will be necessary to press coolant pipe slightly
to side in order to access rear bolt.
– Screw adapter - VAS 542 007/4-1- onto connection of exhaust
gas recirculation cooler using original bolts from connecting
pipe and hand-tighten. Ensure that seal on adapter is not
pinched.
– Remove bolts -2-, open clamp -1- for connecting pipe for ex‐
haust gas recirculation and detach connecting pipe.
– Screw adapter - VAS 542 007/4-1- onto connection on cylinder
head using original bolts from connecting pipe and hand-tight‐
en. Ensure that seal on adapter is not pinched.

– Remove bolts -arrows- and pull pipe connection -1- out of in‐
take manifold.
© satelettronica
Note
♦ Check whether the opening of the pipe connection faces to‐

wards the cylinder head; if not, the pipe connection must be
installed rotated through 180°.
♦ If necessary, use a suitable file to create a new recess in ad‐
dition to the existing recess in the support plate of the pipe
connection.
♦ The pipe connection that has been modified in this way can
then be installed rotated through 180° after it has been
cleaned.
♦ When installing the pipe connection, make sure that the open‐
ing faces towards the cylinder head.

– Release and unplug electrical connector -2- from exhaust gas

recirculation valve - N18- .
– Plug electrical connector of valve actuator - VAS 542007/6-
into exhaust gas recirculation valve - N18- .
Cleaning connecting pipes and pipe connection for exhaust gas
recirculation:

Note
The ultrasonic bath can be heated up more quickly by using hot

tap water.
© satelettronica
– Fill ultrasonic cleaning unit - VAS 6418- with 1800 ml of hot
(approx. 60 °C) tap water and 200 ml of cleaning fluid -D 600
200 A2- .
– Put connecting pipes and pipe connection for exhaust gas re‐
circulation in. If necessary, change the position of the con‐
necting pipes in the bath occasionally.


– Turn rotary temperature control -B- until LED for heating tem‐
perature is at 60 °C.
– Set rotary control for operating time -A- to 10 -arrow-.
– Press ► -D- button to start unit running.
Note
After a temperature of 60 °C has been reached, the cleaning

process must last for at least 10 minutes.
– After cleaning successfully, rinse connecting pipes and pipe

connection for exhaust gas recirculation with clean water and
blow out with compressed air.
On vehicle (continued):
– Connect intake hose - VAS 542007/2-2- of cleaning unit to
adapter on exhaust gas recirculation cooler.
– Connect return hose - VAS 542007/2-3- of cleaning unit to
© satelettronica
adapter on cylinder head.
– Connect battery charger to battery.
– Connect battery clamps of valve actuator - VAS 542007/6- to
battery.
– Connect battery clamps of pump - VAS 542007/3- to battery.
Preparing cooler rinsing system for exhaust gas recirculation -
VAS 542 007- :
– Fill canister - VAS 542007/1- with 9 litres of warm (approx. 40 °
C) tap water.
– Pour 1 litre of cleaning solution - D 600 200 A2- into canister.

– Connect suction hose - VAS 542007/2-1- of pump to connec‐

tion -1- on canister lid.
– Insert open end of return hose - VAS 542007/2-3- into opening
-arrow- on canister lid to approx half height of canister.
– Plug electrical connector of valve actuator - VAS 542007/6-
into exhaust gas recirculation valve - N18- .
– Switch on valve actuator - VAS 542007/6- to open exhaust gas
recirculation valve.
Note
♦ Ensure that the bleeder screw tap on the intake hose - VAS
542007/2-2- is closed.
♦ If the pressure (approx. 1.6 bar) provided by the pump - VAS
542007/3- is not sufficient to activate the exhaust gas recircu‐
lation valve via the valve actuator - VAS 542007/6- , the pump
will switch itself off after a short period.
♦ In this case, the exhaust gas recirculation valve has a me‐
chanical fault or is not supplied with current. The exhaust gas
recirculation cooler must be renewed.
© satelettronica
♦ Before disconnecting the intake hose - VAS 542007/2-2- , the
pressure must be released by carefully opening the bleeder
screw tap and escaping cleaning solution must be caught.
Operate pump - VAS 542007/3- as follows:

Pump - VAS 542 Time Action
007/3-
Switch on 25 minutes Cleaning
Switch off 10 minutes Cleaning solution
taking effect
Switch on 25 minutes Cleaning
Switch off --- End of cleaning pro‐
cedure
– Disconnect intake hose - VAS 542007/2-1- from canister and
leave pump switched on until no more cleaning solution is ex‐
tracted (empty the system).
– Pull return hose - VAS 542007/2-3- out of canister (cleaning
solution may come out).
– Empty canister (observe country-specific requirements for dis‐
posal).
– Fill canister with 10 litres of warm (approx. 40 °C – 50 °C) tap
water.

– Connect intake hose - VAS 542007/2-1- of pump to connection

-1- on canister lid.
– Insert open end of return hose - VAS 542 007/2-3- into a suit‐
able container (minimum capacity of 12 litres) and fix in posi‐
tion.
– Switch on pump - VAS 542007/3- and leave it on until the con‐
tents of the canister have fully flowed through the exhaust gas
recirculation system.
– Detach intake hose - VAS 542007/2-2- from adapter on ex‐
haust gas recirculation cooler.
– Connect compressed air adapter - VAS 542007/5- to adapter
on exhaust gas recirculation cooler.
– Insert open end of return hose - VAS 542 007/2-3- into opening
-arrow- on canister lid to approx half height of canister.
– Intake hose - VAS 542 007/2-1- of pump must be connected
to connection -1- on canister lid.
– Connect compressed air line to compressed air adapter - VAS
542007/5- and blow all remaining water out of exhaust gas
recirculation system (minimum 2 minutes).
© satelettronica
Caution
All water must be removed from the exhaust gas recirculation

system. Otherwise the engine could be damaged.
– Release and unplug compressed air adapter - VAS

542007/5- .
– Remove adapter - VAS 542 007/4-1- from exhaust gas recir‐
culation cooler.
– Install exhaust gas recirculation pipe with new gaskets.

– Unplug connector for valve actuator - VAS 542007/6- on ex‐
haust gas recirculation valve - N18- and plug in original con‐
nector.
– Remove adapter - VAS 542 007/4-1- from cylinder head.
– Position pipe connection -1- with new gasket on cylinder head

with opening facing intake manifold.
– Screw in bolts -arrows- and tighten to 9 Nm.

– Install connecting pipe for exhaust gas recirculation with new

gasket and clamp.
– After cleaning, the effectiveness of the cleaning process must
be checked with ⇒ Vehicle diagnostic tester.
– Interrogate event memory and erase entries if necessary.
♦ Drive train
♦ 01 - Check exhaust gas recirculation valve 1 -GX5
© satelettronica
after cleaning according to the repair manual
– Perform road test.

Tightening torques:
page 290

5 Exhaust manifold
⇒ “5.1 Exploded view - exhaust manifold”, page 302
⇒ “5.2 Removing and installing exhaust manifold”, page 303
5.1 Exploded view - exhaust manifold
1 - Gasket
❑ Renew
⇒ page 303
3 - Nut
❑ 25 Nm
❑ Renew
❑ Lubricate exhaust mani‐
fold studs with high-tem‐
perature paste
© satelettronica
❑ If studs are renewed,
too, tighten them to 15
Nm
4 - Heat shield
5 - Nut
❑ 25 Nm

5.2 Removing and installing exhaust mani‐

fold
Removing
- G505- .
– Detach electrical connectors from bracket and unplug.

3 - For Lambda probe - G39-
4 - For exhaust gas temperature sender 3 - G495-
– Move particulate filter to rear.
© satelettronica
Note
– Remove bolt -1- at retaining clamp for oil supply line.
Note
Disregard -item 2-.
– Remove bolts -1, 2- and detach exhaust gas recirculation pipe.
5. Exhaust manifold 303

– Remove nuts -arrows- and detach heat shield.
– Remove nuts -arrows-.
Caution
Risk of damage to oil supply line.

♦ Do not attempt to bend oil supply line to a different shape.
© satelettronica
– Detach exhaust manifold.
Installing
Note
Renew gaskets and nuts.

Tightening torques
♦ ⇒ “5.1 Exploded view - exhaust manifold”, page 302
page 290

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Exploded view - glow plug system”, page 305
⇒ “1.2 Removing and installing glow plug”, page 305
⇒ “1.3 Removing and installing Hall sender G40 ”, page 307
308
1.1 Exploded view - glow plug system

⇒ page 307
2 - Bolt
❑ 10 Nm
© satelettronica
3 - Glow plug
❑ Glow plug 1 - Q10- ,
glow plug 2 - Q11- , glow
plug 3 - Q12- , glow
plug 4 - Q13-
⇒ page 305
❑ 17 Nm
❑ For glow plug
5 - Bolt
❑ 4.5 Nm
G28-
⇒ page 308
7 - Sealing flange (gearbox
end)
❑ With oil seal
8 - Sender wheel
❑ For engine speed send‐
er - G28-
stalling sealing flange
(gearbox end)”,
page 57
1.2 Removing and installing glow plug

1. Glow plug system 305

♦ Pliers - 3314-
© satelettronica
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.
306 Rep. gr.28 - Glow plug system

– 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
– Fit glow plug connectors -1- back onto glow plugs -arrow-.
Note
© satelettronica
Check that glow plug connectors are securely seated.
Tightening torques
♦ ⇒ “1.1 Exploded view - glow plug system”, page 305
1.3 Removing and installing Hall sender -

G40-
Removing
– Detach toothed belt from idler roller and high-pressure pump
⇒ page 83 .
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
– Seal repair opening in toothed belt cover with rubber plug; for
© satelettronica
rubber plug refer to ⇒ Electronic parts catalogue .
– Fit toothed belt and adjust valve timing ⇒ page 87 .
Tightening torques

sender - G28-
Removing
– Remove pump for exhaust gas recirculation cooler - V400-
⇒ page 170 .
– Unplug electrical connector -1- at engine speed sender - G28-
using assembly tool - T10118- .

– Move wiring clear.
Note
♦ To release electrical connector without assembly tool -

T10118- , use a screwdriver.
♦ Press in connector on engine speed sender.
♦ At the same time, lift release tab with a thin wire hook.
– Remove bolt from engine speed sender - G28- .

Installing
Tightening torques
© satelettronica

Service
Workshop Manual
Audi A6 2011 ➤
6-cylinder direct injection engine (2.5 ltr., 2.8 ltr. 4-
valve)
© satelettronica
Engine ID
CHV CNY CNY CLXA CLXB CVP
A A B A
Edition 11.2017

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
© satelettronica

Copyright © 2017 Audi AG, Ingolstadt D3E8033ADB9

6-cylinder direct injection engine (2.5 ltr., 2.8 ltr. 4-valve) - Edition 11.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine identification number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 6
© satelettronica

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 Exploded view - poly Protected
V-belt by drive . .Copying
copyright. . . . . .for. private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in. part
. . or
. .in.whole,
. . . .is .not. . . . . . . . 65
1.2 Removing and installingwith poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AG.
.......... 66
respect to the correctness of information in this document. Copyright by AUDI
2.3 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.4 Checking sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.5 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.1 Exploded view - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Contents i
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87


1.1 Exploded view - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.2 Exploded view - drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.3 Exploded view - drive chain for balance shaft and oil pump . . . . . . . . . . . . . . . . . . . . . . . . 113
2.6 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.7 Removing and installing drive chain for balance shaft and oil pump . . . . . . . . . . . . . . . . . . 127
© satelettronica
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.2 Removing and installing cylinderProtected head by.copyright.
. . . . . Copying
. . . . .for. private
. . . . or. .commercial
. . . . . .purposes,
. . . . . in. part
. . .or.in. whole,
. . . .is.not136
3.3 Removing and installing cylinderpermitted head cover
unless authorised by AUDI AG. AUDI AG does not guarantee or accept. any
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . liability
. . 161
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

4.5 Removing and installing cam actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.6 Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.7 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.2 Removing and installing crankcase breather hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.1 Exploded view - oil filter housing/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
ii Contents

4.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 210
4.6 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 214
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.7 Removing and installing temperature sender for engine temperature regulation G694 . . 234
© satelettronica
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.5 Removing and installing radiator fan control unit J293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

1.2 Reducing fuel pressure in high-pressure section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3.2 Exploded view - intake manifold (bottom section) with fuel rail . . . . . . . . . . . . . . . . . . . . . . 291
3.3 Removing and installing intake Protectedmanifold . . . . for
by copyright. Copying . .private
. . . .or.commercial
. . . . . . purposes,
. . . . . in. .part
. .or. in. whole,
. . . .is. not
..... 292
3.4 Removing and installing intake permittedmanifold (top bysection)
unless authorised AUDI AG. AUDI . . AG
. . does
. . . not
. .guarantee
. . . . . or. .accept
. . . any
. . liability
....... 294
3.5 Removing and installing intake manifold (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Contents iii
6.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

7 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
7.1 Exploded view - Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

2.1 Removing and installing catalytic converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
© satelettronica
3.3 Checking combination valve for secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
3.4 Removing and installing combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4 Exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
4.1 Exploded view - exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
4.2 Removing and installing exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
28 - Ignition system . . . . . . . . . . . . . . . . . . . . Protected

.permitted
. . . .byunless
. copyright.
. . authorised
. . .Copying
. .by. AUDI
.for.private
.AG.
. .AUDI
. commercial
or . AG
. . does
. . .not
. guarantee
. . . in. part
purposes, .or371
or in whole, is not
1 Ignition system . . . . . . . . . . . . . . . . . . . . . . with
. . .respect
. . . .to. the
. . correctness
. . . . . . of. .information
. . . . . .in.this
. .document.
. . . . . .Copyright
. . . 371by AUDI AG.

1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
1.4 Removing and installing knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
1.5 Removing and installing Hall senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
iv Contents
1 Identification
(ARL005489; Edition 11.2017)
⇒ “1.1 Engine identification number/engine data”, page 1
1.1 Engine identification number/engine da‐

ta
Engine number
Note
The engine cover panel (front) must be removed to make the en‐
gine number visible.
♦ The engine number (“engine code” and “serial number”) can

be found on the front of the cylinder block beneath the cylinder
© satelettronica
head (right-side) -arrow-.
number.
Note

Engine data
Code letters CHVA CLXA CLXB

Capacity ltr. 2.773 2.498 2.498
Power out‐ kW at rpm 150/5750 … 6800 140/5500 150/5500
put
Torque Nm at rpm 280/3250 … 5000 250/3250 … 4750 250/3250 … 4750
Bore ∅ in mm 84.5 80.2 80.2
Stroke mm 82.4 82.4 82.4
Compression ratio 12.0 12.3 12.3
RON at least 951) 951) 951)
Injection/ignition system Simos Simos Simos
Firing order 1-4-3-6-2-5
1-4-3-6-2-5 1-4-3-6-2-5
Exhaust
with respect togas recirculation
the correctness no Copyright by AUDI AG.
of information in this document. no no
Turbocharging/super‐ no no no
charging
Knock control 2 sensors 2 sensors 2 sensors
Charge air cooling no no no
1. Identification 1
Code letters CHVA CLXA CLXB

Lambda control 2 probes before catalytic 2 probes before catalytic 2 probes before catalytic
converter converter converter
2 probes after catalytic 2 probes after catalytic 2 probes after catalytic
Variable valve timing Inlet Inlet Inlet
Exhaust Exhaust Exhaust
Intake manifold change- yes yes yes
over
Secondary air system yes yes yes
Valves per cylinder 4 4 4
• 1) Unleaded regular grade petrol (RON 91) can also be used, but this will result in a loss of power
Code letters CNYA CNYB CVPA

Capacity ltr. 2.773 2.773 2.773
Power out‐ kW at rpm 150/5750 … 6800 162/5750 … 6800 162/5750 … 6800
put
© satelettronica
Torque Nm at rpm 280/3250 … 5000 280/3250 … 5000 280/3250 … 5000
Bore ∅ in mm 84.5 84.5 84.5
Stroke mm 82.4 82.4 82.4
Compression ratio 12.0 12.0 12.0
RON at least 951) 951) 951)
Injection/ignition system Simos Simos Simos
Firing order 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5
Exhaust gas recirculation no no no
Turbocharging/super‐ no no no
charging
Knock control 2 sensors 2 sensors 2 sensors
Charge air cooling no no no
Lambda control 2 probes before catalytic 2 probes before catalytic 2 probes before catalytic
2 probes after catalytic 2 probes after catalytic 2 probes after catalytic
Variable valve timing Inlet Inlet Inlet
Exhaust Exhaust Exhaust
Intake manifold change- yes yes yes
over
Secondary air system yes yes yes
Valves per cylinder 4 4 4
• 1) Unleaded regular grade petrol (RON 91) can also be used, but this will result in a loss of power

⇒ “2.1 Safety precautions when working on the fuel supply sys‐
tem”, page 3
page 5 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “2.5 Safety precautions
with respect towhen working
the correctness on theincooling
of information system”,
this document. Copyright by AUDI AG.
page 5
⇒ “2.6 Safety precautions when working on the ignition system”,
page 6

fuel supply system
Please note the following warnings when working on the fuel sup‐
ply system:
© satelettronica
WARNING
The fuel system operates at extremely high pressure. This can

cause injury.
♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system; for the correct procedure see
⇒ “1.2 Reducing fuel pressure in high-pressure section”,
page 282 .
♦ Wrap a clean cloth around the connection and carefully
loosen the connection to allow the residual pressure to
dissipate.
Observe the following to prevent injuries to persons and damage

to the injection and ignition system:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Always switch off ignition before washing engine.
– Erase any entries in event memory resulting from testing or
installation:
• Vehicle diagnostic tester must be connected.
– Selecting operating mode.
– Using Go To button and “Function/component selection” func‐
tion, select the following in succession from tree:
♦ Drive train
♦ Simos injection and ignition system
♦ Functions
♦ Readiness code
Caution

♦ Always switch off the ignition before disconnecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
WARNING
Escaping fuel can cause a risk.

♦ The power supply for the fuel system pressurisation pump
- G6- must be disconnected before opening the fuel sys‐
tem, since -G6- will be activated briefly when the driver's
door is opened with the battery still connected.
♦ Disconnect power supply by removing fuse for fuel pump
control unit - J538- /fuel delivery unit ⇒ Current flow dia‐
© satelettronica
grams, Electrical fault finding and Fitting locations, or
disconnect battery.

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 (indicated by
a message in the instrument cluster), the engine may start
automatically if it needs to.
♦ 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).


road test
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.
♦ Protected
Test equipment mustforalways
by copyright. Copying private or be secured
commercial on the
purposes, in partrear seat is not
or in whole,
with a unless
permitted strapauthorised
and operated
by AUDI AG.from thedoes
AUDI AG rear
not seat byoraaccept
guarantee secondany liability
person.
© satelettronica

subframe
When working on the subframe note the following warnings:
Caution


cooling system
When working on the cooling system note the following warnings:
WARNING

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

♦ The filler cap must engage positively and audibly when it
is closed.

ignition system
To prevent injuries to persons and/or irreparable damage to the
fuel injection and ignition system, the following must be noted:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as the
ignition system and xenon headlights.
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Always switch off the ignition before cleaning the engine.
© satelettronica
necting the battery, otherwise the engine control unit may be
damaged.
♦ If you want to turn over the engine at cranking speed without
actually starting it (e.g. compression test), first unplug theunless
permitted con‐authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
nectors from the ignition coils. In addition, remove fuse for fuel
pump control unit - J538- ; for identification of fuses refer to
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
– Erase any entries in event memory resulting from testing or
installation:
♦ Drive train
♦ Functions
♦ Readiness code
Caution


8

ply system and injection system:
loosening.
♦ Immediately seal open
permitted lines
unless and connections
authorised by AUDI AG. AUDIwith clean
AG does plugs, or accept any liability
not guarantee
© satelettronica
for example fromwithengine bung set - VAS 6122- .

that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.

♦ In the event of mechanical damage to one of the cylinder
banks, the intake and exhaust systems and combustion cham‐
bers of the opposite cylinder bank must always be examined
for foreign particles to prevent further damage occurring later.

fitted.
Please note:
♦ We recommend the use of Audi accessories.
ranty.

and wiring

Even when the radiator and condenser are correctly installed,
slight impressions may be visible on the fins of these components.
© satelettronica
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 or the condenser.

Procedure
♦ Cracks
– If an entry is stored in the event memory, check the vacuum
lines leading to the corresponding component and also check
the other vacuum lines leading to other components.
hoses for leaks.


⇒ “1.2 Separating engine and gearbox”, page 26
page 41
1.1 Removing engine

equipment required
© satelettronica

♦ Stepladder - VAS 5085-
♦ Scissor-type assembly platform - VAS 6131 B-

♦ Support set for Audi - VAS 6131/10-
♦ Supplementary set -VAS 6131/11-

♦ Supplementary set, Audi Q7 >2005 - VAS 6131/13-
© satelettronica
♦ Puller - T40160- for vehicles with manual gearbox
Procedure
Note
♦ The engine is removed from underneath together with the

gearbox and subframe (with lock with

carrier
respectinstalled).

WARNING
moved.
must be empty.
cause injury.
prior to opening the system.
– Reduce fuel pressure in high-pressure system

⇒ “1.2 Reducing fuel pressure in high-pressure section”, page
282 .
– Bring front wheels into straight-ahead position.
Caution
© satelettronica
Risk of irreparable damage to electronic components.

battery .
– Discharge refrigerant system ⇒ Air conditioner with refrigerant
R134a .
– Remove lock carrier cover ⇒ General body repairs,
permitted unlessexterior;
Rep. gr. 63 ; Bumper (front); Removing andwith
installing attach‐
ments .
Vehicles with four-wheel drive:
– Remove propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
– Remove engine cover panel:
♦ Pull off cover panel (one-piece version) -arrows-.

♦ Pull off both sections of cover panel (two-piece version)

-arrows-.
© satelettronica
WARNING

hot.

– Remove both front wheels ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres .
noise insulation .
gine.
– Remove drain plug -1- and drain off coolant. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Lift retaining clip -2- and disconnect coolant hose from radia‐
tor.

Vehicles with multitronic gearbox 0AW (front-wheel drive) or 7-

speed dual clutch gearbox 0B5:
– Release hose clip -1-, disconnect coolant hose from coolant
pipe (bottom left) and drain off coolant.
Note
♦ Disregard -item 2-.

♦ The illustration shows the 2.8 ltr. engine.

chamber cover .
© satelettronica
Note
Disregard -item 2-.
– Move fuel hose -1- and hose -2- from activated charcoal filter
clear at air pipe.


-arrow-.
– Release hose clip -1- and disconnect vacuum hose from ple‐
num chamber partition panel.
© satelettronica
– Unplug electrical connector -2- at activated charcoal filter sol‐
enoid valve 1 - N80- and detach vacuum hose -3-.
– Detach activated charcoal filter solenoid valve 1 - N80- from
bracket and move it clear to the side with hoses still attached.
WARNING
Risk of injury caused by fuel.

♦ To allow the fuel pressure to dissipate, wrap a clean cloth
around the connection and carefully loosen the connec‐
tion before opening the fuel system.
Caution
Take care to keep components clean.

♦ Observe rules for cleanliness when working on the fuel
supply system ⇒ “3.1 Rules for cleanliness”, page 7 .

Plug-in connectors; Disconnecting plug-in
Protected by copyright. connectors
Copying for .
private or commercial purposes, in part or in whole, is not
– Seal off open lines andwith
connections with clean
respect to the correctness plugs infrom
of information en‐ Copyright by AUDI AG.
this document.

– Lift retaining clip -arrow- and detach coolant hose going to heat
exchanger from rear of engine.
Note

the engine removed.
– Lift retaining clip -arrow- and detach coolant hose (front right)
from coolant pipe (front).
© satelettronica
– Remove bolt -1- and move refrigerant line clear.
– Lift retaining clip -arrow-, detach coolant hose (left-side) from
coolant pipe (front) and move coolant hose clear.

Caution

– Unscrew bolt -2- and remove refrigerant line from air condi‐
tioner compressor.
Note
– Remove fasteners -arrows- on both sides and unclip cover

-1-.
© satelettronica
body brace .




earth cables clear.
– Release catches -arrow- to open wiring duct -1- and move
electrical wiringProtected
harness clear. Copying for private or commercial purposes, in part or in whole, is not
by copyright.
© satelettronica



box in engine compartment.
– Unplug electrical
Protected connectors
by copyright. Copying for-1- and
private unscrew
or commercial nut -2-
purposes, fororelec‐
in part in whole, is not
trical wiring.
holder -3-.
– Disengage engine wiring harness at electronics box in engine
compartment and move clear.
© satelettronica
-arrow B-.
trol unit.

Vehicles with 2.5 ltr. engine:

– Unplug electrical connector -2- at secondary air pump motor -
V101- and move electrical wiring clear.
– Press release tabs, disconnect secondary air hose -1- and
move hose clear.
Note
Vehicles with 2.8 ltr. engine: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
© satelettronica
– Unplug electrical connector -4- atwith
secondary
respect to the air pumpofmotor
correctness - in this document. Copyright by AUDI AG.
information
move hose clear.
Note

– Unplug electrical connector -1- at front wheel speed sensor
-2- -G45- / -G47- on both sides.
– If fitted, unplug electrical connector -1- at front vehicle level

senders on both sides ( -G78- and -G289- ) and move electri‐
cal wiring clear -arrow-.
– Remove brake caliper and tie up in wheel housing with wire
(brake hose remains attached) ⇒ Brake system; Rep. gr. 46 ;
Front brakes; Removing and installing brake caliper .
Caution
Risk of damage to brake pistons.

♦ Do not press brake pedal with brake caliper removed.

– Remove nut -2- and pull out bolt -1-.

– Pull upper suspension links upwards out of wheel bearing
housing -arrows-.
– Remove bolt -1- for anti-roll bar on both sides.

– Remove nut -3- on both sides.
Note
The bolts -2- are removed at a later stage.
© satelettronica
– Move clip clear -arrow-.
cross brace .
Caution

– Remove bolts -arrows- on both sides and detach heat shield
-1- on subframe.

– Unscrew nuts -arrows- for front silencer (left-side).
– Unscrew nuts -arrows- for front silencer (right-side).
© satelettronica
Caution

♦ Do NOT bend the flexible joint in the front silencer more
than 10°.
– Loosen and push back clamps -1, 2- and remove front silenc‐
ers.
– Detach intermediate steering shaft from steering rack and
move clear by telescoping splines together ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Steering column; Removing and
installing intermediate steering shaft .

– Remove bolt -2- and tie up clutch slave cylinder at side of en‐
gine compartment.
Caution
Risk of damage to clutch slave cylinder.

♦ Do not press clutch pedal after removing slave cylinder.
– Remove nut -1- for selector rod.


– Apply puller - T40160- and pull off selector rod -1-.
Vehicles with multitronic gearbox 0AW (front-wheel drive):

– Pry ball socket -A- of selector lever cable off gearbox selector
lever -arrow- using removal lever - 80 - 200- .
© satelettronica
– Remove bolts -2- for cable support bracket.
Note
♦ Take care not to bend or kink selector lever cable.

♦ Disregard -item 1- and -arrow-.

– Unplug electrical connector -2- at power steering control unit
- J500- (release retainer -arrow- and press down release
catch).
- J500- .

Set up the scissor-type assembly platform as follows:

– Set up scissor-type assembly platform - VAS 6131 B- with
support set for Audi - VAS 6131/10- , support set -VAS
6131/11- and supplementary set -VAS 6131/13- as follows:
Platform Parts of support set for Audi - VAS 6131/10- , sup‐
coordinates port set -VAS 6131/11- and supplementary set -
VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /10-11
G6 /10-1 /10-2 /10-5 /10-11
A8+C8 /13-6 – – /13-2
F8+H8 /13-5 – – /13-2
B14 /10-1 /10-3 /10-5 /11-1
G14 /10-1 /10-4 /10-5 /11-1
– Initially hand-tighten the support elements on the scissor-type
assembly platform.
© satelettronica
– Position scissor-type assembly platform - VAS 6131 B- hori‐
zontally.
• Take note of spirit level (bubble gauge).
– Position scissor-type assembly platform - VAS 6131 B- below
engine/gearbox assembly.
WARNING
Accident risk if subframe mountings are detached.

♦ Subframe bolts -2- and -3- must not be loosened.
– Remove subframe bolts -1- on both sides.
– Position support elements from -VAS 6131/10- and -VAS

6131/13- at front left and right of subframe as shown.
– Make sure that threaded spindles are screwed in completely.

– Position support elements from -VAS 6131/10- (rear left and

right) at front attachment points of subframe cross brace as
shown.
– Position support elements from -VAS 6131/13- under left and

right wheel bearing housings as shown.
© satelettronica
6131/11- (rear left and right) at tunnel cross member as
shown.
– Turn all spindles for support elements upwards until all locat‐
ing lugs make contact with mounting points.
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform - VAS 6131 B- .
– Mark installation position of subframe and tunnel cross mem‐

ber onProtected
longitudinal members with felt-tip pen.
– Unscrew subframe bolts -2- and -3- on both sides in several

stages and in diagonal sequence.

– Remove bolts -arrows- on tunnel cross member.
Note
The illustration shows the tunnel cross member for vehicles with
front-wheel drive; it is similar on other vehicles.
– Remove bolt -2- on both sides.
Caution

© satelettronica
♦ Carefully guide out engine/gearbox assembly with sub‐
frame from engine compartment when lowering.
Vehicles with manual gearbox or dual clutch gearbox 0B5:

– Lower engine/gearbox assembly using scissor-type assembly
platform - VAS 6131 B- initially only as far as distance -a-.
• Dimension -a- = 100 mm (maximum).

– Remove bolts -1- and -3- for selector rod and push rod.
Note
Disregard
Protected by-item 2-.Copying for private or commercial purposes, in part or in whole, is not
copyright.


– Pry ball socket -2- of selector lever cable off gearbox selector
lever using removal lever - 80 - 200- .
– Press off securing clip -1- and remove selector lever cable
from gearbox.
Note
Take care not to bend or kink selector lever cable.

– Lower engine/gearbox assembly. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Pull out scissor-type assembly platform - VAS 6131 B- with
engine/gearbox assembly from underneath vehicle.
1.2 Separating engine and gearbox

⇒ “1.2.1 Separating engine and gearbox - manual gearbox 0B1”,
page 26
© satelettronica
⇒ “1.2.2 Separating engine and gearbox - multitronic gearbox
0AW”, page 30
⇒ “1.2.3 Separating engine and gearbox - dual clutch gearbox
0B5”, page 36
1.2.1 Separating engine and gearbox - man‐

ual gearbox 0B1
♦ Support -VAS 6131/13-7-

♦ Gearbox support - VAS 6131/14-
♦ Wrench, 21 mm - T40263-

♦ Turning-over tool - -
Procedure
• Engine/gearbox assembly removed and secured to scissor-
type assembly platform - VAS 6131 B-
– Remove electrical connector -3- for Lambda probe 2 after cat‐
alytic converter - G131- from bracket and unplug connector.
Note
© satelettronica
– Remove bolt -1- and nuts -arrows- and detach catalytic con‐
verter (left-side).
– Remove electrical connector -1- for Lambda probe after cata‐

lytic converter - G130- from bracket and unplug connector.
Note

verter (right-side).

and move wiring clear.
Note
Disregard -item 1-.
© satelettronica
Note
– Unbolt drive shafts (left and right) from gearbox flange shafts
⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .

– Fit turning-over tool - T40272- onto wrench (21 mm) -

T40263- .
– Position adapter on bolts of vibration damper.
• Hole -arrow A- on turning-over tool - T40272- must be posi‐
tioned between markings -arrows B- on vibration damper.
Note
If necessary, remove radiator fan control unit.
– Counterhold crankshaft using wrench (21 mm) - T40263- and

turning-over tool - T40272- when loosening bolts for clutch
module.
Note
© satelettronica
– Remove 6 bolts -arrow- for clutch module, turning crankshaft
60° in normal direction of rotation each time.

support set for Audi - VAS 6131/10- , support -VAS 6131/13-7-
and gearbox support - VAS 6131/14- as follows.
Note
The other support elements remain unchanged.
Platform Parts from support set for Audi - VAS 6131/10- ,

coordinates support -VAS 6131/13-7- and gearbox support -
VAS 6131/14-
D2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5

– Secure support -VAS 6131/13-7- in threaded hole for poly V-

belt tensioner at front left of engine with M8x35 bolt and
washer (outside diameter 25 mm), as illustrated.
– Secure support -VAS 6131/13-7- to scissor-type assembly
platform and tighten to 20 Nm.
– Position support elements from -VAS 6131/10- and gearbox

support - VAS 6131/14- at front of gearbox, as illustrated.
– Screw spindles on both sides upwards until gearbox support
- VAS 6131/14- makes full contact with gearbox.
© satelettronica
– Remove bolts -1- and -2- for starter.
– Unscrew remaining bolts -3 ... 11- securing engine to gearbox.
Note
Disregard -item A-.
– Loosen clamping bolts -1- on sides of scissor-type assembly

platform - VAS 6131 B- and pull rear section of platform to‐
gether with gearbox towards rear -arrow-.
1.2.2 Separating engine and gearbox - multi‐

tronic gearbox 0AW

♦ Support -VAS 6131/13-7- from support set,to Audi
with respect Q7 >2005
the correctness -
VAS 6131/13-
© satelettronica
♦ Wrench, 21 mm - T40263-
♦ Turning-over tool - T40272-

Procedure
Note
verter (left-side).
© satelettronica
Note
– Remove bolt -arrow- and detach ATF lines from gearbox.

Caution

with your hands.

gloves) to eliminate electrostatic charge.
Note

Note
Disregard -item 2-.

Note
© satelettronica
– Lift retaining clip -arrow- and detach connection
with respect from coolantof information in this document. Copyright by AUDI AG.
to the correctness
pipe (top).

– Remove bolts -arrows- and detach heat shield for drive shaft
(left-side).
– Unbolt drive shaft (left and right) from gearbox flange shafts
Note

– Remove bolts -arrows- and detach ATF cooler.
© satelettronica

T40263- .
Note

turning-over tool - T40272- when loosening bolts for dual-
mass flywheel.
Note

– Remove 6 bolts -arrow- for clutch module. Turn crankshaft

each time by 60° in direction of engine rotation.
Note

Note
© satelettronica
VAS 6131/14-
F2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5
– Secure support -VAS 6131/13-7- at tapped hole at front of en‐

gine (right-side) as illustrated.
Note
If bore has no thread, tap hole.


– Screw spindles upwards on both sides until mountings -
VAS 6131/11-4- make fullbycontact
Protected with gearbox.


Note
Disregard -item A-.

© satelettronica
1.2.3 Separating engine and gearbox - dual
clutch gearbox 0B5

♦ Support -VAS 6131/13-7- from support set, Audi Q7 >2005 -
VAS 6131/13-

♦ Wrench, 21 mm - T40263-
© satelettronica
Procedure permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Note
verter (left-side).

Caution

with your hands.

gloves) to eliminate electrostatic charge.
Note
Disregard -item 2-.
© satelettronica
Note

– Lift retaining clip -arrow- and detach connection from coolant

pipe (top).
(left-side).
© satelettronica
– Release hose clip -1- and detach ATF cooler from coolant pipe
on right side of gearbox.
– Swivel ATF cooler to the side.



T40263- .
Note

turning-over tool - T40272- when loosening bolts for dual-
mass flywheel.
© satelettronica
– Remove 6 bolts -arrow- for clutch module. Turn crankshaft
each time by 60° in direction of engine rotation.

support set for Audi - VAS 6131/10- , supplementary set -VAS
6131/11- and support -VAS 6131/13-7- as follows:
Note

coordinates supplementary set -VAS 6131/11- and support -
VAS 6131/13-7-
F2 /13-7
B10 /10-1 /10-3 /10-5 /11-4
G10 /10-1 /10-3 /10-5 /11-4


Note

– Position support elements from -VAS 6131/10- and mountings

-VAS 6131/11-4- at front of gearbox, as shown in illustration.
VAS 6131/11-4- make full contact with gearbox.
© satelettronica

Note
Disregard -item A-.

1.3 Securing engine to engine and gearbox support


equipment required
© satelettronica
♦ Engine and gearbox support - VAS 6095- with universal
mounting - VAS 6095/1- and bracket for V6 FSI engine,
Audi A6 - VAS 6095/1-5-
♦ Lift arm extension (workshop hoist) - VAS 6101-
Procedure
WARNING
Risk of accident!
♦ The engine can only be transported with the gearbox re‐
moved using the method described.
• Engine/gearbox assembly removed; engine separated from

gearbox.
• Engine secured with support -VAS 6131/13-7- .
– Detach poly V-belt from air conditioner compressor
⇒ “1.2 Removing and installing poly V-belt”, page 66 .

– Remove air conditioner compressor ⇒ Heating, air condition‐

ing; Rep. gr. 87 ; Air conditioner compressor; Detaching and
attaching air conditioner compressor at bracket .
– Unscrew nut -1- and detach bracket with electrical wiring from
subframe.
Note
Disregard -item 2-.
– Attach lifting tackle - 2024 A- to engine lifting eyes and work‐

shop hoist as shown in illustration.
Note
© satelettronica
WARNING
Risk of accident.
must be secured with locking pins -arrows-.
– Take up weight of engine with workshop hoist, but do not lift.
Note
Disregard -item 1-.

– Remove support -VAS 6131/13-7- from engine.

– Lift engine off engine cross member.

with bracket for air conditioner compressor.
© satelettronica
– Remove nut -1- and move earth wire clear at engine support.
– Unscrew bolts -arrows- and remove engine support (right-
side).
– Tie up starter on engine.
– Secure engine with universal mounting - VAS 6095/1- and

support bracket for V6 FSI engine, Audi A6 - VAS 6095/1-5-
to engine and gearbox support - VAS 6095- as shown in
illustration and tighten to 40 Nm.


♦ Ring spanner insert AF 16 - V.A.G 1332/14-
© satelettronica
Tightening torques
Note

Component Nm
Bolts/nuts M6 9
M7 15

Component Nm
M8 20
M10 40
M12 65
♦ Assembly mountings
gearbox; Tightening torques for gearbox / ⇒ Rep. gr. 37 ;
box
Procedure
Note

and O-rings.
© satelettronica
• Engine with subframe positioned on scissor-type assembly
platform - VAS 6131 B-
– Install engine supports and engine mountings
⇒ “2.1 Exploded view - assembly mountings”, page 52 .
– Before installing gearbox, remove residue from threaded holes
for engine/gearbox bolts in cylinder block using a thread tap.
and installing gearbox; Tightening torques for gearbox / ⇒
and gearbox:
dual-mass flywheel and gearbox housing from below, as illus‐
trated.
Note


– Insert transport lock - T40170- into gearbox housing and dual-

mass flywheel from below and clamp onto flange shaft -1-.
© satelettronica
sleeves.
-1, 6 … 11-.
Vehicles with 7-speed dual clutch gearbox 0B5:

sleeves.
-1, 6 … 10-.
Note
The following step is necessary to ensure that the dual-mass fly‐

wheel is straight and that it makes even contact with the drive
plate.
– Use assembly lever -1- to press dual-mass flywheel -2- slightly

against drive plate -3- in direction of -arrow-.

– Bolt dual-mass flywheel onto drive plate as follows:
Note
Use ring spanner insert AF 16 - V.A.G 1332/14- to tighten bolts.

T40263- .
Note
© satelettronica
– Turn crankshaft 180° further in normal direction of engine ro‐

tation -arrow- with wrench (21 mm) - T40263- and turning-over
tool - T40272- .
– Now tighten bolt accessible in this position to specified torque
⇒ Rep. gr. 30 ; Clutch; Exploded view - clutch module ; ⇒
Rep. gr. 30 ; Clutch; Exploded view - flywheel and dual clutch /
⇒ Rep. gr. 37 ; Removing and installing gearbox; Installing
gearbox .
– Turn crankshaft by 60° each time and tighten remaining 5 bolts
to specified torque ⇒ Rep. gr. 30 ; Clutch; Exploded view -
clutch module ; ⇒ Rep. gr. 30 ; Clutch; Exploded view -
flywheel and dual clutch / ⇒ Rep. gr. 37 ; Removing and
installing gearbox; Installing gearbox .
– Install ATF cooler ⇒ Rep. gr. 34 ; ATF circuit;
permitted Removing
unless authorised byand
installing ATF cooler / ⇒ Rep. gr. 37 ; with
ATF circuit; Removing
and installing ATF cooler .

– Install drive shafts and heat shield for drive shaft ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Exploded view
- drive shaft .
– Install ATF lines ⇒ Rep. gr. 37 ; ATF circuit; Removing and
installing ATF lines .
– Install catalytic converters
⇒ “1.1 Exploded view - silencers”, page 333 .
– Raise engine/gearbox assembly using scissor-type assembly
platform - VAS 6131 B- .


platform - VAS 6131 B- only until distance between subframe
and body is -a-.
• Dimension -a- = min. 100 mm.
– Install selector lever cable and adjust it if necessary ⇒ Rep.
gr. 34 ; Selector mechanism; Removing and installing selector
lever cable .
– Raise engine/gearbox assembly further using scissor-type as‐
sembly platform - VAS 6131 B- .
– Align subframe and gearbox carrier on longitudinal members
according to markings made before removal.
– Tighten subframe bolts only to specified torque (do not turn
further); the bolts should only be fully tightened after perform‐
ing the wheel alignment check ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Subframe; Exploded view - subframe .
WARNING
© satelettronica
Risk of accident if bolted connections are loose.
♦ Do NOT drive the vehicle unless the subframe bolts have
been tightened to their final torque.
– Tighten bolts for tunnel cross-piece ⇒ Rep. gr. 34 ; Assembly

mountings; Exploded view - assembly mountings / ⇒ Rep. gr.
37 ; Assembly mountings; Exploded view - assembly mount‐
ings .
– with
Install selector rod and push rod ⇒ Rep. gr. 34 ; Selector
mechanism; Exploded view - selector mechanism .

lever cable .
note the following:
Note
♦ Do not remove plugs or protective caps until you are ready to

fit the relevant line.
– Secure intermediate steering shaft to steering rack ⇒ Running

gear, axles, steering; Rep. gr. 48 ; Steering column; Removing
and installing intermediate steering shaft .

– Install front silencers

– Install upper suspension links and suspension strut ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Suspension strut,
upper links; Exploded view - suspension strut, upper links .
– Install subframe cross brace, anti-roll bar and heat shield ⇒
Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe .
– Install brake calipers ⇒ Brake system; Rep. gr. 46 ; Front
brakes; Removing and installing brake caliper .
– Install engine control unit
⇒ “8.2 Removing and installing engine/motor control unit J623
”, page 330 .
– Electrical connections and
permitted unless routing
authorised ⇒ Current
by AUDI AG. AUDI AG flowdoesdiagrams,
Electrical fault with
finding
respectand
to theFitting locations.

© satelettronica
– Install refrigerant lines ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; Exploded view - condenser .
ing battery .
Caution

sive voltage.
– Install air cleaner housing

page 285 .
ments .
chamber cover .
– Install front longitudinal member (bottom) ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Lock carrier; Exploded view - lock
carrier .
411 .
– Connect coolant hoses with plug-in connector
⇒ Fig. ““Connecting coolant hose with plug-in connector”“ ,
page 252 .

Note

– Charge refrigerant system ⇒ Air conditioner with refrigerant
R134a .
Wheels, tyres .
– Check wheel alignment ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheel alignment check; Wheel alignment procedure .
WARNING
© satelettronica
♦ Tighten subframe bolts to final setting after performing
wheel alignment check.

insulation .


Engine mounting
1 - Engine mounting
stalling engine mount‐
ings”, page 55
2 - Bolt
❑ 20 Nm
3 - Bracket
© satelettronica
fective
4 - Bolt
❑ 40 Nm
5 - Bolt
❑ 20 Nm
6 - Engine support
❑ Left-side: with bracket
for air conditioner com‐
pressor
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ Renew
❑ 90 Nm +90°
10 - Subframe
11 - Bolt
❑ 55 Nm
Gearbox mounting for manual gearbox 0B1


1 - Nut
mountings; Exploded
ings
2 - Bolt
mountings; Exploded
ings
3 - Bolt
mountings; Exploded
ings
4 - Nut
© satelettronica
mountings; Exploded Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
view - assembly mount‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ings
5 - Gearbox support
installing gearbox sup‐
port with gearbox
mounting - dual clutch
gearbox 0B5”,
page 62
installing gearbox mounting - manual gearbox 0B1”, page 61
7 - Stop (bottom)
8 - Bolt
Gearbox mounting for multitronic gearbox 0AW
1 - Nut
mountings; Exploded
ings
2 - Bolt
mountings; Exploded
ings
3 - Bolt
mountings; Exploded
ings
4 - Nut
© satelettronica
mountings; Exploded
ings with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Gearbox support
installing gearbox
mounting - multitronic
gearbox 0AW”,
page 62
7 - Stop (bottom)
8 - Bolt
Gearbox mounting for dual clutch gearbox 0B5

1 - Bolt
mountings; Exploded
ings
⇒ Rep. gr. 34 ; Assem‐
bly mountings; Explo‐
ded view - assembly
mountings
3 - Stop
4 - Gearbox mounting Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installingwith respect to the correctness of information in this document. Copyright by AUDI AG.
installing gearbox
mounting - dual clutch
gearbox 0B5”,
page 63
© satelettronica
5 - Bolt
mountings; Exploded
ings
6 - Nut
mountings; Exploded
ings
7 - Bolt
8 - Gearbox support
⇒ “2.3.4 Removing and installing gearbox support with gearbox mounting - dual clutch gearbox 0B5”,
page 62
9 - Bolt
10 - Nut

ings
Note

♦ Renew engine mounting and corresponding bracket.
© satelettronica
♦ Engine support (basic set) - T40091-
♦ Engine support bracket (supplementary set) - T40093-

Removing
– Pull off foam wedge -arrow- (left and right) upwards.
– Remove engine cover panel
⇒ “3.1 Removing and installing engine cover panel”,
page 64 .
Engine mounting (left-side) - vehicles with 2.5 ltr. engine:

– Set up support bracket - 10-222A- on suspension turrets (left
© satelettronica
Engine mounting (left-side) - vehicles with 2.8 ltr. engine:
and right) as Protected
illustrated.
– Attach spindle with
- 10-222A/11- to engine lifting eye (right-side).
– Attach further components of support bracket as shown in il‐

lustration. Position supports -T40093/3- on both sides on
flanges of longitudinal members (left and right).

– Partly take up weight of engine with spindle.
noise insulation .
Engine mounting (left-side):

– Place used oil collection and extraction unit - VAS 6622A- un‐
derneath.
– Remove bolts -arrows- and tie up engine oil coolerProtected
to one by side
with coolant hoses -1, 2- attached. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
– Remove bolts -1 and 2- and press coolant pipe (bottom left) to
the side.
Note
♦ Disregard -arrows-.
– Remove bolt -2- for subframe (left-side).
Note
Bolts -1- and -3- on left side and all bolts for subframe on right
side remain fitted.


subframe.
Note
Disregard -item 2-.

– Remove bolts -1- and -arrows- and place relevant retaining
plate to one side.
Note
Disregard -item 2-.
© satelettronica
– Using spindle - 10 - 222 A /11- -item 1-, raise engine through

distance -a- on corresponding side.
• Distance -a- = approx. 20 mm.
– Detach engine mounting on relevant side.
Installing
Note

– Install engine oil cooler
⇒ “2.1 Removing and installing engine oil cooler”, page 203 .
page 285 .
© satelettronica
– Install engine cover panel
page 64 .
Tightening torques
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe
♦ ⇒ General body repairs, exterior; Rep.
permitted gr.authorised
unless 66 ; Wheel
by AUDI housing
AG. AUDI AG does not guarantee or accept any liability
liners; Exploded view - wheel housing
with respectliner (front) of information in this document. Copyright by AUDI AG.
to the correctness


mounting
mounting - manual gearbox 0B1”, page 61
⇒ “2.3.3 Removing and installing gearbox mounting - multitronic
gearbox 0AW”, page 62
mounting - dual clutch gearbox 0B5”, page 62

gearbox 0B1
Removing
© satelettronica
Installing
Tightening torques
sembly mountings

mounting - manual gearbox 0B1
Removing
– Remove gearbox support with gearbox mounting
⇒ “2.3.4 Removing and installing gearbox support with gear‐
box mounting - dual clutch
Protected gearbox
by copyright. 0B5”,
Copying page
for private 62 . purposes, in part or in whole, is not
or commercial
– Unscrew bolts -1- and detach
with respect to thestop (bottom)
correctness -2- for
of information gearbox
mounting.
box support -3-.
Installing
– Install gearbox support with gearbox mounting
box mounting - dual clutch gearbox 0B5”, page 62 .
Tightening torques
sembly mountings

mounting - multitronic gearbox 0AW
Removing
mounting.
box support -3-.
Installing
Tightening torques
sembly mountings
© satelettronica
gearbox 0B5
Removing
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Tightening torques
sembly mountings


mounting - dual clutch gearbox 0B5
Removing
Installing
box mounting - dual clutch gearbox 0B5”, page 62 .
© satelettronica
Tightening torques
sembly mountings


panel
Removing
– Carefully pull engine cover panel off ball studs one after an‐
other -arrows-. Do not jerk engine cover panel away, and do
not try to pull on one side only.
© satelettronica
♦ One-piece version
♦ Two-piece version
Installing
– Observe oil filler neck when positioning engine cover panel
(one-piece version).
– First press the engine cover panel (one-piece version) with
both hands onto the ball studs at the rear and then onto the
ball studs at the front.

⇒ “1.1 Exploded view - poly V-belt drive”, page 65
page 68
68
1.1 Exploded view - poly V-belt drive
1 - Poly V-belt
❑ Check for wear
© satelettronica
stalling poly V-belt”,
page 66
❑ Do not kink
on pulleys
2 - Alternator
⇒ Electrical system;
Rep. gr. 27 ; Alternator;
alternator
3 - Bolt
Electrical system; Rep.
gr. 27 ; Alternator; Ex‐
ploded view - alternator
4 - Idler roller
❑ For poly V-belt
❑ 45 Nm
5 - Bolt
6 - Poly V-belt pulley
❑ For coolant pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7 - Bolt
8 - Coolant pump
❑ Removing and installing ⇒ “2.4 Removing and installing coolant pump”, page 231

❑ With poly V-belt pulley
❑ Removing and installing ⇒ “1.4 Removing and installing vibration damper”, page 68
10 - Tensioner
❑ For poly V-belt
❑ Removing and installing ⇒ “1.3 Removing and installing tensioner for poly V-belt”, page 68
❑ 40 Nm
11 - Engine support (left-side)
❑ With bracket for air conditioner compressor
12 - Bolt
13 - Bolt
14 - Bolt
© satelettronica
16 - Dowel sleeves
17 - Bolt
❑ Renew
❑ 20 Nm +90°

– Tighten bolts -arrows- in stages and in diagonal sequence; fi‐
nal torque 9 Nm.

Removing
– Remove engine cover panel (front)
page 64 .

WARNING

♦ Even when the ignition is switched off, the radiator fans
can start up without warning due to accumulated heat in
the engine compartment, etc.
Caution

irreparable damage.
♦ Mark direction of rotation of poly V-belt with chalk or felt-
tip pen for re-installation.
– Move tensioner in clockwise direction -arrow- to slacken poly

V-belt.
– Remove poly V-belt and release tensioner.
© satelettronica
Note
Ignore -T10060 A- .
Installing
Installation is carried out in reverse order; note thepermitted
following:
– Fit poly V-belt on pulleys as shown in illustration.
1- Alternator
2- Idler roller
3- Coolant pump
6- Vibration damper
Note

pulleys.

page 64 .


poly V-belt
Removing
– Remove poly V-belt
– If fitted, detach cover from tensioner.
– Remove bolt -1- and detach poly V-belt tensioner -2- from cyl‐
inder block.
Installing
– Install poly V-belt
Tightening torques
♦ ⇒ “1.1 Exploded view - poly V-belt drive”, page 65
© satelettronica
er
Removing
– Remove poly V-belt
– Unscrew bolts -1- and remove vibration damper.
Installing
Note

♦ Can only be installed in one position.

Tightening torques
♦ ⇒ “1.1 Exploded view - poly V-belt drive”, page 65

(pulley end)

♦ Pin wrench - 3212-
♦ Assembly tool - T40048A-
© satelettronica
♦ Electric drill with plastic brush
♦ Safety goggles
Procedure
noise insulation .
– Remove vibration damper
⇒ “1.4 Removing and installing vibration damper”, page 68 .
– Slacken bolts for coolant pump pulley (counterhold with pin
wrench - 3212- ).
– Remove bolts and take off poly V-belt pulley.

– Remove bolts -arrows- and release sealing flange (pulley end)

from bonded joint.
Note
Renew sealing flange (pulley end).
© satelettronica
Caution
Protect lubrication system against contamination.

WARNING
Risk of eye injury.

– Remove sealant residue from cylinder block and sump (top

section) -1- using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
Note
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5

mm).

Caution

– Apply bead of sealant -arrow- onto sealing surface of new

sealing flange (pulley end) as shown in illustration.
• The groove on the sealing surface must be completely filled
with sealant.
• The bead of sealant must project 1.5 … 2.0 mm above the
sealing surface.
Note
The sealing flange (pulley end) must be installed within 5 minutes

after applying the sealant.
© satelettronica
– Fit assembly aid -T40048/1- onto assembly sleeve -T40048/2-
and slide sealing flange -1- onto assembly sleeve.
– Detach assembly aid.

– First position sealing flange (with assembly sleeve -T40048/2-

inserted) on crankshaft.
– Keep sealing flange straight while pushing it onto engine seal‐
ing surface. Then bolt on
⇒ Fig. ““Sealing flange (pulley end) - tightening torque and se‐
quence”“ , page 66 .
note the following:
– Install poly V-belt pulley for coolant pump
⇒ “2.1 Exploded view - coolant pump/thermostat”,
page 228 .
– Install vibration damper
Tightening torques
♦ ⇒ Fig. ““Sealing flange (pulley end) - tightening torque and se‐
© satelettronica


⇒ “2.3 Removing and installing sender wheel”, page 75
⇒ “2.4 Checking sender wheel”, page 76
⇒ “2.5 Renewing crankshaft oil seal (gearbox end)”, page 77
Note
When performing assembly work, secure engine to engine and gearbox support - VAS 6095-
⇒ “1.3 Securing engine to engine and gearbox support”, page 41 .
1 - Drive plate
© satelettronica
❑ With bearing flange
❑ Check running surface
on bearing flange and
holes for clutch module
for cracks and scoring.
stalling drive plate”,
page 74
2 - Bolt
❑ Renew
❑Protected
60 Nm +90°
3 - Needle bearing

ual gearbox or multitron‐
ic gearbox 0AW (front-
wheel drive)
closed side towards en‐
gine
⇒ “2.6 Renewing needle
bearing in drive plate”,
page 79
4 - Sender wheel
er - G28-

Caution
Risk of magnetic fields
causing irreparable
damage to sender
wheel.
The
♦ sender wheel must
be kept away from mag‐
nets (e.g. base of torch,
loudspeaker).
If♦the drive plate/flywheel
or the sender wheel itself
has been removed or re‐
newed, check that the
sender wheel is operat‐
ing correctly before in‐
stallation
⇒ “2.4 Checking sender
wheel”, page 76 .
❑ Removing and installing ⇒ “2.3 Removing and installing sender wheel”, page 75
❑ Checking ⇒ “2.4 Checking sender wheel”, page 76
© satelettronica
5 - Crankshaft
6 - Dowel pin
7 - Oil seal
❑ For crankshaft (gearbox end)
❑ Renewing ⇒ “2.5 Renewing crankshaft oil seal (gearbox end)”, page 77

♦ Counterhold tool - 10-201-

Removing
– Insert counterhold tool - 10-201- to slacken bolts.
Caution

drive plate.
– Remove bolts and take off drive plate and sender wheel.
Installing
Note
© satelettronica

– Fit counterhold tool - 10-201- the other way round to tighten
bolts.
Tightening torques
page 73
2.3 Removing and installing sender wheel

Removing
– Remove drive plate
⇒ “2.2 Removing and installing drive plate”, page 74 .
Caution
Risk of magnetic fields causing irreparable damage to sender

wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation
⇒ “2.4 Checking sender wheel”, page 76 .

– Detach sender wheel -arrow-.

Installing
– Install drive plate
2.4 Checking sender wheel

♦ Magnetic lens - T10473-
© satelettronica
Procedure
• Sender wheel removed
Caution

wheel.
is operating correctly before installation.
– Check whole circumference of sender wheel using magnetic

lens - T10473- as shown in illustration.

Inspection image of sender wheel

A - Sender wheel OK
B - Sender wheel defective
2.5 Renewing crankshaft oil seal (gearbox

end)
© satelettronica
♦ Fitting tool - T10122 A-
♦ Guide piece - T10122/6-

♦ Extractor hook - T20143/2-

Procedure
– Pry out oil seal using extractor tool -T20143/2- .
– Fit assembly aid -T10122/1- onto guide piece - T10122/6- and

slide oil seal -A- onto guide piece.
– Detach assembly aid -T10122/1- .
© satelettronica
– Fit guide piece - T10122/6- onto crankshaft.
– Bolt guide piece to crankshaft through securing points -A- us‐
ing bolts -arrows-.
Caution
Risk of leaks if installed incorrectly.

♦ Slide oil seal onto crankshaft
Protected byCopying
by copyright. handfortoprivate
prevent sealing
lip on oil seal from folding
permitted unlessover.
– Slide oil seal over guide piece - T10122/6- onto crankshaft by

hand.
– Press in oil seal evenly all round using thrust piece -

T10122/5- .
– Remove guide piece - T10122/6- .
– Check that oil seal and its sealing lip are correctly seated. If
sealing lip is partially folded over, repeat procedure with a new
oil seal.

Note
The needle bearing in the drive plate is only fitted in vehicles with
manual gearbox or with multitronic gearbox 0AW.

♦ Thrust plate - VW 402-
© satelettronica
♦ Tube - VW 418 A-
♦ Tube - VW 421-

♦ Support - 40-103-
Procedure
– Place support - 40-103- under drive plate when pressing out
© satelettronica
bearing.

gine.
⇒ “2.2 Removing and installing drivebyplate”,
Protected copyright. page
Copying74 .

3 Crankshaft
Note

❑ Renewing
© satelettronica
(pulley end)”, page 68
2 - Bolt
sequence
⇒ Fig. ““Sealing flange
(pulley end) - tightening
torque and sequence”“ ,
page 66
3 - Crankshaft
❑ Measuring axial clear‐
ance
⇒ “3.3 Measuring axial
clearance of crank‐
shaft”, page 85
❑ Measuring radial clear‐
ance
⇒ “3.4 Measuring radial
shaft”, page 85
❑ Crankshaft dimensions
⇒ “3.2 Crankshaft di‐
mensions”, page 85
4 - Dowel sleeve
❑ 4x
❑ Inserting in retaining
frame
⇒ Fig. ““Applying seal‐
permitted unless ant to retaining
authorised by AUDI AG.frame,
with respect toposition of dowel
sleeves”“ , page 83
5 - Seal
❑ Renew
6 - Bolt
❑ For sealing surfaces: retaining frame to cylinder block
❑ Differing bolt lengths and bolt heads
❑ Renew
❑ Tightening torque and sequence ⇒ Fig. ““Installing retaining frame”“ , page 84
3. Crankshaft 81
7 - Bolt
❑ Long, large collar
❑ For retaining frame (inner row)
❑ Renew
8 - Bolt
❑ Short, small collar
❑ For retaining frame (outer row)
❑ Renew
9 - Retaining frame
❑ With valve for oil pressure control - N428- ⇒ Fig. ““ Valve for oil pressure control -N428- ”“ , page 83
❑ To remove, detach guide rail ⇒ Item 1 (page 111) for drive chain for valve gear
❑ Applying sealant ⇒ Fig. ““Applying sealant to retaining frame, position of dowel sleeves”“ , page 83
❑ Removing and installing valve for oil pressure control - N428-
⇒ “4.6 Removing and installing valve for oil pressure control N428 ”, page 214
10 - Seal
© satelettronica
❑ Renew
11 -Protected
Thrustbywasher
❑ with Only fitted
respect to theon 3rd crankshaft
correctness bearing
❑ Installation position: oil groove faces outwards

❑ Make sure it engages in retaining frame
12 - Bearing shell
❑ For retaining frame (without oil groove)
❑ Renew used bearing shells
❑ Install new bearing shells for retaining frame with correct coloured markings
⇒ Fig. ““Matching crankshaft bearing shells to bearings in retaining frame”“ , page 84
13 - Thrust washer
❑ Only fitted on 3rd crankshaft bearing
14 - Bearing shell
❑ For cylinder block (with oil groove)
❑ Install new bearing shells for the cylinder block with the correct coloured markings
⇒ Fig. ““Matching crankshaft bearing shells to bearings in cylinder block”“ , page 84
15 - Cylinder block

Plug for “TDC” marking - tightening torque
Note
Fit new O-ring.
– Tighten plug -arrow- to 14 Nm.
Valve for oil pressure control - N428-

1- Electrical connector
2- O-ring - renew
3- Bolt, 9 Nm
4- Valve for oil pressure control - N428-
© satelettronica
Applying sealant to retaining frame, position of dowel sleeves

– Apply sealant beads -arrows- onto clean sealing surfaces of
retaining frame as shown in illustration.
with sealant.
• The beads of sealant must project 1.5 … 2.0 mm above the
sealing surface.
– Fit seals -1- and -2-.
– Check that dowel sleeves -3 ... 6- are inserted in retaining
frame at positions shown in illustration.
3. Crankshaft 83
Installing retaining frame
Note
– Install long bolts in inner row on retaining frame.

– Tighten bolts in stages in the sequence shown:
1. -1 … 16- 50 Nm
2. -1 … 16- Turn 90° further
3. -17 … 31- 20 Nm
4. -17 … 31- Turn 90° further
Matching crankshaft bearing shells to bearings in cylinder block
© satelettronica
♦ Bearing shells of the correct thickness are matched to the
bearings in the cylinder block at the factory. Coloured dots on
the side of the bearing shells are used to identify the bearing
shell thickness.
♦ The allocation of the bearing shells to the bearing positions in
the cylinder block is indicated by a code letter at the relevant
bearing on the retaining frame.
Code letter on retaining frame Colour coding of bearing
R = Red
G = Yellowby AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
B = Blue
S = Black
Matching crankshaft bearing shells to bearings in retaining frame

bearings in the retaining frame at the factory. Coloured dots
on the side of the bearing shells are used to identify the bear‐
ing shell thickness.
the retaining frame is indicated by a sequence of letters on the
flywheel flange on the crankshaft. The first letter in the se‐
quence stands for bearing “1”, the second letter for bearing
“2”, etc.
Letter on crankshaft Colour coding of bearing
R = Red
G = Yellow
B = Blue
S = Black


Honing di‐ Main bearing journal ∅ Conrod journal ∅
mension mm mm
Basic dimen‐ 58.000 – 0.022 54.000 – 0.022
sion – 0.042 – 0.042

© satelettronica
Procedure
bracket - VW 387- to cylinder block as shown in illustration.
– Apply dial gauge to crank web.
– withPress
respect crankshaft against dialingauge by hand and set gauge to
to the correctness of information this document. Copyright by AUDI AG.
“0”.
• Axial clearance: 0.15 ... 0.25 mm

shaft
♦ Plastigauge
Procedure
– Remove retaining frame and clean bearing journals.
3. Crankshaft 85

ing shell.
– Fit retaining frame, secure with old bolts and tighten to final
torque ⇒ page 81 without rotating crankshaft.
Radial clearance:
• New: 0.015 ... 0.055 mm.
© satelettronica

4 Balance shaft
⇒ “4.1 Exploded view - balance shaft”, page 87
⇒ “4.2 Removing and installing balance shaft”, page 87
4.1 Exploded view - balance shaft
1 - Balance shaft
stalling balance shaft”,
page 87
2 - Bolt
❑ 60 Nm
3 - Balance weight (gearbox
end)
❑ Can only be fitted on
balance shaft in one po‐
sition.
© satelettronica
4 - Bearing plate
5 - Bolt
❑ 13 Nm
6 - Balance weight (pulley end)
sition.

4. Balance shaft 87
♦ Locating pins - T40116-
Removing
– Remove sealing flange (pulley end)
⇒ “1.5 Removing and installing sealing flange (pulley end)”,
page 68 .
© satelettronica
– Remove timing chain cover (bottom)
⇒ “1.2.2 Removing and installing timing chain cover (bottom)”,
page 102 .
– Remove drive chain for auxiliary drives
⇒ “2.7 Removing and installing drive chain for balance shaft
and oil pump”, page 127 .
– Use locating pin -T40116- to lock balance weight -1- in position
at rear of engine.
– Unscrew bolt -2- and detach balance weight from balance
shaft.
– Unscrew bolt -2- (counterhold balance weight -1- with a suit‐

able pin) and detach balance weight at front of engine from
balance shaft. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Unscrew bolts -arrows- and detach bearing plate for balance

shaft at rear of engine.
– Pull balance shaft to rear out of cylinder block.
Installing
• Crankshaft -1- locked in “TDC” position with locking pin -
T40069- .
Note
© satelettronica
Balance weights can only be fitted on balance shaft in one posi‐
tion.
– Install drive chain for auxiliary drives

– Install timing chain cover (bottom)
page 102 .
– Install sealing flange (pulley end)
page 68 .
Tightening torques
♦ ⇒ “4.1 Exploded view - balance shaft”, page 87
4. Balance shaft 89

page 94
Note

♦ Oil spray jet for piston cooling ⇒ Fig. ““Oil spray jet for piston cooling”“ , page 92 .
1 - Bolts
❑ Renew
© satelettronica
ance
contact surface
❑ 40 Nm +90°
❑ Mark cylinder and con‐
rod allocation in colour
-B-
⇒ Fig. ““Marking con‐
rods”“ , page 91
❑ Note when fitting bear‐
ing cap: the wide con‐
tact shoulder -A- must
point towards same side
on conrod and conrod
bearing cap
❑ Installation position of
conrod pairs
⇒ Fig. ““Conrod installa‐
tion position”“ ,
page 92
3 - Bearing shells
❑ Ensure that retaining
lugs are securely seat‐
ed.
shells
❑ There
Protected are oversized
bearings
permitted available
unless authorised for
machined crankshaft
conrod journals ⇒ Elec‐

tronic parts catalogue
❑ Lugs on conrod bearings must be on the same side
4 - Conrod
❑ Mark cylinder and conrod bearing cap allocation in colour ⇒ Fig. ““Marking conrods”“ , page 91

❑ Installation position of conrod pairs ⇒ Fig. ““Conrod installation position”“ , page 92

❑ Axial clearance for each conrod pair (when new): 0.20 … 0.45 mm
❑ Measuring radial clearance ⇒ “5.4 Checking radial clearance of conrod bearings”, page 94
5 - Piston pin
❑ Removing and installing ⇒ “5.2 Removing and installing pistons”, page 92
6 - Circlip
❑ Renew
7 - Piston
❑ Note cylinder bank allocation markings ⇒ Fig. ““Installation position of pistons”“ , page 91
❑ Mark installation position and cylinder number ⇒ Fig. ““Installation position of pistons”“ , page 91
❑ Renew piston if cracking is visible on piston crown or piston skirt
❑ Checking pistons and cylinder bores ⇒ “5.3 Checking pistons and cylinder bores”, page 93
8 - Piston rings
❑ Measuring ring gap ⇒ Fig. ““Measuring piston ring gap”“ , page 94
❑ Measuring ring-to-groove clearance ⇒ Fig. ““Measuring ring-to-groove clearance”“ , page 94
❑ Use piston ring pliers (commercially available) to remove and install
© satelettronica
Installation position of pistons
Caution
Do not damage the coating of the piston crown.

♦ If you intend to re-install used pistons, mark the cylinder
number on the piston crown using paint. Do not attempt to
mark the piston crown with a centre punch or by making
a notch or similar.
Installation position: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1- Arrows on piston crowns point to pulley end.with respect to the correctness of information in this document. Copyright by AUDI AG.
2- Markings must be made indicating cylinder allocation
3- Cylinder allocation markings: “R” = right, “L” = left
Marking conrods
Note
Only renew conrods as a complete set.
– Use a coloured pen to mark matching conrods and conrod

bearing caps with cylinder numbers -arrow- for re-installation.

Conrod installation position

• The cast lugs -arrows- on the ground surfaces of the conrod
pairs “1 and 2”, “3 and 4”, and “5 and 6” must face each other.
Oil spray jet for piston cooling

1- Apply locking fluid to bolt and tighten to 9 Nm; for locking
fluid refer to ⇒ Electronic parts catalogue .
2- Oil spray jet with spray nozzle valve
Caution
© satelettronica

♦ Drift - VW 222 A-

Removing
• Engine secured to engine and gearbox support - VAS 6095-
⇒ “1.3 Securing engine to engine and gearbox support”, page
41
– Remove cylinder head Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “3.2 Removing and installing cylinder head”, pagewith136 . to the correctness of information in this document. Copyright by AUDI AG.
respect
– Remove sump (top section)

⇒ “1.4 Removing and installing sump (top section)”,
page 199 .
to cylinder and to conrods for re-installation
⇒ Fig. ““Marking conrods”“ , page 91 .

Note

Installing
Note

© satelettronica
• Pistons ⇒ Fig. ““Installation position of pistons”“ , page 91
• Conrods ⇒ Fig. ““Conrod installation position”“ , page 92
– Install sump (upper section)
page 199 .
– Install cylinder head
⇒ “3.2.1 Removing and installing cylinder head - camshafts
with assembly clearance feature”, page 136 .
Tightening torques

Checking piston
Piston ∅ mm
2.5 ltr. engine 2.8 ltr. engine
Nominal dimension 80.1851) 84.491)
• 1)
Dimensions including coating (thickness approx. 0.02
mm). The coating will wear down in service.


-B-.
Cylinder bore ∅ mm
2.5 ltr. engine 2.8 ltr. engine
Nominal dimension 80.2101) 84.511)
• 1) Measure at 50 mm into cylinder bore.
© satelettronica
of cylinder.
mm mm

mm mm
Compression rings 0.02 … 0.08 0.20

bearings

♦ Plastigauge
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.

– Fit conrod bearing cap and tighten with old bolts

⇒ Item 1 (page 90) . Do not rotate crankshaft.
Radial clearance:
• New: 0.010 ... 0.052 mm.
© satelettronica


⇒ “1.1 Exploded view - timing chain cover”, page 96
⇒ “1.2 Removing and installing timing chain cover”, page 99
1.1 Exploded view - timing chain cover
1 - Bolt
sequence
⇒ Fig. ““Timing chain
cover (bottom) - tighten‐
ing torque and se‐permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
quence”“ , page 98with respect to the correctness of information in this document. Copyright by AUDI AG.
2 - Oil seal
❑ For crankshaft (gearbox
end)
© satelettronica
❑ Renewing
⇒ “2.5 Renewing crank‐
shaft oil seal (gearbox
end)”, page 77
3 - Bolt
sequence
ing torque and se‐
4 - Dowel sleeve
❑ 2x
5 - Threaded pin
6 - Cylinder head gasket (left-
side)
7 - Bolt
❑ Renew
sequence
cover (left-side) - tight‐
ening torque and sequence”“ , page 98
8 - Bracket
❑ For heat shield
9 - Timing chain cover (left-side)
⇒ “1.2.1 Removing and installing timing chain covers (left and right)”, page 99
10 - Bracket
❑ For wiring harness
11 - Bolt
❑ Renew

❑ Tightening torque and sequence

⇒ Fig. ““Timing chain cover (left-side) - tightening torque and sequence”“ , page 98
12 - Bracket
❑ For electrical connectors for Lambda probes (left-side)
13 - Bolt
14 - Gaskets
❑ Renew
15 - Bracket
❑ For electrical connectors for Lambda probes (right-side)
16 - Bolt
17 - Bolt
⇒ Fig. ““Timing chain cover (right-side) - tightening torque and sequence”“ , page 98
18 - Bracket
© satelettronica
❑ For electrical connectors
19 - Timing chain cover (right-side)
⇒ “1.2.1 Removing and installing timing chain covers (left and right)”, page 99
20 - Sleeve
❑ Prevents sealant from entering bolted connection between engine and gearbox
❑ Installation instructions ⇒ page 106
21 - Cylinder head gasket (right-side)
22 - Bracket
❑ For heat shield
23 - Bolt
❑ Renew
24 - Dowel sleeve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 2x with respect to the correctness of information in this document. Copyright by AUDI AG.
25 - Bolt
⇒ Fig. ““Timing chain cover (bottom) - tightening torque and sequence”“ , page 98
26 - Timing chain cover (bottom)
❑ Removing and installing ⇒ “1.2.2 Removing and installing timing chain cover (bottom)”, page 102
❑ Removing and installing ⇒ “1.6 Removing and installing engine speed sender G28 ”, page 381
28 - Bolt
❑ Tightening torque ⇒ “1.1 Exploded view - ignition system”, page 371

Timing chain cover (left-side) - tightening torque and sequence
Note

♦ The brackets -arrows A and B- are secured together with the
timing chain cover (left-side).
– Tighten bolts inpermitted
2 stages unlessinauthorised
the sequence
by AUDI AG.shown:
1. -1 … 8- 5 Nm
Timing chain cover (right-side) - tightening torque and sequence
Note
© satelettronica
timing chain cover (right-side).

1. -1 … 8- 5 Nm
Timing chain cover (bottom) - tightening torque and sequence
Note
– Tighten bolts in stages as follows:

1. -arrows- 3 Nm
3. -1, 2, 4, 5, 7- Turn 90° further
4. -arrows- 9 Nm
5. -8, 9, 10- 8 Nm
6. -8, 9, 10- Turn 90° further
7. -3- 16 Nm
8. -6- 20 Nm
9. -6- Turn 180° further

1.2 Removing and installing timing chain

cover
⇒ “1.2.1 Removing and installing timing chain covers (left and
right)”, page 99
page 102
1.2.1 Removing and installing timing chain

covers (left and right)
♦ Safety goggles
Removing
Note
© satelettronica
– Remove engine cover panel (rear)

page 64 .
Timing chain cover (left-side):
– Remove combination valve for secondary air (left-side)
⇒ “3.4.1 Removing and installing combination valve (left-
side)”, page 358 .
– Remove bolts -1- and move bracket with electrical connectors
to one side.
Note
– Unscrew bolts -1 ... 8- and detach brackets -arrows A, B-.

– Carefully release timing chain cover (left-side) from bonded
joint and detach.

Timing chain cover (right-side):

– Remove combination valve for secondary air (right-side)
⇒ “3.4.2 Removing and installing combination valve (right-
5 - For Lambda probe after catalytic converter - G130-
Note
Disregard -items 1, 2 and 3-.

to one side.
Note
© satelettronica
– Move wiring harness clear at timing chain cover (right-side).

– Carefully release timing chain cover (right-side) from bonded
joint and detach.
Installing
Note


– Remove old sealant from sealing surfaces.
Caution

WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain covers -1-, cylinder

block and cylinder head using rotating plastic brush or similar.
© satelettronica
Note

2 mm).

Caution

– Apply sealant bead -arrow- onto clean sealing surface of tim‐

ing chain cover as shown in illustration.
• Width of sealant bead: 2.5 mm.
Note
The timing chain covers must be installed within 5 minutes after

applying sealant.
– Install timing chain cover (left-side) and tighten bolts

⇒ Fig. ““Timing chain cover (left-side) - tightening torque and
sequence”“ , page 98 .
– Install timing chain cover (right-side) and tighten bolts
© satelettronica
⇒ Fig. ““Timing chain cover (right-side) - tightening torque and
note the following:
– Install combination valve for secondary air system: left-side
side)”, page 358 , right-side
side)”, page 360 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

page 64 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (left-side) - tightening torque and
sequence”“ , page 98
♦ ⇒ Fig. ““Timing chain cover (right-side) - tightening torque and

cover (bottom)
♦ Safety goggles
Removing

Note

– Remove timing chain covers (left and right)
right)”, page 99 .
– Remove oil filter housing
⇒ “4.5 Removing and installing oil filter housing”, page 212 .
– Unplug electrical connector -3- at starter (push retainer to the
rear and press down release catch).
– Remove nut -2- for electrical wiring and detach starter.
Note
© satelettronica
– Carefully release timing chain cover (bottom) from bonded
joint and remove cover.
– Press crankshaft oil seal (gearbox end) out of timing chain
cover (bottom).

Installing
Note
– Pull dowel sleeve at top right out of cylinder block.

– Bevel the dowel sleeve with a file, as illustrated.
• Dimension -x- = 6.5 mm.
• Dimension -y- = 8 mm.
– Fit dowel sleeve on cylinder block in such a way that the bev‐
elled side points upwards.
Note
Bevelling the dowel sleeve makes it easier to fit the timing chain
cover (bottom) with the cylinder head installed.
© satelettronica
Caution

WARNING
Risk of eye injury. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Put on safety goggles. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove remaining sealant on timing chain cover -1-, cylinder


– Clean old sealant from holes -arrow- in cylinder head gaskets.
Note
With the cylinder head installed the holes in the cylinder head
gasket are only half visible.
© satelettronica
Caution
Avoid damage to cylinder head gasket.

♦ Only bend the ends of the cylinder head gaskets slightly
and do not kink.
Note
If the cylinder head gasket has been bent and kinked it must be
renewed.
– Carefully bend the ends of the cylinderProtected

head gaskets down
very slightly -arrows-, just far enough topermitted
be able to authorised
unless clean the by AUDI AG. AUDI AG does not guarantee or accept any liability
upper sealing surface on the cylinder headwithgasket and
respect to cylinder of information in this document. Copyright by AUDI AG.
the correctness
head.
– Clean cylinder head gaskets (top and bottom); they must be
free of oil and grease.
Note

2 mm).
Note
The sealant must be applied at several points on the engine as

described below.

– Apply a small amount of sealant to sealing surfaces of cylinder

head gaskets (top and bottom). To do so, you again have to
bend cylinder head gaskets down very slightly -arrows-.
– Use a flat object (e.g. a feeler gauge) to apply sealant to the
area between cylinder head and gasket.
– Clean holes -arrow- in cylinder head gaskets and fill them with
sealant.
© satelettronica
Caution
Risk of sealant entering hole for gearbox bolt.

♦ Appropriate sleeve -1- ⇒ Electronic parts catalogue must
be fitted before installing timing chain cover (bottom).
♦ Projection of sleeve -a- = 3 mm above the sealing surface.
Note
Sleeves -1- and -2- have different diameters and are not inter‐
changeable.

Caution

– Apply sealant beads -1 ... 4- onto the clean sealing surfaces

of the timing chain cover (bottom) as illustrated.
with sealant.
sealing surface.
• Apply sealant -2- in a continuous bead as shown in illustration
(although groove is not continuous).
Note
The timing chain cover must be installed within

private 5 minutespurposes,
after in part or in whole, is not
© satelettronica
Protected by copyright. Copying for or commercial
applying sealant. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Insert seals -arrows- in grooves on timing chain cover (bot‐

tom).
– Fit timing chain cover (bottom), guiding it towards the sealing
surface on cylinder block and cylinder head at an angle and
from below.
– Take care not to damage the cylinder head gaskets when fit‐
ting the cover.
– Tighten bolts for timing chain cover (bottom)
⇒ Fig. ““Timing chain cover (bottom) - tightening torque and
note the following:
– Install crankshaft oil seal (gearbox end)
⇒ “2.5 Renewing crankshaft oil seal (gearbox end)”,
page 77 .
– Install oil filter housing
– Install timing chain covers (left and right)
411 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (bottom) - tightening torque and
♦ ⇒ Electrical system; Rep. gr. 27 ; Starter; Exploded view -
starter

2 Chain drive
⇒ “2.2 Exploded view - drive chain for valve gear”, page 111
⇒ “2.3 Exploded view - drive chain for balance shaft and oil pump”,
page 113
page 114
page 124
⇒ “2.6 Removing and installing drive chain for valve gear”,
page 125
⇒ “2.7 Removing and installing drive chain for balance shaft and
oil pump”, page 127

Camshaft timing chain (left-side)
© satelettronica
1 - Bolt
❑ Renew
❑ 80 Nm +90°
2 - Bolt
❑ Renew
❑ 80 Nm +90°
3 - Camshaft adjuster
❑ For exhaust camshaft
❑ Identification: “EX”
⇒ “2.4 Removing cam‐
shaft timing chain from
camshafts”, page 114
❑ For inlet camshaft
❑ Identification: “IN”
5 - Camshaft timing chain (left-
side)
❑ Mark direction of rota‐
with a paint marker
❑ Removing from cam‐
shafts
camshafts”, page 114 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.

6 - Bolt
❑ 9 Nm
7 - Slide
8 - Chain tensioner
❑ For camshaft timing chain (left-side)
❑ Removing and installing ⇒ “2.4 Removing camshaft timing chain from camshafts”, page 114
9 - Bearing plate
❑ For drive chain sprocket
10 - Bolt
11 - Drive chain sprocket
12 - Bearing mounting
❑ For drive chain sprocket for camshaft timing chain (left-side)
13 - Bolts
© satelettronica
Camshaft timing chain (right-side)
1 - Bolt
❑ Renew
❑ 80 Nm +90°
❑ Renew
❑ 80 Nm +90°
5 - Bolt
for camshaft timing
chain (right-side)
❑ Asymmetric version
⇒ Fig. ““Installation po‐
sition: bearing mounting
2. Chain drive 109

for drive sprocket for camshaft timing chain (right-side)”“ , page 112
❑ For camshaft timing chain (right-side)
⇒ Fig. ““Installation position: bearing mounting for drive sprocket for camshaft timing chain (right-side)”“ ,
page 112
8 - Camshaft timing chain (right-side)
❑ Mark direction of rotation for re-installation with a paint marker
❑ Removing from camshafts ⇒ “2.4 Removing camshaft timing chain from camshafts”, page 114
❑ Removing and installing ⇒ “2.5 Removing and installing camshaft timing chain”, page 124
9 - Thrust washer
❑ For drive chain sprocket for camshaft timing chain (right-side)
page 112
10 - Chain tensioner
© satelettronica
11 - Slide
12 - Bolt
❑ 9 Nm

2.2 Exploded view - drive chain for valve gear
1 - Guide rail
2 - Bolt
❑ Renew
❑ 10 Nm +90°
❑ Renew permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 30 Nm +90°
4 - Bolts
❑ Renew
❑ 5 Nm +90°
for camshaft timing
chain (left-side)
© satelettronica
❑ For camshaft timing
chain (left-side)
7 - Bolt
❑ Renew
❑ 8 Nm +45°
8 - Bearing plate
for camshaft timing
chain (left-side)
9 - Drive chain
❑ For timing drive
running direction with
paint
❑ Removing and installing ⇒ “2.6 Removing and installing drive chain for valve gear”, page 125
10 - Guide rail
11 - Bolt
❑ Renew
❑ 10 Nm +90°
12 - Thrust washer
page 112
page 112
2. Chain drive 111

15 - Seal
❑ Renew
17 - Bolt
❑ 9 Nm
18 - Crankshaft
Installation position: bearing mounting for drive sprocket for cam‐

shaft timing chain (right-side)
• Dowel pins in bearing mounting -3- for drive sprocket for cam‐
shaft timing chain (right-side) must engage in drillings in thrust
washer -1- and in cylinder block drillings.
2 - Drive sprocket for camshaft timing chain (right-side)
4 - Bolt
© satelettronica

2.3 Exploded view - drive chain for balance shaft and oil pump
1 - Crankshaft
2 - Drive chain
❑ For auxiliary drives
with a paint marker
stalling drive chain for
balance shaft and oil
pump”, page 127
❑ For oil pump
Side with lettering faces
engine
4 - Bolt
© satelettronica
❑ Renew
❑ 30 Nm +90°
5 - Compression spring
6 - Bolt
❑ Renew
❑ 15 Nm +90°
7 - Chain sprocket for balance
shaft with respect to the correctness of information in this document. Copyright by AUDI AG.
gearbox
8 - Chain tensioner
❑ With guide rail
9 - Bolt
❑ Renew
❑ 10 Nm +45°
2. Chain drive 113

2.4 Removing camshaft timing chain from camshafts

equipment required
© satelettronica
♦ Used oil collection and extraction unit - VAS 6622A- or -V.A.G
1782-
♦ Socket - T10035-
♦ Counterhold tool - T10172- with -T10172/2-
♦ Locking bolt - T40069-
♦ 2x Locking pin - T40071-

♦ 2x Camshaft clamp - T40133-
♦ Wrench, 21 mm - T40263-
© satelettronica
Removing
WARNING

Note
♦ In the following procedure the camshaft timing chains remain

on the engine.
♦ Even when working on one cylinder head only, the procedure
must still be carried out on both cylinder banks.
2. Chain drive 115


– Remove cylinder head cover (left and right)
⇒ “3.3 Removing and installing cylinder head cover”,
page 161 .
noise insulation .
– Detach poly V-belt from tensioner
derneath.
– Remove bolts -arrows- and tie up engine oil cooler to one side
with coolant hoses -1, 2- attached.
© satelettronica
WARNING

Caution

– Detach air conditioner compressor from bracket and tie up on

longitudinal member (left-side) with lines/wiring connected.
Note
Disregard -item 1-.


T40263- .
Note
– Turn crankshaft to TDC in normal direction of engine rotation

-arrow- using wrench (21 mm) - T40263- and turning-over tool
- T40272- .
– Unscrew plug -arrow- for “TDC” marking from cylinder block.
© satelettronica
Note
♦ The bore provided for locking the crankshaft is difficult to see

when the engine is installed.
♦ Therefore, turn the engine until the small notch -1- on the vi‐
bration damper is in line with the housing joint -2- between the
cylinder block and the retaining frame on the left side (as seen
in direction of travel). This makes it easier to screw in locking
pin - T40069- .
♦ The marking on the vibration damper is only
permitted a authorised
unless visual aid. The
exact “TDC” position can only be obtained bytoscrewing
with respect in ofthe
the correctness information in this document. Copyright by AUDI AG.
locking pin - T40069- .
• The threaded holes -arrows- in the camshafts must face up‐

wards.
2. Chain drive 117

– Screw locking pin - T40069- into bore (tightening torque:

20 Nm); if necessary, turn crankshaft backwards and forwards
slightly to fully centralise locking pin.
– Fit camshaft clamps - T40133- onto both cylinder heads and

tighten bolts -arrows- to 25 Nm.
Note
The illustration shows the left-side cylinder head.
© satelettronica
Cylinder bank 1 (right-side):
– Press guide rail of chain tensioner for camshaft timing chain
(right-side) inwards as far as the stop using a screwdriver
-1-. Then lock chain tensioner by inserting locking pin -
T40071- .
Note
The chain tensioner is oil-damped and can therefore only be

compressed slowly by applying constant pressure.
Cylinder bank 2 (left-side):

– Press guide rail of chain tensioner for camshaft
Protected by copyright. timing
Copying for chain
(left-side) inwards as far aspermitted
the stop using a screwdriver -1-.
Then lock chain tensioner by inserting locking pin - T40071- .

Note


Continued for both cylinder banks:
Caution
Risk of damage to camshafts.

♦ Do NOT use camshaft clamp - T40133- to counterhold
when loosening camshaft adjuster bolt.
– Apply socket -T40269- to counterhold at corresponding cam‐

shaft adjuster and loosen bolt -1-.
– Mark position of camshaft adjusters with paint for re-installa‐
tion.
Caution
Risk of irreparable damage to engine.

♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine.
© satelettronica
tion.

– Unscrew bolts -1 and 2- and detach both camshaft adjusters.

Installing
Note

Caution

the camshafts are turned.
2. Chain drive 119

• Drive chain for valve gear installed

page 125
• Crankshaft locked in “TDC” position with locking pin -
T40069- .
• Camshaft clamps - T40133- installed on both cylinder heads
and tightened to 25 Nm -arrows-.
Note
© satelettronica
Caution
Risk of damage to engine.

♦ When performing the following steps, make sure to fit
camshaft adjusters so that the grooves -1- and -4- are
aligned with the adjustment areas (ground surfaces) -2-
and -3-.

– Fit camshaft adjusters according to marks applied during re‐
moval.
– Fit timing chain onto drive chain sprocket and camshaft ad‐
justers and fit bolts -1 and 2- without tightening.
• It should just be possible to turn both camshaft adjusters on
the camshaft without axial movement.
– Remove locking pin - T40071- .


moval.

– Fit socket -T40269- onto camshaft adjuster of exhaust cam‐
shaft.
– Apply torque wrench - V.A.G 1332- with open ring spanner
insert - V.A.G 1332/9- to socket -T40269- .
– Have a second mechanic apply a torque of 40 Nm to camshaft
adjuster in direction of -arrow-.
© satelettronica
– Tighten bolts as follows while keeping camshaft adjuster un‐
der tension:
Stage Bolt Tightening torque
1. -1- At camshaft: 60 Nm
– Remove socket -T40269- .
– Remove camshaft clamp - T40133- -arrows-.
Note
The illustration shows the cylinder head on the left side.
– Fit socket -T40269- onto camshaft adjuster of inlet camshaft.
der tension:
2. Chain drive 121


– Tighten camshaft adjuster bolts on cylinder head (right-side)
as follows:
2. -1- Tighten on camshaft to final tightening
torque ⇒ Item 3 (page 109)
© satelettronica
Cylinder bank 2 (left-side): Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten camshaft adjuster bolts on cylinder head (left-side) as
follows:


– Turn crankshaft two rotations back to TDC in normal direction

of engine rotation -arrow- using wrench (21 mm) - T40263- and
turning-over tool - T40272- .
Note
If you turn the crankshaft beyond “TDC” by mistake, turn it back

approx. 30° and set to “TDC” again.

wards.
© satelettronica
2. Chain drive 123

– Screw the locking pin - T40069- directly into the hole.

• The locking pin - T40069- must engage in the locating hole in
crankshaft -1-. If it does not, reset valve timing.
– Remove camshaft clamps from both cylinder heads.
note the following:
– Install cylinder head covers
page 161 .
Tightening torques
© satelettronica
♦ ⇒ “2.1 Exploded view - camshaft timing chains”, page 108
pressor;
ProtectedExploded view -forairprivate
by copyright. Copying conditioner compressor
or commercial purposes, in partdrive unitis not
or in whole,
♦ ⇒ Fig. ““Plug
with fortheTDC
respect to marking
correctness - tightening
of information torque”“
in this document. , page
Copyright 83
by AUDI AG.


ing chain
Removing
page 102 .
– Remove timing chains from camshafts
⇒ “2.4 Removing camshaft timing chain from camshafts”, page
114 .
Caution
If a used timing chain rotates in the opposite direction when it

is refitted, this can cause breakage.
♦ Mark running direction of timing chains (left and right) with
paint for re-installation. Do not attempt to mark the timing
chain with a centre punch or by making a notch or similar.
– Remove locking pin - T40071- and detach camshaft timing

chain (left-side).

– Remove bolts -1- and -2- and take off chain tensioner (right-
side).
Installing
Note
♦ Note the correct installation position if the tensioning element

has been removed from the chain tensioner: drilling in base of
housing faces chain tensioner and piston faces tensioner rail.
Caution

– Position timing chain (left-side) as shown in the illustration
© satelettronica
(according to marks applied during removal).
– Press down guide rail of chain tensioner for timing chain (left-
side) and lock chain tensioner by inserting locking pin -
T40071- .
Note
Disregard -arrow-.
– Fit chain tensioner on cylinder head (right-side) and position

timing chain.
– Tighten bolts -1- and -2-.
note the following:
– Fit timing chains on camshafts
114 .
page 102 .
Tightening torques

valve gear
2. Chain drive 125

♦ Locking pin - T40071-
Removing
– Remove timing chains
page 124 .
© satelettronica
– Remove chain tensioner for camshaft timing chain (left-side).

– Press guide rail of chain tensioner for drive chain in direction

of -arrow- and lock chain tensioner by inserting locking pin -
T40071- .
Caution
If a used drive chain rotates in the opposite direction when it is

refitted, this can cause breakage.
♦ Mark running direction of drive chain with paint for re-in‐
stallation. Do not attempt to mark the drive chain with a
centre punch or by making a notch or similar.
– Unscrew bolts -1- and remove guide rail.

– Remove bolts -2- and take off chain tensioner.
– Detach drive chain for valve gear.
Installing
© satelettronica
Note
– Position drive chain for valve gear onto drive chain sprockets
– Install guide rail and tighten bolts -1-.

– Install chain tensioner and tighten bolts -2-.
of -arrow- and remove locking pin - T40071- .
– Install camshaft timing chains
page 124 .
page 102 .
Tightening torques
♦ ⇒ “2.2 Exploded view - drive chain for valve gear”, page 111
2.7 Removing and installing drive chain

AG. AUDI for
permitted unless authorised by AUDI AG does not guarantee or accept any liability
balance shaft and oil pump

2. Chain drive 127

♦ Key - T40049-
© satelettronica

Removing
page 102 .
Caution
Risk of damage to drive chain
permitted if authorised
unless thread of boltAG.
by AUDI exceeds speci‐
fied length. with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Use bolts with a maximum thread length -a- of 22 mm to

attach key -T40049- .
♦ If no suitable bolts are available, position suitable washer
(s) under bolt head so that remaining thread length does
not exceed 22 mm.
– Attach key - T40049- at rear end of crankshaft using 2 bolts
© satelettronica
-arrows-.
– Remove plug -arrow- for crankshaft “TDC” marking from cyl‐

inder block.
– Rotate crankshaft in normal direction of rotation to “TDC”.
2. Chain drive 129

Note
♦ The bore provided for locking the crankshaft is difficult to see

when the engine is installed.
♦ Therefore, turn the engine until the small notch -1- on the vi‐
bration damper is in line with the housing joint -2- between the
cylinder block and the retaining frame on the left side (as seen
in direction of travel). This makes it easier to screw in locking
pin - T40069- .
♦ The marking on the vibration damper is only a visual aid. The
exact “TDC” position can only be obtained by screwing in the
– Screw locking pin - T40069- into hole (20 Nm); if necessary,

turn crankshaft -1- backwards and forwards slightly to fully
centralise locking pin.
© satelettronica
– Press guide rail of chain tensioner in direction of -arrow- and
lock chain tensioner by inserting locking pin - T40071- .
Caution

♦ Mark running direction of drive chain with
Protected paint for
by copyright. re-in‐
stallation. Do not attempt to markpermitted

the
with respect to the correctnessaof information in this document. Copyright by AUDI AG.
drive chain with
– Unscrew bolts -3- and detach chain sprocket from balance

shaft.
– Remove bolts -1- and -2- and take off chain tensioner with
chain.
Installing
T40069- .

– Install chain tensioner with chain and balance shaft sprocket.

– Lock balance shaft in “TDC” position using locating pin -
T40116- .
• The elongated holes in the balance shaft sprocket must be
aligned centrally over the threaded holes in the balance shaft.
If necessary move chain one tooth further.
– Tighten bolts for chain tensioner.
– Fit bolts -1- for chain sprocket without tightening.
• It should just be possible to turn the sprocket on the balance
shaft without axial movement.
– Pull out locking pin - T40071- to release chain tensioner.
– Press against guide rail of chain tensioner -arrow- using a
screwdriver, and at the same time tighten bolts -1- securing
chain sprocket.
– byPull
Protected locating
copyright. Copying pin -T40116-
for private out purposes,
or commercial of balance
in part shaft.
or in whole, is not
Remaining
with respect installation
to the correctness stepsin this
of information aredocument.
carriedCopyright
out in by reverse
AUDI AG.sequence;
note the following:
© satelettronica
page 102 .
Tightening torques
♦ ⇒ “2.3 Exploded view - drive chain for balance shaft and oil
pump”, page 113
♦ ⇒ Fig. ““Plug for TDC marking - tightening torque”“ , page 83
2. Chain drive 131

3 Cylinder head
Note
Illustration shows the cylinder head for cylinder bank 2 (left-side).

❑ Renewing
page 136
© satelettronica
❑ Installation position: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
part number must face permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
cylinder head with respect to the correctness of information in this document. Copyright by AUDI AG.
2 - Cylinder head
⇒ page 136
❑ ⇒ Fig. ““Camshafts with
recesses for bolts”“ ,
page 135
❑ ⇒ Fig. ““Checking cylin‐
der head for distortion”“ ,
page 134
❑ ⇒ Fig. ““Cylinder head
machining limit”“ ,
page 135
3 - Bolt
Brake system; Rep. gr.
47 ; Vacuum system;
Exploded view - vacuum
pump
4 - Vacuum pump
⇒ Brake system; Rep.
gr. 47 ; Vacuum system;
vacuum pump
5 - O-ring
❑ Renew
6 - Bolt
❑ 20 Nm


8 - Hall sender for inlet camshaft
❑ Cylinder bank 1 (right-side): Hall sender - G40-
❑ Cylinder bank 2 (left-side): Hall sender 2 - G163-
❑ Removing and installing ⇒ “1.5 Removing and installing Hall senders”, page 380
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ Renew
❑ Procedure for camshafts with assembly clearance feature
⇒ Fig. ““Camshafts with recesses for bolts”“ , page 135 :
♦ Loosening ⇒ page 141
♦ Tightening ⇒ page 149
♦ Tighten in three stages:
40 Nm
Turn 90° further
Turn 90° further
❑ Procedure for camshafts without assembly clearance feature
© satelettronica
⇒ Fig. ““Camshafts with recesses for bolts”“ , page 135 :
♦ Loosening ⇒ page 159
♦ Tightening
⇒ Fig. ““Cylinder head with camshafts without assembly clearance feature - tightening torque and se‐
11 - Ignition coil
❑ Removing and installing ⇒ “1.3 Removing and installing ignition coils with output stages”, page 374
❑ Removing and installing ⇒ “3.3 Removing and installing cylinder head cover”, page 161
13 - Gasket
❑ Renew if damaged or leaking
14 - Filler cap
❑ Renew if gasket is damaged
❑ Tightening torque:
♦ ⇒ Fig. ““Cylinder head cover (left-side) - tightening torque and sequence”“ , page 134
♦ ⇒ Fig. ““Cylinder head cover (right-side) - tightening torque and sequence”“ , page 134
16 - Bolt
17 - Connector rail
❑ For ignition coils
18 - Gasket for cylinder head cover
19 - Bolt
❑ 5 Nm
20 - Solenoid valve for camshaft control (exhaust side)
❑ Cylinder bank 1 (right-side): exhaust camshaft control valve 1 - N318-
❑ Cylinder bank 2 (left-side): exhaust camshaft control valve 2 - N319-
❑ Removing and installing ⇒ “4.6 Removing and installing camshaft control valves”, page 178

21 - Solenoid valve for camshaft control (inlet side)

❑ Cylinder bank 1 (right-side): camshaft control valve 1 - N205-
❑ Cylinder bank 2 (left-side): camshaft control valve 2 - N208-
22 - O-rings
❑ Renew
23 - O-ring
❑ Renew
24 - Bolt
❑ 9 Nm
25 - Hall sender for exhaust camshaft
❑ Cylinder bank 1 (right-side): Hall sender 3 - G300-
❑ Cylinder bank 2 (left-side): Hall sender 4 - G301-
Cylinder head cover (left-side) - tightening torque and sequence
© satelettronica
– Tighten boltspermitted
in theunless
sequence
authorised-1
by ...
AUDI12-
AG.to 9 Nm.
Cylinder head cover (right-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 12- to 9 Nm.

• Max. distortion: 0.05 mm.

Cylinder head machining limit

Machining of the cylinder head (surface grinding) is only permis‐
sible down to the minimum dimension -a-.
• Minimum dimension: -a- = 139.20 mm
Guide tube for oil dipstick - tightening torque

– Tighten bolt -arrow- to 9 Nm.
© satelettronica
Camshafts with recesses for bolts
Note
♦ Camshafts with assembly clearance feature have recesses at

the points marked with -arrows-. The cylinder head can be re‐
moved and installed without performing any additional work.
♦ Camshafts with no assembly clearance feature do not have
these recesses. The camshafts must be removed before you
can remove and install the cylinder head.
Cylinder head with camshafts without assembly clearance feature

- tightening torque and sequence Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note

1. -1 … 8- 40 Nm


⇒ “3.2.1 Removing and installing cylinder head - camshafts with
assembly clearance feature”, page 136
⇒ “3.2.2 Removing and installing cylinder head - camshafts with‐
out assembly clearance feature”, page 156
3.2.1 Removing and installing cylinder head -

camshafts with assembly clearance fea‐
ture
Note
Camshafts with assembly clearance feature have recesses at the

points marked with -arrows-. The cylinder head can be removed
and installed without performing any additional work.
© satelettronica
♦ Wrench, 21 mm - T40263-

Removing
• Engine in vehicle.
Note
♦ The following chapter describes how to remove both cylinder

heads together.
♦ If only one of the cylinder heads is to be removed, refer to the
corresponding procedure described in this chapter.
WARNING

cause injury.
© satelettronica
282 .
– Remove coolant pipe (top)
⇒ “3.2.4 Removing and installing coolant pipe (top)”,
page 244 .
– Lift retaining clips -arrows- and disconnect coolant hoses from
coolant expansion tank. Remove coolant expansion tank.


– Unplug electrical connectors at injectors -arrows- and at fuel
pressure sender - G247- -item 1-.
– Remove intake manifold (bottom sections)
⇒ “3.5 Removing and installing intake manifold (bottom sec‐
tion)”, page 296 .
– Unplug electrical connectors at injectors.

– Unplug electrical connector -2- at temperature sender for en‐
gine temperature regulation - G694- .
Note
Disregard -item 1-.
© satelettronica
– Unplug electrical connectors on cylinder head (left-side):
3 - For inlet camshaft control valve 2 - N208- and exhaust cam‐
shaft control valve 2 - N319-
– Move electrical wiring harness to one side.
Note
– Unplug electrical connectors at engine (front).

1- For coolant temperature sender - G62-
2- For solenoid for coolant circuit - N492-
– Remove bolts -arrows- at coolant pipe (front).

– Unscrew connection -1- and move fuel supply hose clear to

one side.
– Remove bolt -1- for earth wire on both sides.
Note
Disregard -item 2-.
© satelettronica
– Unplug electrical connectors -arrows- (left and right) at cam
actuators and move electrical wiring harness clear.
– Unplug electrical connectors on cylinder head (right-side):
1 - For inlet camshaft control valve 1 - N205- and exhaust cam‐
shaft control valve 1 - N318-
– Remove cylinder head covers ⇒ page 161 .

– Remove bolt -arrow- and pull out guide tube for oil dipstick.
– Release hose clip -1-, disconnect vacuum hose from vacuum

pump and move vacuum hose clear.
Note
Disregard -arrows-.
© satelettronica
– Remove bolts -arrows- at rear of cylinder head.
♦ Cylinder head (left-side): 3 bolts
♦ Cylinder head (right-side): 4 bolts

Note
♦ The cams on the inlet camshaft prevent access to some of the

cylinder head bolts – in this example bolts -1- and -2-.
♦ Use a plastic wedge to press the slider on the camshaft in
direction of -arrow A- to remove bolt -1-.
♦ Use a plastic wedge to press the slider on the camshaft in
direction of -arrow B- to remove bolt -2-.
Caution
Risk of damage. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Move the sliders only when the rocker fingers are not un‐
der load from the cams (i.e. when they are in contact only
with the base circle of the cam). For this reason it is im‐
portant to keep to sequence described in the following
when loosening the cylinder head bolts.
Risk of breakage
© satelettronica
♦ Do not apply pressure to the thin webs when moving the
sliders.

T40263- .
Note
– Use wrench (21 mm) - T40263- and turning-over tool -

T40272- to turn crankshaft in normal direction of engine rota‐
tion -arrow- until camshaft position shown in following
illustration is attained.

• The recesses -arrows- on the exhaust camshaft must point

towards the outside of the engine as shown in the illustration.
Cylinder head (left-side):
© satelettronica
– Press slider -B- as far as stop in direction of -arrow- (slider
should not be under load).
Cylinder head (right-side):

– Press slider -F- as
with respect far
to the as stopof in
correctness direction
information in thisof -arrow-
document. (slider

Continued for both cylinder heads:

– Turn crankshaft one complete rotation (360°) further in normal
direction of engine rotation -arrow- using wrench (21 mm) -
T40263- and turning-over tool - T40272- .

wards.
© satelettronica

– Unscrew bolt -1- and remove.


– Unscrew bolt -2- and remove.
© satelettronica

towards the outside of the engine.


– Press sliders -B- and -C- as far as stop in direction of -arrow-
(sliders should not be under load).
© satelettronica
– Press slider -F- as far as stop in direction of -arrow- (slider



wards.

114 .
– Remove locking pin - T40071- from cylinder head (left-side).
© satelettronica
– Remove bolts -1- and -2- and detach chain tensioner from cyl‐
inder head (right-side).
Note
Locking pin - T40071- remains in place. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Caution

♦ Do not turn crankshaft if one or both of the camshaft timing
chains has been removed from the cylinder head(s).


– Move slider -A- as required (slider should not be under load)
and unscrew and remove bolts -3 ... 9-.
– Detach cylinder head and set it down on a soft surface (foam
plastic).
© satelettronica


– Move sliders -D- and -E- as required (sliders should not be
under load) and unscrew and remove bolts -10 ... 16-.
plastic).
Installing
Caution
Risk of damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Risk of damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Ensure that cylinder head gasket seals properly:
© satelettronica
♦ 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
gasket.
Risk of damage to open valves.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
valve gear.
♦ Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐
erated.

♦ Renew self-locking nuts as well as seals, gaskets and O-rings.
♦ Note the different sealants for sealing surfaces and cylinder
head bolts.
♦ When installing an exchange cylinder head, the contact sur‐
faces between the hydraulic compensation elements, roller
rocker fingers and cams must be oiled before installing the
cylinder head cover.
♦ After fitting a new cylinder head or cylinder head gasket,
change the coolant and the engine oil.

– Before fitting cylinder head set crankshaft and camshafts to

“TDC”. To do so, fit camshaft clamps - T40133- to both cylinder
heads and tighten to 25 Nm -arrows-.
• The camshaft clamp - T40133- is positioned correctly if the
holes for the cylinder head bolts remain free.
• The locking pin - T40069- must be screwed into the crankshaft.
© satelettronica
– Place cylinder head gasket in position.
• Note position of centring pins -arrows- in cylinder block.
• Installation position of cylinder headpermitted
gasket: the
unless word by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
“oben” (top) or the part number should withface
respecttowards the cyl‐
inder head.

– Move slider -A- as required (slider should not be under load)
and fit bolts -1 ... 7-.
– Tighten bolts in the sequence -1 ... 7- in 3 stages
⇒ “3.1 Exploded view - cylinder head”, page 132 .


– Move sliders -D- and -E- as required (sliders should not be
under load) and fit bolts -8 ... 14-.
– Tighten bolts in the sequence -8 ... 14- in 3 stages
© satelettronica
– Fit timing chains on camshafts ⇒ page 119 .
– Remove camshaft clamp - T40133- and locking pin - T40069- .



– Press sliders -B- and -C- as far as stop in direction of -arrow-
(sliders should not be under load).
© satelettronica



wards.

– Fit bolt -15- and tighten in three stages
© satelettronica
– Fit bolt -16- and tighten in three stages



© satelettronica

– Press slider -B- as far as stop in direction of -arrow- (slider


© satelettronica


– Tighten bolts -arrows-.
Note
Cylinder head bolts do not have to be torqued down again later

after repair work.

note the following:
page 161 .
– Install coolant pipe (front)
page 241 .
© satelettronica
– Install intake manifold (bottom sections)
tion)”, page 296 / install intake manifold
⇒ “3.3 Removing and installing intake manifold”, page 292 .
– Install coolant pipe (top)
page 244 .
– Fill cooling system with fresh coolant
Tightening torques
♦ ⇒ Fig. ““Guide tube for oil dipstick - tightening torque”“ ,
page 135

3.2.2 Removing and installing cylinder head -

camshafts without assembly clearance
feature
Note
Camshafts with no assembly clearance feature do not have re‐

cesses -arrows-. The camshafts must be removed before you can
remove and install the cylinder head.
Removing
Note

heads together.
© satelettronica
WARNING

cause injury.

282 .
page 244 .


coolant expansion tank. Remove coolant expansion tank.
© satelettronica
– Remove intake manifold (bottom sections) ⇒ page 296 .
– Unplug electrical connectors at engine (front).

1- For coolant temperature sender - G62-
2- For solenoid for coolant circuit - N492-

one side.

– Remove bolt -1- for earth wire on both sides.
Note
Disregard -item 2-.
– Remove camshafts
– Move electrical wiring harnesses
permitted unlessclear to by
authorised the side.

© satelettronica


plastic).
Installing
Caution

cylinder block.
surfaces.
terial.
© satelettronica
gasket.
valve gear.
none of the valves make
Protected contact
by copyright. when
Copying the starter
for private is op‐
erated. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note

head bolts.
change the coolant and the engine oil.

• The locking pin - T40069- must be screwed into the crankshaft.

• Note position of centring pins -arrows- in cylinder block.
inder head.
– Insert and hand-tighten cylinder head bolts.
© satelettronica
– Tighten cylinder head bolts
⇒ Fig. ““Cylinder head with camshafts without assembly clear‐
ance feature - tightening torque and sequence”“ , page 135 .


Note

after repair work.

note the following:
– Install camshafts
page 161 .
page 241 .
© satelettronica
– Install intake manifold (bottom sections)
page 244 .
Tightening torques
page 135

Protected cylinder
by copyright. Copying for privatehead
cover permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing
– Remove ignition coils
⇒ “1.3 Removing and installing ignition coils with output
stages”, page 374 .

Cylinder head cover (left-side):

– Disconnect crankcase breather hose -arrow- by pressing re‐
lease tabs.
– Remove bolts in the sequence -12 ... 1- and remove cylinder
head cover (left-side).
Cylinder head cover (right-side):

– Remove air cleaner housing
page 285 .
lease tabs.
head cover (right-side).
© satelettronica
Installing
Note
♦ Renew gasket for cylinder head cover if damaged.

♦ Renew bolts for cylinder head cover if seals on bolts are dam‐
aged.

– Tighten bolts for cylinder head cover (left-side)
⇒ Fig. ““Cylinder head cover (left-side) - tightening torque and
– Tighten bolts for cylinder head cover (right-side)
⇒ Fig. ““Cylinder head cover (right-side) - tightening torque
and sequence”“ , page 134 .
page 285 .
– Install ignition coils
TighteningProtected
torques by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ ⇒ Fig. ““Cylinder head cover (left-side) - tightening torque and

♦ ⇒ Fig. ““Cylinder head cover (right-side) - tightening torque
and sequence”“ , page 134


♦ Spark plug spanner - 3122 B-
♦ Compression tester - V.A.G 1763-
© satelettronica
Procedure
– Remove all ignition coils
– Unplug electrical connector -2- for injectors at rear of cylinder
head (left-side).
Note



head (right-side).
Note
– Unscrew spark plugs using spark plug socket - 3122 B- .

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

pletely and at the same time operate the starter until the by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
pressure on the tester display no longer increases.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
When new 14.5 … 21.0
Wear limit 14.0
Installing
– Install spark plugs ⇒ Maintenance ; Booklet 411 .
– Erase any entries in event memory resulting from testing:
♦ Drive train
♦ Functions
♦ Readiness code

4 Valve gear
⇒ “4.5 Removing and installing cam actuators”, page 177
⇒ “4.6 Removing and installing camshaft control valves”,
page 178
⇒ “4.7 Checking hydraulic compensation elements”, page 179
⇒ “4.8 Removing
authorised byand
AUDI installing
AG. AUDI AGvalvedoes notstem oilorseals”, page
liability181
permitted unless guarantee accept any
Note
♦ Cylinder heads which have cracks between the valve seats or between a valve seat insert and the spark
© satelettronica
plug thread can be re-installed without reducing service life, provided the cracks are only slight and do not
exceed a maximum of 0.3 mm in width, and no more than the first 4 turns of the spark plug threads are
cracked.
♦ Illustration shows the cylinder head for cylinder bank 2 (left-side).
4. Valve gear 165

1 - Sealing plug
❑ Apply sealant when in‐
stalling; refer to ⇒ Elec‐
2 - Cylinder head
⇒ “5.1 Checking valve
guides”, page 190
head installed
installing valve stem oil
seals (cylinder head in‐
stalled)”, page 181
head removed
installing valve stem oil
seals (cylinder head re‐
moved)”, page 185
© satelettronica
4 - Valve spring permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sition of valve spring”“ ,
page 168
5 - Hydraulic compensation el‐
ement
❑ Clipped into roller rocker
finger -item 8-
❑ Checking
⇒ “4.7 Checking hy‐
draulic compensation
elements”, page 179
tion for re-installation with a coloured pen
7 - Valve cotters
❑ Allocation to cylinders ⇒ Fig. ““Allocation of roller rocker fingers to cylinders”“ , page 168
❑ Attach to hydraulic compensation element -item 5- using securing clip -item 9-
9 - Securing clip
❑ Not supplied separately
❑ Check for firm attachment
10 - Inlet camshaft
❑ With 3 sliders
❑ Measuring axial clearance ⇒ “4.2 Measuring axial clearance of camshaft”, page 169

❑ Measuring radial clearance ⇒ “4.3 Measuring radial clearance of camshaft”, page 170
❑ Runout: max. 0.04 mm
11 - Bolt
❑ Renew
❑ Tightening sequence:
♦ ⇒ Fig. ““Retaining frame for camshafts of cylinder head, bank 1 (right-side) - tightening torque and se‐
♦ ⇒ Fig. ““Retaining frame for camshafts of cylinder
Protected head,
by copyright. bank
Copying 2 (left-side)
for private - tightening
or commercial torque
purposes, in part and issequence”“
or in whole, not ,
page 169 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
12 - Actuator
❑ For camshaft adjustment
❑ Removing and installing ⇒ “4.5 Removing and installing cam actuators”, page 177
13 - Bolt
❑ 5 Nm
14 - O-ring
❑ Renew
© satelettronica
16 - Compression ring
17 - Rectangular section seals
19 - Oil strainer
❑ Not fitted on all versions; for allocation refer to ⇒ Electronic parts catalogue
20 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ “5.3 Valve dimensions”, page 191
❑ Checking valve guides ⇒ “5.1 Checking valve guides”, page 190
21 - Exhaust valve
❑ Do not machine, only grinding-in is permitted
4. Valve gear 167

Allocation of roller rocker fingers to cylinders
Caution

♦ Note allocation of roller rocker fingers to cylinders
• Roller rocker fingers with wide rollers -arrow 1- correspond to

cylinders without cylinder shut-off.
• Roller rocker fingers with narrow rollers -arrow 2- correspond
to cylinders with cylinder shut-off.
Installation position of valve spring

• Closely spaced spring coils -arrow- face towards cylinder
head.
© satelettronica
Retaining frame for camshafts of cylinder head, bank 1 (right-
side) - tightening torque and sequence
Note

the full surface
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further

Retaining frame for camshafts of cylinder head, bank 2 (left-side)

- tightening torque and sequence
Note

the full surface
2. -1 … 21- 8 Nm
3. -1 … 21- Turn 90° further
© satelettronica
4. Valve gear 169

Procedure
– For re-installation, mark original positions of roller rocker fin‐
gers, retaining clips and hydraulic compensation elements,
remove and put down on a clean surface.
– Re-insert camshafts, install retaining frame ⇒ page 169 and
tighten with old bolts to 8 Nm (do not turn further).
– Secure universal dial gauge bracket - VW 387- with dial gauge
- VAS 6079- to cylinder head as shown in illustration.
Axial clearance:
• Inlet camshaft: 0.080 ... 0.165 mm
• Exhaust camshaft: 0.100 ... 0.191 mm
© satelettronica
4.3 Measuring radial clearance
permitted unlessof camshaft
♦ Plastigauge
Procedure
– Mark allocation of roller rocker fingers for re-installation.
– Carefully remove roller rocker fingers and place them on a
clean surface.
ing.
– Re-insert camshafts, fit retaining frame and tighten with old
bolts to 8 Nm (do not turn further) ⇒ page 169 without rotating
camshafts.
– Remove retaining frame and camshafts again.
Radial clearance:
• 24 mm bearing ∅: 0.024 ... 0.066 mm
• 36 mm bearing ∅: 0.032 ... 0.078 mm


♦ Impact extractor attachment -T10133/3- from tool set for FSI

engines - T10133 C-
© satelettronica
♦ Safety goggles
Removing
114 .
– To remove camshafts in cylinder head (left-side), remove vac‐
uum pump ⇒ Brake system; Rep. gr. 47 ; Vacuum system;
Removing and installing vacuum pump .
– To remove camshafts in cylinder head (right-side), first re‐
move high-pressure pump and housing for high-pressure
pump drive
⇒ “6.2 Removing and installing high-pressure pump”,
page 314 .
– Remove bolts -arrows- and detach camshaft control valves
concerned. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4. Valve gear 171


– Unplug electrical connector -1- at Hall sender.
Note
Disregard -arrow-. with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
– Unplug electrical connector -1- at Hall sender concerned.
Note
Disregard -item 2-.
– Remove retaining frame:

♦ Cylinder head, bank 1 (right-side): Slacken bolts in the se‐
quence -19 ... 1-.

♦ Cylinder head, bank 2 (left-side): Slacken bolts in the se‐

quence -21 ... 1-.
– Remove bolts, carefully release retaining frame from bonded
joint and set it down on a soft surface on workbench.
© satelettronica
– Mark and remove camshafts.
Installing
Note
Renew all seals and gaskets.

T40069- .
• Hydraulic compensation elements and roller rocker fingers in‐
stalled.
Caution

tion.
4. Valve gear 173

WARNING
Risk of eye injury.


frame -1- using rotating plastic brush or similar.
– Check strainer -arrow- for dirt and clean as necessary.

© satelettronica
– Fit camshafts in retaining frame.
• Camshafts must be in correct position in axial bearings
-arrows- in retaining frame.
• The ends of the rectangular section seals -1, 2, 3- must point
up or down. The ends of the rectangular section seals must
never point to the side.
– Turn retaining frame over with camshafts fitted, holding cam‐
shafts firmly in position.
– Turn camshafts until threaded holes -arrows- point upwards.

– Check that camshafts are still in correct position in axial bear‐
ings in retaining frame.

– Fit camshaft clamp - T40133- and tighten bolts -arrows- to

25 Nm.
Note

2 mm).
© satelettronica
– Turn retaining frame upside down again.
Caution

– Apply beads of sealant -4 ... 8- onto clean sealing surfaces of

• Width of sealant beads: 2.0 mm.
Note
The retaining frame must be installed within 5 minutes after ap‐

plying the sealant.
4. Valve gear 175

– Fit retaining frame onto cylinder head.

– Insert locating pins -T40116- in retaining frame and cylinder
head.
– Tighten bolts for retaining frame for camshafts:
♦ ⇒ Fig. ““Retaining frame for camshafts of cylinder head, bank
1 (right-side) - tightening torque and sequence”“ , page 168
2 (left-side) - tightening torque and sequence”“ , page 169
Note
After installing the retaining frame, wait about 30 minutes for the
sealant to dry.
– Clean bore for sealing plug in cylinder head; it must be free of

oil and grease.
– Coat outer circumference of sealing plug -arrow- with sealant;
for sealant refer to ⇒ Electronic parts catalogue .
© satelettronica
– Drive in sealing plug until flush. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Use impact extractor attachment -T40116- to pull out locating

pins -T10133/3- .
note the following:
– Install camshaft control valves
– Install housing for high-pressure pump drive and high-pres‐
sure pump
page 314 .
114 .
Caution

valve gear.
© satelettronica
erated.
Tightening torques
4.5 Removing and installing cam actuators

Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove engine cover panelwith respect to the correctness of information in this document. Copyright by AUDI AG.
page 64 .
4. Valve gear 177

– Remove bolt -1- and pull off cam actuator.
Note
Disregard -item 2-.
Installing
Note
Fit new O-rings.
© satelettronica
Caution

♦ Pins of all actuators for camshaft adjustment must be
brought into installation position.
– Press down pins of actuators for camshaft adjustment

-arrow- by hand. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Pins of all actuators must not bewith
inrespect
extended position.
Tightening torques

trol valves
Removing
page 64 .
Applies to cylinder bank 1 (right-side):
– Move clear fuel hose -1- and hose -2- leading to activated
charcoal filter at air pipe.

All vehicles (continued)

– Unplug relevant electrical connector -1-.
– Unscrew bolt -2- and detach valve.
Installing
Note
♦ Renew O-rings after removing.


page 64 .
Tightening torques
© satelettronica
♦ ⇒ Fig. ““Installing air pipespermitted
and hoses with screw-type
unless authorised clips”“
by AUDI AG. AUDI , not guarantee or accept any liability
AG does
4.7 Checking hydraulic compensation ele‐

ments
Note
♦ The hydraulic compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge
♦ Wrench, 21 mm - T40263-
4. Valve gear 179

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 the compensation elements are still noisy, locate the defec‐
tive compensation element as follows:
© satelettronica
WARNING

– Remove corresponding cylinder head cover

page 161 .
T40263- .
Note
– Turn crankshaft with wrench (21 mm) - T40263- and turning-

over tool - T40272- in normal direction of engine rotation
-arrow- until cam of hydraulic compensation element to be
checked is at top. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– 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
Additional steps required
– Install cylinder head cover
page 161 .

seals
4.8.1 Removing and installing valve stem oil seals (cylinder head installed)
© satelettronica
equipment required
4. Valve gear 181


A- with guide plate -VAS 5161/19C- , or substitute -VAS
5161/19B-
♦ Adapters - T40012-
Procedure
– Apply drift -VAS 5161/3A- to valve spring plate and use plastic-
© satelettronica
headed hammer to release sticking valve cotters.
– Fit guide plate -VAS 5161/19C- from removal and installation

device for valve cotters - VAS 5161 A- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw adapter - T40012- with seal hand-tight into the corre‐
sponding spark plug thread.


– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
• The compressed air hose remains connected.
© satelettronica
If the puller -3364- cannot be used on some of the valve stem oil
seals due to the confined space, proceed as follows:
– Knock out pin -arrow- of puller using a drift and remove impact
extractor attachment.
– Apply bottom section of puller -3364- to valve stem oil seal.

– Secure puller with a punch or roll-pin drift -1-, as shown in il‐
lustration.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.
4. Valve gear 183

Caution
ling.

If valve cotters had been removed from assembly cartridge they

© satelettronica
and pick up valve cotters.
• Installation position of valve spring
⇒ Fig. ““Installation position of valve spring”“ , page 168 .

– Secure guide plate -VAS 5161/19C- back onto cylinder head.

– Insert assembly cartridge in guide plate.
cotters.
tion.
Installing
Caution
© satelettronica
valve gear.
erated.
4. Valve gear 185


equipment required
© satelettronica
5161/19B-
Procedure


supply.
with valve heads.
© satelettronica
– Fit guide plate -VAS 5161/19C- onto cylinder head.

4. Valve gear 187

Caution
ling.
© satelettronica

• Installation position of valve spring
⇒ Fig. ““Installation position of valve spring”“ , page 168 .


cotters.
tion.
Installing
⇒ “4.4 Removing and installing
by AUDI AG.camshaft”,
AUDI AG does page 170 or. accept any liability
permitted unless authorised not guarantee
© satelettronica
4. Valve gear 189



© satelettronica
Procedure
Note


– Secure dial gauge - VAS 6079- to cylinder head with universal

dial gauge bracket - VW 387- as shown in illustration.
• End of valve stem must be flush with valve guide.
new valves.
Note
5.2 Checking valves

– Visually inspect for scoring on valve stems and contact surfa‐
ces.
© satelettronica
Note
Inlet and exhaust valves must not be machined. Only grinding-in

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

2.5 ltr. engine 2.8 ltr. engine 2.5 ltr. engine 2.8 ltr. engine
∅a mm 32.35 ± 0.10 33.85 ± 0.10 28.0 ± 0.1 28.0 ± 0.1
∅b mm 5.98 ± 0.01 5.98 ± 0.01 5.96 ± 0.01 5.96 ± 0.01
c mm 104.97 ± 0.20 103.97 ± 0.20 102.87 ± 0.20 101.87 ± 0.2
α ∠° 45 45 45 45

WARNING
♦ Care must be taken when disposing of old sodium-cooled

exhaust valves.
♦ The valves must be sawn in two with a metal saw between
the centre of the stem and valve head. When doing so, the
valves must not come into contact with water. After pre‐
paring the valves, throw a maximum of ten into a bucket
of water. Then step away immediately, since a chemical
reaction
Protected will occur
by copyright. Copyingin
for which
private or the sodium
commercial filling
purposes, burns.
♦ with
After performing
respect these
to the correctness steps the
of information in thisvalves can
document. be disposed
of in the normal way.
© satelettronica

17 – Lubrication
1 Sump/oil pump
page 196
er G266 ”, page 202
Note
© satelettronica

1 - Nut
❑ 9 Nm
2 - Oil level and oil temperature
sender - G266-
stalling oil level and oil
temperature sender
G266 ”, page 202
3 - Seal
❑ Renew
4 - Sump (bottom section)
stalling sump (bottom
section)”, page 196
5 - Bolt
❑ Renew
❑ 3 Nm +90°
© satelettronica
6 - Baffle plate (bottom)
7 - Bolt
sequence Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Fig. ““Sump (top sec‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
tion) - tightening torque
and sequence”“ ,
page 196
8 - Sump (top section)
stalling sump (top sec‐
tion)”, page 199
9 - Dowel sleeve
❑ 2x
10 - O-ring
❑ Renew
❑ Insert in retaining frame
11 - Bolt
❑ Renew
❑ Apply locking fluid when installing; refer to ⇒ Electronic parts catalogue
❑ 3 Nm +90°
12 - Baffle plate (top)
13 - Gasket
❑ Renew
14 - Gasket
❑ Renew
15 - Bolt
❑ Renew
❑ 3 Nm +90°


❑ With oil cooler bypass valve
❑ Removing and installing ⇒ “2.1 Removing and installing engine oil cooler”, page 203
17 - Bolt
❑ 9 Nm
18 - Drive shaft
❑ For oil pump
20 - Distance sleeve
❑ 2x
21 - Bracket
22 - Bolt
❑ 9 Nm
23 - Chain sprocket
❑ For oil pump
© satelettronica
❑ Can only be fitted in one position on drive shaft
24 - Bolt
❑ Renew
❑ To loosen and tighten, use pin wrench - 3212- to counterhold chain sprocket
❑ 30 Nm +90°
25 - O-ring
❑ Renew
26 - Gasket
❑ Renew
27 - O-ring
❑ Renew
28 - Oil pump
❑ Removing and installing ⇒ “1.5 Removing and installing oil pump”, page 202
29 - Bolt
❑ 20 Nm
30 - Bolt
❑ Renew
⇒ Fig. ““Sump (bottom section) - tightening torque and sequence”“ , page 196
31 - Seal
❑ Renew
32 - Oil drain plug
❑ 30 Nm

Sump (bottom section) - tightening torque and sequence
Note
– Tighten bolts in 2 stages as follows:

Stage Tightening torque/angle specification
1. 8 Nm in diagonal sequence
2. Turn 90° further in diagonal sequence
Sump (top section) - tightening torque and sequence

– Tighten bolts to 20 Nm in the sequence shown.
Note
Depending on version, -item 3- comprises 3 or 4 bolts.
© satelettronica
1.2 Engine oil
Refer to ⇒ Maintenance tables for engine oil capacity, oil speci‐
fications and viscosity grades.
Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the “MAX” mark on the
dipstick.

section)

♦ Safety goggles

Removing
Lay a cloth under the engine oil cooler to catch escaping engine
oil.
with coolant hoses -1- and -2- attached.
© satelettronica
sender - G266- and move electrical wiring clear.
– Remove bolts for sump (bottom section) -1-.
– Release sump (bottom section) from bonded joint, taking care
not to bend sump.
Installing
Note
♦ Renew seals.
♦ The sump (bottom section) must be renewed if its coating is
damaged or if it is bent.

Caution

tion.
WARNING
Risk of eye injury.

– Remove remaining sealant on bottom section and top section

of sump -1- with a rotating plastic brush or similar.
© satelettronica
Take care not to damage the coating on the sump (bottom sec‐
tion).
Note

1 mm).
Caution

– Apply bead of sealant -arrow- onto clean sealing surface of

sump (bottom section) as illustrated.
• Width of sealant bead: approx. 1.5 mm.
Note
The sump (bottom section) must be installed within 5 minutes af‐

ter applying the sealant.

– Fit sump (bottom section) and tighten bolts

⇒ Fig. ““Sump (bottom section) - tightening torque and se‐
note the following:
411 .
Tightening torques
♦ ⇒ Fig. ““Sump (bottom section) - tightening torque and se‐

tion)
© satelettronica
♦ Safety goggles
Removing
41
page 102 .
– Remove oil pump Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.5 Removing and installingwith

oil respect
pump”, page 202of. information in this document. Copyright by AUDI AG.
to the correctness
– Remove bolts -arrows- and detach baffle plate (bottom).

– Remove bolt -arrow- for coolant pipes (left-side).
– Remove bolts -1 ... 6- for sump (top section).
Note
Depending on version, -item 3- comprises 3 or 4 bolts.
– Carefully release sump (top section) from bonded joint and pry
sump off dowel pins on cylinder block.
© satelettronica
Installing
Note
Renew gasket and O-ring.
Caution

tion.
– Remove old sealant from grooves on sump (top section) and

from sealing surfaces.
WARNING
Risk of eye injury.

♦ permitted
Put on safety goggles.
– Remove sealant residue from sump (top section) -1- and cyl‐
inder block using rotating plastic brush or similar.

Note

1.5 mm).
Caution

© satelettronica
sump (top section) as shown in illustration.
• The grooves on the sealing surfaces
permittedmust
unless be completely
authorised by AUDI AG.filled
with sealant. with respect to the correctness of information in this document. Copyright by AUDI AG.

sealing surface.
Note
The sump (top section) must be installed within 5 minutes after

applying the sealant.
– Fit seal -1- and O-ring -2- in retaining frame.

– Check that dowel sleeves are fitted, fit sump (top section) and
tighten bolts
⇒ Fig. ““Sump (top section) - tightening torque and se‐
note the following:
– Install coolant pipes (left-side)
⇒ “3.2.1 Removing and installing coolant pipes (left-side)”,
page 239 .
– Install oil pump
page 102 .
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torque and se‐


Removing
– Remove sump (bottom section)
page 196 .
– Remove bolts -1, 2, 3-.
– Using long-nose pliers, push drive shaft back slightly against
spring pressure -arrow- and pull oil pump towards front off of
drive shaft.
Installing
Note
– Fit oil pump onto drive shaft and tighten bolts.

– Install sump (bottom section)
© satelettronica
page 196 .
411 .
Tightening torques


– Remove nuts -1- and detach oil level and oil temperature
Installing
Note
Renew seal -2-.
411 .
Tightening torques

2 Engine oil cooler


er
© satelettronica
Removing
noise insulation .
2. Engine oil cooler 203

gine.
– Use hose clamps -3094- to clamp off coolant hoses -1- and
-2-.
– Detach coolant hose -1- and, if necessary, -2- from engine oil
cooler; release hose clip to do so.
derneath.
Installing
Note
♦ Renew gasket.
© satelettronica
Note

Tightening torques

⇒ “3.2 Removing and installing crankcase breather hoses”, page
206
3.1 Exploded view - crankcase breather system
1 - Plug
❑ 20 Nm
2 - Gasket
❑ Renew
3 - Cover with oil separator
❑ With connection for
crankcase breather
© satelettronica
stalling oil separator”,
page 206
4 - Bolt
❑ 9 Nm
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 2.5 Nm
7 - Crankcase breather hose
stalling crankcase
breather hoses”,
page 206
8 - Crankcase breather hoses
❑ To cylinder head covers
stalling crankcase
breather hoses”,
9 - O-rings
❑ Renew
❑ To air pipe
11 - Plug
❑ 20 Nm

3.2 Removing and installing crankcase

breather hoses
Removing
Note

Vehicles with 2.5 ltr. engine: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove intake manifold
– Remove intake manifold (top section)
⇒ “3.4 Removing and installing intake manifold (top section)”,
page 294 .
– Detach crankcase breather hoses -arrows- from cylinder head
covers.
© satelettronica
Note
On USA models, it is not possible to detach crankcase breather

hoses from cylinder head covers without damaging hoses. Renew
crankcase breather hoses after removal.
– Move crankcase breather hoses clear.

– Remove bolt -1- and detach connection with crankcase
breather hoses.
Installing
Note
Renew gaskets and O-rings.
– Install intake manifold

⇒ “3.3 Removing and installing intake manifold”, page 292 /
install intake manifold (top section)
page 294 .
Tightening torques
♦ ⇒ “3.1 Exploded view - crankcase breather system”,
page 205

Removing
– Remove crankcase breather hoses
⇒ “3.2 Removing and installing crankcase breather hoses”,
page 206 .


– Remove intake manifold (bottom section, left-side)
page 244 .
– Detach bracket for high-pressure pipes and oil separator -1-.
Installing
Note
Renew gasket.
© satelettronica
page 244 .
– Install intake manifold (bottom section, left-side)
– Install crankcase breather hoses
⇒ “3.2 Removing and installing crankcase breather hoses”,
page 206 .
Tightening torques
page 205


⇒ “4.1 Exploded view - oil filter housing/oil pressure switches”,
page 208
page 209
⇒ “4.3 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 210
⇒ “4.6 Removing and installing valve for oil pressure control N428
”, page 214
4.1 Exploded view - oil filter housing/oil pressure switches
1 - Bolt
❑ 13 Nm
© satelettronica
❑ Opening/closing pres‐
sure 2.5 ... 3.2 bar
❑ With grey insulation
❑ Check in Guided Fault
Finding ⇒ Vehicle di‐
agnostic tester
stalling oil pressure
switch F22 ”, page 209
❑ 20 Nm
3 - Seal
❑ Renew
4 - Flange nut
❑ 13 Nm
5 - Bolt
❑ 9 Nm
6 - Distance sleeve Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7 - Rubber grommet with respect to the correctness of information in this document. Copyright by AUDI AG.
8 - Oil filter housing

❑ With filter bypass valve
❑ With oil retention valve
❑ The oil retention valve
cannot be renewed
9 - O-ring
❑ Renew
❑ Installing
⇒ Fig. ““Installing O-ring on oil filter housing”“ , page 209
10 - Filler cap
❑ 25 Nm
11 - Seal
❑ Renew

❑ Removing and installing ⇒ Fig. ““Renewing seal on sealing cap”“ , page 209
❑ Removing and installing ⇒ Maintenance ; Booklet 411
13 - Bolt
❑ 16 Nm
14 - Gasket
❑ Renew
Renewing seal on sealing cap

– Take hold of tab -arrow A- and pull seal -2- out of sealing cap
-1-. by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
– Install new
with respect seal
to the so that
correctness semi-circular
of information profileCopyright
in this document. fits in by
groove
AUDI AG.
-arrow B- in sealing cap.
• Lug -arrow A- must point upwards.
© satelettronica
Installing O-ring on oil filter housing
– Fit O-ring -2- in groove -arrow- on oil filter housing -1-.
Oil pressure switch for reduced oil pressure - F378-

1- Oil pressure switch for reduced oil pressure - F378-
♦ Opening/closing pressure 0.75 ... 1.05 bar
♦ With grey insulation
♦ Check in Guided Fault Finding ⇒ Vehicle diagnostic tester
♦ Removing and installing ⇒ page 210
♦ 20 Nm

switch - F22-
Removing
page 64 .

Note
Place a cloth beneath the oil filter housing to catch escaping oil.
– Unplug electrical connector -arrow-.

– Unscrew oil pressure switch - F22- .
Installing
Note
♦ Renew seal.
♦ Fit the new oil pressure switch - F22- into the connection im‐
mediately to avoid loss of oil.

Tightening torques
© satelettronica
♦ ⇒ “4.1 Exploded view - oil filter housing/oil pressure switches”,
page 208

switch for reduced oil pressure - F378-

Removing
page 64 .
– Press noise insulation to the side.
– Use assembly tool - T10118- to unplug electrical connector
-2-.
– Use articulated wrench (24 mm) - T40175- to unscrew oil
pressure switch for reduced oil pressure - F378- -item 1-.
Installing
Note
Renew seal.

page 64 .
© satelettronica
Tightening torques
♦ ⇒ Fig. ““ Oil pressure switch for reduced oil pressure -F378-
”“ , page 209

Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch - F22-
⇒ “4.2 Removing and installing oil pressure switch F22 ”, page
209 .
sure switch. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Screw oil pressure switch with
- F22- into oil pressure tester.
– Start engine.
• Minimum oil pressure at idling speed: 1.2 bar.
• Minimum oil pressure at 2000 rpm: 1.5 bar.

Installing
– Install oil pressure switch - F22-
209 .

© satelettronica
Removing
– Extract engine oil from oil filter housing using used oil collec‐
tion and extraction unit - VAS 6622A- .
clear at air pipe.

– Detach electrical connectors -1 … 4- from bracket and move

clear to side.
– Remove bolts -arrows- and bracket and move bracket clear.

F22- .
© satelettronica
– Remove bolts -2- and push secondary air hose to rear.
Note
Disregard -item 1-.


– Remove nut -1- and threaded pin, and detach oil filter housing.
Installing
Note
Renew seals, gasket and O-ring.

Tightening torques
♦ ⇒ “4.1 Exploded view - oil filter housing/oil pressure switches”,
page 208
© satelettronica
♦ ⇒ Fig. ““Installing air pipes and hoses with screw-type clips”“ ,
page 285

unless valve
authorised by AUDI AG. AUDIforAG oil
permitted does not guarantee or accept any liability
pressure with
control - N428-

Removing
noise insulation .
derneath.


– Remove bolt -3- and detach valve for oil pressure control -
N428- -item 4-.
Installing
Note
Fit new O-ring -2-.

Tightening torques
♦ ⇒ Fig. ““ Valve for oil pressure control -N428- ”“ , page 83
© satelettronica

19 – Cooling

Note
© satelettronica

1 - Radiator
er - G62-
3 - Thermostat
4 - Coolant pump
5 - Cylinder head
❑ Cylinder bank 1 (right-
side)
❑ For vehicles with multi‐
tronic gearbox 0AW
(front-wheel drive) or 7-
speed dual clutch gear‐
box 0B5
❑ Colour of housing: grey
7 - Bleeder screw
© satelettronica
V50-
Coolant circuit; Over‐
view of fitting locations -
coolant circuit
10 - Temperature sender for
engine temperature regulation
- G694-
11 - ATF cooler
❑ For vehicles with multitronic gearbox 0AW (front-wheel drive) or 7-speed dual clutch gearbox 0B5
❑ Removing and installing ⇒ Rep. gr. 34 ; ATF circuit; Removing and installing ATF cooler /⇒ Rep. gr.
37 ; ATF circuit; Removing and installing ATF cooler .
12 - Cylinder head
❑ Cylinder bank 2 (left-side)
13 - Filler cap
❑ Checking pressure relief valve ⇒ page 221
❑ On vehicles for hot countries only

Note

1 - Radiator
er - G62-
3 - Thermostat
© satelettronica
❑ With circulation pump -
V55-
⇒ Auxiliary/supplemen‐
tary heater; Rep. gr. 82 ;
Auxiliary/supplementa‐
ry heater; Removing
and installing auxiliary/
supplementary heater
5 - Coolant pump
6 - Cylinder head
side)
❑ For vehicles with multi‐
tronic gearbox 0AW
(front-wheel drive) or 7-
speed dual clutch gear‐
box 0B5
❑ Colour of housing: grey
valve - N279-
Coolant circuit;Protected
Over‐by copyright. Copying for private or commercial purposes, in part or in whole, is not
view of fitting locations - authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
coolant circuit with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Bleeder screw
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Front air conditioning unit; Removing
and installing heat exchanger

11 - Temperature sender for engine temperature regulation - G694-

12 - ATF cooler
13 - Cylinder head
14 - Filler cap
© satelettronica


equipment required
© satelettronica

Procedure
WARNING

♦ Cover filler cap on expansion tank with a cloth and open

V.A.G 1274/8- onto coolant expansion tank.
© satelettronica
nutes.
inate fault.
Note

engine is cold.

– Build up pressure with hand with
pump onto cooling
respect system
the correctness tester.

1.4 ... 1.6 bar.
scribed.


equipment required
© satelettronica

Draining
WARNING


WARNING

hot.
noise insulation .
gine.
© satelettronica
Note
Disregard -item 2-.

Note

Filling
Caution


Note


© satelettronica
ical climates.
♦ The refractometer - T10007A- MUST be used to determine the
current level of frost protection.
♦ Read off the level of frost protection on the scale for the rele‐
vant coolant additive.
♦ The temperature indicated on the refractometer - T10007A-
ses.

• Coolant (50 %) and water (50 %) for frost protection to –36 ℃

Procedure
– Connect coolant hose to coolant pipe (bottom left) with hose

clip -1-.
Note
The illustration shows the 2.8 ltr. engine.
© satelettronica
12 litres of premixed coolant (according to recommended ratio
⇒ page 224 ).
V.A.G 1274/8- .
Note

rection of flow).


• The suction jet pump generates a vacuum in the cooling sys‐
tem. The needle on the gauge should move into the green
zone.
• The suction jet pump will continue generating a vacuum in the
cooling system. The needle on the gauge should remain in the
green zone.
sequent filling.
Note
© satelettronica
ess.
tained.

– Open valve -A-.
drawn out of theProtected
reservoir of theCopying
by copyright. cooling system
for private charge
or commercial unit -in part or in whole, is not
purposes,
VAS 6096- ; thepermitted
cooling system is then filled.

– Fill up with coolant until pipe for cooling system tester is filled.
If required, add further coolant when performing bleeding pro‐
cedure.


chamber cover .
Note
– Release coolant hose going to heat exchanger and pull back

hose until coolant flows out at bleeder hole -arrow- in coolant
hose.
– Push coolant hose back onto connection and secure with hose
clip.
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Close filler cap -arrow- on coolant expansion tank (make sure

it engages).
– Start engine.
– Set temperature to “HI” for allpermitted
zonesunless
andauthorised
select by lowest blower
© satelettronica
speed (= 0). with respect to the correctness of information in this document. Copyright by AUDI AG.

tion .
chamber cover .

• The coolant level must be at the MAX marking when the en‐
gine is cold.
• The coolant level can be above the MAX marking when the
engine is warm.


page 229
”, page 233
⇒ “2.7 Removing and installing temperature sender for engine
temperature regulation G694 ”, page 234
1 - Bolt
© satelettronica
❑ 20 Nm
❑ For coolant pump
3 - Coolant pump
❑ With gasket
stalling coolant pump”,
page 231
4 - Bolt
❑ 9 Nm
5 - Connection
❑ For coolant hose
6 - Gasket
❑ Renew
7 - Gasket
❑ Renew
8 - Thermostat
stalling thermostat”,
page 232
❑ Starts to open at approx.
87 ℃
❑ Fully open at approx.
102 ℃
❑ Opening travel at least 8
mm
9 - Bolt
❑ 9 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

10 - Solenoid for coolant circuit - N492-

11 - Bolt
❑ 9 Nm
1 - Coolant hose
2 - Bracket
3 - Bolts
❑ 9 Nm
4 - Coolant hose
5 - Bolt
❑ 4 Nmpermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tion pump - V51-
© satelettronica
stalling electric coolant
pump”, page 229

pump

© satelettronica
Removing
WARNING

hot.

noise insulation .

– Unplug electrical connector -2- and remove bolt -1-.

gine.
– Release hose clips -arrows- and disconnect continued coolant
circulation pump - V51- from coolant hoses.
Installing
Note

Tightening torques
© satelettronica

Removing
– Drain coolant
– Detach poly V-belt from coolant pump, but do not remove
completely
wrench - 3212- ).

Note
– Remove bolts -arrows- for coolant pump and detach coolant

pump to the side.
Installing
Note
© satelettronica
Tightening torques

Removing
– Drain coolant
Vehicles with 2.8Protected
ltr. engine:
– Remove intake with

manifold
respect to(top section)
page 294 .
– Remove coolant pipe (front)
page 241 .


– Detach coolant thermostat with hose connection.
Installing
Note

♦ When removing and installing the thermostat, makeCopying
Protected by copyright. sureforthat
the needle is fitted correctly (conicalpermitted
end fitted
unless in wax expan‐
sion element of thermostat). If necessary, push thermostat
needle as far as possible into wax expansion element.

page 241 .
© satelettronica
page 294 .
Note

Tightening torques

ature sender - G62-
Removing
• Engine cold.
– Remove engine cover panel (front)
page 64 .


- G62- .
Note
– Pull off retaining clip -1- and detach coolant temperature send‐
er - G62- .
Installing
Note
♦ Fit new O-ring.

© satelettronica
page 64 .
2.7 Removing and installing temperature

sender for engine temperature regula‐
tion - G694-
Removing
– Remove fuel rail (right-side)
⇒ “4.2 Removing and installing fuel rail”, page 300 .
– Protected
Remove intakeCopying
by copyright. manifold (bottom
for private section,
or commercial right-side)
⇒ “3.5unless
permitted Removing
authorisedand installing
by AUDI AG. AUDI AG intake manifold
does not (bottom
guarantee or accept anysec‐
liability
tion)”, page
with respect 296
to the .

– Unscrew temperature sender for engine temperature regula‐
tion - G694- -item 1-
Installing
– Install intake manifold (bottom section, right-side)
– Install fuel rail (right-side)
Tightening torques
♦ ⇒ Fig. ““ Temperature sender for engine temperature regula‐
tion -G694- - tightening torque”“ , page 238


© satelettronica
Removing
noise insulation .
– Detach gearbox oil cooling valve - N509- .
Installing
Note

Tightening torques

3 Coolant pipes
Note

❑ Remove and install to‐
gether with -item 17-
installing coolant pipes
(left-side)”, page 239
© satelettronica
2 - Bolt
❑ 9 Nm
3 - O-ring
❑ Renew
4 - Connecting hose
5 - Bolts
❑ 9 Nm
installing coolant pipe
(front)”, page 241
7 - Bolts
❑ 9 Nm
8 - O-ring
❑ Renew
9 - Retaining clip
10 - Coolant temperature
sender - G62-
stalling coolant temper‐
ature sender G62 ”, permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
11 - Seal
❑ Renew
12 - Coolant hose
13 - Seal
❑ Renew
14 - O-ring
❑ Renew

15 - Coolant pipe (top)

❑ Removing and installing ⇒ “3.2.4 Removing and installing coolant pipe (top)”, page 244
16 - Bolt
❑ 9 Nm
❑ Remove and install together with -item 1-
⇒ “3.2.1 Removing and installing coolant pipes (left-side)”, page 239
18 - Bolt
❑ 9 Nm
19 - Coolant hoses
Coolant pipes on multitronic gearbox 0AW (front-wheel drive)
1 - Bolt
❑ 22 Nm
© satelettronica
(bottom left)”,
page 240
N509-
stalling coolant valves”,
page 235
4 - Bolt
❑ 9 Nm
5 - Heat shield
6 - Bolt
❑ 9 Nm
gearbox
❑ Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “3.2.5 Removing and permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
installing coolant pipe with respect to the correctness of information in this document. Copyright by AUDI AG.
(left-side) on gearbox”,
page 246
8 - Bolt
❑ 9 Nm
9 - Bracket
valve - N509-
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 22 Nm
Coolant pipes to 7-speed dual clutch gearbox 0B5

1 - Bolt
❑ 22 Nm
(bottom left)”,
page 240
N509-
page 235
4 - Bolt
❑ 9 Nm
5 - Heat shield Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 9 Nm
© satelettronica
gearbox
(right-side) on gearbox”,
page 248
8 - Bolt
❑ 9 Nm
9 - Bracket
valve - N509-
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 22 Nm
Temperature sender for engine temperature regulation - G694- -

tightening torque
– Tighten temperature sender for engine temperature regulation
- G694- -item 1- to 3 Nm.


page 239
240
page 241
⇒ “3.2.4 Removing and installing coolant pipe (top)”, page 244
box”, page 246
3.2.1 Removing and installing coolant pipes

(left-side)
© satelettronica
Removing
– Drain coolant
– Detach poly V-belt from air conditioner Protected
compressorby copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.2 Removing and installing poly V-belt”, page
permitted unless66 .
– Remove engine mounting (left-side)
⇒ “2.2 Removing and installing engine mountings”, page 55 .


– Release hose clips -1- and -2- and disconnect coolant hoses
from coolant pipes.
Installing
Note
♦ Fit new O-ring.


– Lubricate O-ring with coolant and slide onto coolant pipe.
– Install engine support (left-side) with bracket for air conditioner
compressor and engine mounting (left-side)
© satelettronica

Tightening torques

(bottom left)

Removing
– Remove engine mounting (left-side)
Note
© satelettronica

hose clips -arrows- and disconnect coolant hoses from coolant
pipe (bottom left).
– Detach coolant pipe (bottom left).
Note
♦ Disregard items -1 and 2-.

Installing
Note
– Install engine mounting (left-side)

Note

Tightening torques

(front)

© satelettronica
Removing
ments .
– Unscrew bolts -arrows- and detach air ducts -1- and -2-
– Detach poly V-belt from coolant pump, but do not remove
completely

wrench - 3212- ).

– Press release tabs and detach secondary air hose -arrow- to

front from bracket.
– Unclip solenoid
Protectedfor coolantCopying
by copyright. circuit
for -private
N492- -item 4-purposes,
or commercial from brack‐
et. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- G62- .
– Lift retaining clips -1, 5-, release hose clips -3, 6, 7- and detach
coolant hoses.
– Unscrew bolts -arrows- and remove coolant pipe (front).
© satelettronica
Installing
Note
♦ Renew seals and O-rings.

– Clean or smoothen sealing surfaces for seals and O-rings.

– Lubricate seals and O-rings with coolant and slide onto coolant
pipe.
page 252 .
ments .
Note

Tightening torques


(top)
Removing
Note
– Drain coolant
page 294 .
© satelettronica
– Remove bolts -arrows- and detach guard plate -1- for high-
pressure pipe.
– Vehicles with secondary air system: press release tabs and

detach secondary air hose -arrow- from bracket towards front.
WARNING

cause injury.
dissipate.

⇒ “1.2 Reducing fuel pressure inwithhigh-pressure section”, pagein this document. Copyright by AUDI AG.
respect to the correctness of information
282 .

– Unscrew connection -1-.

– Unscrew union nuts -2- and -3- (counterhold connection).
– Unscrew bolts -arrows- on retaining clips and detach high-
pressure pipe.
– Detach connection -arrow- for high-pressure pipe.
Note
The illustration shows the 2.8 ltr. engine.
© satelettronica

Note
– Detach coolant hose -2- from coolant pipe.

– Remove bolt -1- and pull coolant pipe rearwards out of cylinder
block -arrow-.
Installing
Note
Fit new O-rings.

– Install high-pressure pipe
© satelettronica
⇒ “6.3 Removing and installing high-pressure pipe”,
page 317 .
page 294 .
page 252 .
Note

Tightening torques

(left-side) on gearbox

© satelettronica
Removing
page 64 .
noise insulation .
WARNING

hot.

gine.
hose clips -1, 2- and disconnect coolant hoses.
– Unscrew bolts -arrows- and remove coolant pipe.
Installing
Note

page 64 .
Tightening torques
© satelettronica

(right-side) on gearbox
♦ Hose clamps, up to Protected
25 mmby-copyright.
3094- Copying for private or commercial purposes, in part or in whole, is not

Removing
– Move fuel hose Protected
-1- andbyhose -2-Copying
copyright. from for
activated charcoal
private or commercial filterin part or in whole, is not
purposes,
clear at air pipe. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
-1- on subframe.
WARNING

hot.

noise insulation .
tion.


Installing
Note

Tightening torques
© satelettronica
page 285

⇒ “4.5 Removing and installing radiator fan control unit J293 ”,
page 263
1 - Radiator fan control unit -

J293-
stalling radiator fan con‐
trol unit J293 ”,
page 263
2 - Bolt
© satelettronica
❑ 4.5 Nm
3 - Bolt
❑ 5 Nm
4 - Radiator cowl permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.

stalling radiator cowl”,
page 257
stalling radiator fan V7 ”,
page 263
6 - Bolt
❑ 3.5 Nm
7 - Support pad
8 - Rubber mounting
❑ For radiator
9 - Coolant hose
tach
❑ Connecting to radiator
⇒ Fig. ““Connecting
coolant hose with plug-
in connector”“ , page 252
10 - O-ring
❑ Renew
11 - O-ring
❑ Renew
12 - Coolant hose
❑ Lift retaining clip to detach
❑ Connecting to radiator ⇒ Fig. ““Connecting coolant hose with plug-in connector”“ , page 252

13 - Coolant hose
❑ To coolant expansion tank
14 - O-ring
❑ Renew
15 - Radiator
❑ Remove and install together with radiator cowl ⇒ “4.2 Removing and installing radiator”, page 252
16 - Retaining pin
17 - Rubber buffer
19 - Bolt
❑ 4.5 Nm
20 - O-ring
❑ Renew
21 - Coolant hose
© satelettronica
❑ Depending
permitted on equipment
❑ Removing and installing ⇒ “4.4 Removing and installing radiator fan V7 ”, page 263
23 - Bolt
❑ 5 Nm

ant hose.
bly.
Note
gether as one unit.

© satelettronica
Removing
noise insulation .
– Remove impact bar ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing impact bar .
gine.
tor.
– Detach connection from radiator (lift retaining clip -arrow-).

WARNING

diator.
© satelettronica
Note
Disregard -item 2-.

– For vehicles with frame -2-, unscrew bolts -1- and remove
frame.
– Release catches -arrows A- and detach air duct -1- on left and
right -arrow B-.
© satelettronica
upwards -arrows-.

Condenser with angled connection for refrigerant line:

-arrows B-.
Caution

hoses.
♦ Do NOT stretch,
Protected kink or
by copyright. bend
Copying for refrigerant linespurposes,
private or commercial and hoses.

Condenser with straight connection for refrigerant line:
© satelettronica
– Slightly lower radiator.

Installing
Note
If there are slight impressions on the fins, refer to

⇒ “3.5 Installing radiators and condensers”, page 8 .

page 252 .
Note
© satelettronica
Tightening torques

⇒ “4.3.1 Removing and installing radiator cowl - Audi A6”,
page 257
page 260
4.3.1 Removing and installing radiator cowl -

Audi A6

Removing
ments .
Note
© satelettronica
Disregard -item 2-. with respect to the correctness of information in this document. Copyright by AUDI AG.

noise insulation .
– For vehicles with frame -2-, unscrew bolts -1- and remove
frame.

– Release catches -arrows A- and swivel air duct -1- on left and
right to centre of vehicle -arrow B-.
– Place drip
with respect tray
to the for workshop
correctness hoist
of information in this -document.
VAS 6208- beneath
Copyright by AUDI AG.en‐
gine.
© satelettronica
tor.
WARNING



multaneously -arrow-, lift radiator cowl off radiator and remove
from below.
Installing
– Connect coolant hose with plug-in connector
page 252 .
© satelettronica
– Install bumper cover, closure plate and lock carrier cover ⇒
Note

Tightening torques

Audi A7
Removing
noise insulation . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

WARNING

ments .
© satelettronica
Note
Disregard -item 2-.
– Detach air duct -1-.

– Remove bolt -2- on both sides and press bumper cover for‐
wards slightly.

– Lift retaining clip -arrow- and disconnect coolant hoses from

© satelettronica
upwards -arrows-.

Installing
– Connect coolant hose with plug-in connector
page 252 .
Tightening torques

V7-
© satelettronica
Removing
– Remove radiator cowl
⇒ “4.3 Removing and installing radiator cowl”, page 257 .

side).
Installing
– Install radiator cowl
Tightening torques
4.5 Removing permitted

and installing
unless authorised radiator fan

Removing
noise insulation .

trol unit.

Installing
Tightening torques
© satelettronica


1 Injection system
page 265
page 282
1.1 Overview of fitting locations - injection

system
⇒ “1.1.1 Overview of fitting locations - injection system, vehicles
with 2.5 ltr. engine”, page 265
1.1.1 Overview of fitting locations - injection system, vehicles with 2.5 ltr. engine
Engine compartment (right-side)
© satelettronica
- V101-
⇒ Fig. ““Fitting location
of secondary air pump
motor -V101- ”“ ,
page 274
❑ Exploded view
page 352
⇒ Fig. ““Fitting locations
on cylinder bank 1
(right-side)”“ ,
page 271
❑ Exploded view
- ignition system, vehi‐
cles with 2.5 ltr. engine”,
page 371
❑ Fitting location Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Fig. ““Fitting location with respect to the correctness of information in this document. Copyright by AUDI AG.
of Lambda probes on
cylinder bank 1 (right-
side)”“ , page 273
❑ Fitting location of elec‐
trical connector
⇒ Fig. ““Electrical con‐
nectors for Lambda
probes on cylinder bank
1 (right-side)”“ ,
page 273
❑ Exploded view
⇒ “7.1 Exploded view - Lambda probes”, page 319

4 - Exhaust camshaft control valve 1 -N318-

❑ Fitting location ⇒ Fig. ““Fitting locations on cylinder bank 1 (right-side)”“ , page 271
❑ Exploded view ⇒ “3.1 Exploded view - cylinder head”, page 132
6 - Lambda probe after catalytic converter - G130- with Lambda probe 1 heater after catalytic converter - Z29-
❑ Fitting location ⇒ Fig. ““Fitting location of Lambda probes on cylinder bank 1 (right-side)”“ , page 273
❑ Fitting location of connector
⇒ Fig. ““Electrical connectors for Lambda probes on cylinder bank 1 (right-side)”“ , page 273
❑ Exploded view ⇒ “7.1 Exploded view - Lambda probes”, page 319
❑ Including throttle valve drive for electric throttle - G186- , throttle valve drive angle sender 1 for electric
throttle - G187- and throttle valve drive angle sender 2 for electric throttle - G188-
❑ Fitting location ⇒ Fig. ““Fitting location: at rear of intake manifold”“ , page 273
© satelettronica
❑ Exploded view ⇒ “3.1.1 Exploded view - intake manifold, vehicles with 2.5 ltr. engine”, page 287
❑ Fitting location ⇒ Fig. ““Fitting locations: components on inside of right cylinder bank 1”“ , page 271
❑ Exploded view ⇒ “4.1 Exploded view - fuel rail with injectors”, page 299
❑ Exploded view ⇒ “1.1.1 Exploded view - ignition system, vehicles with 2.5 ltr. engine”, page 371
⇒ “2.7 Removing and installing temperature sender for engine temperature regulation G694 ”,
page 234
15 - Variable intake manifold change-over valve - N156-
❑ Fitting location ⇒ Fig. ““Fitting location: at front of engine”“ , page 272
❑ Fitting location ⇒ Fig. ““Fitting location:
Protected at Copying
by copyright. front offor engine”“ , pagepurposes,
private or commercial 272 in part or in whole, is not
❑ Exploded view ⇒ “3.1 Exploded view - coolant pipes”, page 236
18 - Actuators for camshaft adjustment
❑ Actuator 1 for camshaft adjustment - F366-


❑ With fuel pressure sender, low pressure - G410- and fuel metering valve - N290-
❑ Fitting location ⇒ Fig. ““Fitting locations at high-pressure pump”“ , page 272
❑ Exploded view ⇒ “6.1 Exploded view - high-pressure pump”, page 312
20 - Ignition coils, cylinder bank 1
❑ Ignition coil 1 with output stage - N70-
❑permitted
Ignition coil 2 with by output
AUDI AG. stage
AUDI AG-doesN127-
unless authorised not guarantee or accept any liability
Engine compartment (left-side)
1 - Variable intake manifold po‐
© satelettronica
sition sender - G513-
⇒ Fig. ““Fitting location:
at front of engine”“ ,
page 272
⇒ Fig. ““Fitting locations:
components on inside of
left cylinder bank 2”“ ,
page 271
❑ Exploded view
fuel rail with injectors”,
page 299
G247-
page 271
❑ Exploded view
page 299
page 271
❑ Fitting location of con‐
nector
nectors for Lambda probes on cylinder bank 2 (left-side)”“ , page 274


❑ Fitting location ⇒ Fig. ““Fitting locations: components on inside of left cylinder bank 2”“ , page 271
7 - Oil pressure switch for reduced oil pressure - F378-
❑ Fitting location ⇒ Fig. ““Fitting location of engine speed sender -G28- ”“ , page 273
❑ Fitting location ⇒ Fig. ““Fitting location of oil pressure switch -F22- -A-”“ , page 272
❑ Exploded view ⇒ “4.1 Exploded view - oil filter housing/oil pressure switches”, page 208
10 - Lambda probe 2 after catalytic converter - G131- with Lambda probe 2 heater after catalytic converter -
Z30-
❑ Fitting location ⇒ Fig. ““Fitting location of Lambda probes on cylinder bank 2 (left-side)”“ , page 274
© satelettronica
❑ Fitting location of electrical connector
⇒ Fig. ““Electrical connectors for Lambda probes on cylinder bank 2 (left-side)”“ , page 274
11 - Accelerator position sender - G79- / accelerator position sender 2 - G185-
⇒ Fig. ““Fitting location of accelerator position sender -G79- / accelerator position sender 2 -G185- ”“ ,
page 270
⇒ Fig. ““Fitting locations of brake light switch -F- and clutch position sender -G476- ”“ , page 270
❑ Only on vehicles with manual gearbox
❑ Fitting location ⇒ Fig. ““Fitting location of engine control unit -J623- ”“ , page 269
❑ Fitting location ⇒ Fig. ““Fitting location of gearbox oil cooling valve -N509- ”“ , page 274
❑ Exploded view ⇒ “3.1 Exploded view - coolant pipes”, page 236
16 - Camshaft control valve 2 - N208- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Fitting location ⇒ Fig. ““Fitting locations onwith
cylinder bank 2 (left-side)”“ , page 271

17 - Exhaust camshaft control valve 2 - N319-
❑ Fitting location ⇒ Fig. ““Fitting locations on cylinder bank 2 (left-side)”“ , page 271
18 - Lambda probe 2 - G108- with Lambda probe heater 2 - Z28-


❑ Fitting location ⇒ Fig. ““Fitting location of valve for oil pressure control -N428- ”“ , page 272
❑ Removing and installing ⇒ “4.6 Removing and installing valve for oil pressure control N428 ”, page 214
© satelettronica
24 - Coolant valve for cylinder headProtected
- N489- by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Fitting location ⇒ Fig. ““Fitting location:
with respect toat
thefront of engine”“
correctness , page
of information 272 Copyright by AUDI AG.
in this document.
Fitting location of secondary air inlet valve - N112-
Note
Secondary air inlet valve - N112- is fitted on vehicles from model

year 2013 onwards.

3 - Vacuum line to vacuum supply
4 - Control pipe to combination valves for secondary air inlet

♦ In left electronics box in engine compartment

Fitting location of fuel pump control unit - J538-

♦ Fuel pump control unit - J538- -arrow- is located between floor
panel and fuel tank level with rear seat bench (right-side).
Note
For illustration purposes, the floor panel is cut open in the illus‐
tration.
Removing and installing ⇒ Fuel supply system; Rep. gr. 20 ; Fuel

pump; Removing and installing fuel pump control unit - J538-

Note
© satelettronica

accelerator pedal module with accelerator position sender -G79- /
-G185- .
Fitting locations of brake light switch - F- and clutch position send‐

er - G476-
2- Clutch position sender - G476- (vehicles with manual gear‐
box only)
Removing and installing brake light switch - F- ⇒ Brake system;
Rep. gr. 45 ; Sensors; Removing and installing brake light switch
Removing and installing clutch position sender - G476- ⇒ Rep.
gr. 30 ; Clutch mechanism; Removing and installing clutch master
cylinder permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Fitting locations on cylinder bank 1 (right-side)

1- Hall sender 3 - G300-
2- Exhaust camshaft control valve 1 - N318-
3- Camshaft control valve 1 - N205-
4- Actuator 6 for camshaft adjustment - F371-
Fitting locations on cylinder bank 2 (left-side)

1- Hall sender 2 - G163- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
9- Exhaust camshaft control valve 2 - N319-
Fitting locations: components on inside of right cylinder bank 1

1- Injector, cylinder 1 - N30-
2- Temperature sender for engine temperature regulation -
G694-
3- Knock sensor 1 - G61-
Fitting locations: components on inside of left cylinder bank 2

5- Fuel pressure sender - G247-

Fitting location of oil pressure switch - F22- -A-

The oil pressure switch - F22- is screwed into the oil filter flange
Fitting location of valve for oil pressure control - N428-
© satelettronica
Fitting location: at front of engine
1- Coolant temperature sender - G62-
2- Variable intake manifold change-over valve - N156-
3- Variable intake manifold position sender - G513-
4- Coolant valve for cylinder head - N489-
Fitting locations at high-pressure pump

1- Fuel pressure sender for low pressure - G410-
2- Fuel metering valve - N290-


♦ Bolted into gearbox from below
Fitting location: at rear of intake manifold

1- Throttle valve module - J338-
2- Activated charcoal filter solenoid valve 1 - N80-
3- Intake air temperature sender - G42- / intake manifold pres‐
sure sender - G71-
© satelettronica
Fitting location of Lambda probes on cylinder bank 1 (right-side)
1- Lambda probe - G39-
2- Lambda probe after catalytic converter - G130-
Electrical connectors for Lambda probes on cylinder bank 1 (right-

side)
1- For knock sensor 1 - G61-
3 - by
Protected For injectors
4with
- respect
FortoLambda probe
the correctness - G39-in this document. Copyright by AUDI AG.
of information
5- For Lambda probe after catalytic converter - G130-

Fitting location of Lambda probes on cylinder bank 2 (left-side)

1- Lambda probe 2 - G108-
2- Lambda probe 2 after catalytic converter - G131-
Electrical connectors for Lambda probes on cylinder bank 2 (left-

side)
1- For Lambda probe 2 - G131- (after catalytic converter)
2- For Lambda probe 2 - G108-
3- For injectors on cylinder bank 2, fuel pressure sender -
G247- , oil pressure switch for reduced oil pressure - F378-
and valve for oil pressure control - N428-
© satelettronica

♦ At front right in engine compartment below longitudinal mem‐
ber
Fitting location of gearbox oil cooling valve - N509-

♦ At left of subframe

1.1.2 Overview of fitting locations - injection system, vehicles with 2.8 ltr. engine

of Lambda probes on
trical connector
nectors on cylinder bank
1 (right-side)”“ ,
page 282
❑ Exploded view
Lambda probes”,
page 319
valve 1 -N318-
© satelettronica
on cylinder bank 1
(right-side)”“
by AUDI ,AG.page
AUDI 271
permitted unless authorised AG does not guarantee or accept any liability
❑ Exploded view
cylinder head”,
page 132
N205-
on cylinder bank 1
(right-side)”“ , page 271
❑ Exploded view
cylinder head”,

page 132
4 - Lambda probe after catalytic converter - G130-
❑ Fitting location of connector ⇒ Fig. ““Electrical connectors on cylinder bank 1 (right-side)”“ , page 282
5 - Connectors
❑ For injectors, cylinder bank 1
❑ For temperature sender for engine temperature regulation - G694-
❑ For throttle valve module - J338-
❑ For knock sensor 1 - G61-
❑ For Lambda probe - G39-
❑ For Lambda probe after catalytic converter - G130-
❑ Fitting locations of connectors
⇒ Fig. ““Electrical connectors on cylinder bank 1 (right-side)”“ , page 282
❑ Including throttle valve drive for electric throttle - G186- , throttle valve drive angle sender 1 for electric
throttle - G187- and throttle valve drive angle sender 2 for electric throttle - G188-
© satelettronica
❑ Exploded view ⇒ “3.2 Exploded view - intake manifold (bottom section) with fuel rail”, page 291
⇒ Fig. ““Electrical connectorswith
onrespect
cylinder bank 1 (right-side)”“
to the correctness of information in this, document.
page 282 Copyright by AUDI AG.
11 - Injectors, cylinder bank 1
12 - Variable intake manifold position sender - G513-
14 - Actuator for intake manifold changeover
❑ Vacuum unit


❑ With fuel pressure sender, low pressure - G410- and fuel metering valve - N290-
❑ Exploded view ⇒ “6.1 Exploded view - high-pressure pump”, page 312
19 - Ignition coils, cylinder bank 1 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Ignition coil 1 with output stage - N70- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
21 - Secondary air pump motor - V101-

1 - Bracket (left-side) for con‐

nectors
❑ For knock sensor 2 -
G66-
❑ For injectors, cylinder
bank 2
❑ For fuel pressure send‐
er - G247-
❑ Fitting locations of con‐
nectors
nectors”“ , page 281
2 - Lambda probe 2 after cata‐
lytic converter - G131-
of Lambda probes on
cylinder bank 2 (left-
trical connector
© satelettronica
nectors for Lambda
probes on cylinder bank
2 (left-side)”“ ,
page 274
❑ Exploded view
Lambda probes”,
page 319
N208-
on cylinder bank 2 (left-


6 - Lambda probe 2 - G108-
© satelettronica
❑ Removing and installing ⇒ “4.6 Removing and installing valve for oil pressure control N428 ”, page 214
❑ Fitting
permitted location
unless authorised ⇒ Fig.
by AUDI ““Fitting
AG. AUDI AG does locations:
not guaranteecomponents on
inside of left cylinder bank 2”“ , page 281
❑ Fitting location of connector ⇒ Fig. ““Electrical connectors”“ , page 281


A - Engine speed sender - G28-
B - Fuel pump control unit - J538-
❑ Fitting location ⇒ Fig. ““Fitting location of fuel pump control unit -J538- ”“ , page 270
C - Accelerator position sender - G79- / accelerator position sender 2 - G185-
page 270
D - Brake light switch - F-
E - Clutch position sender - G476-
© satelettronica
❑ Only fitted on vehicles with manual gearbox
F - Oil pressure switch - F22-
❑ Fitting location ⇒ Fig. ““Fitting location of oil pressure switch -F22- -A-”“ , page 272
❑ Exploded view ⇒ “4.1 Exploded view - oil filter housing/oil pressure switches”, page 208
G - Oil pressure switch for reduced oil pressure - F378-
❑ Fitting location ⇒ Fig. ““ Oil pressure switch for reduced oil pressure -F378- ”“ , page 281
H - Relay and fuse holder in electronics box in plenum chamber (left-side)
❑ Fitting locations ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
Fitting locations: components on inside of right cylinder bank with
1 respect to the correctness of information in this document. Copyright by AUDI AG.

Fitting locations: components on inside of left cylinder bank 2

© satelettronica
Fitting location: at front of engine
1- Coolant temperature sender - G62-
4- Coolant valve for cylinder head - N489-
2 - Injectors, cylinder bank 2, and for fuel pressure sender - G247-

Electrical connectors on cylinder bank 1 (right-side)

2 - Throttle valve module - J338- and temperature sender for en‐
gine temperature regulation - G694-
1.2 Reducing fuel pressure in high-pressure

section
WARNING
© satelettronica
cause injury.
♦ The injection system consists of a high-pressure section
(maximum approx. 120 bar) and a low-pressure section
(approx. 6 bar).
♦ The fuel pressure in the high-pressure section must be
reduced to a residual pressure of approx. 7 bar prior to
opening the system. The procedure is described below.
Reducing fuel pressure in high-pressure section

– Connect a vehicle diagnostic tester .
– Start engine and run at idling speed.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Basic setting”.
– Select “Reducing fuel pressure in fuel rail” from the list.
– Then select “Measured values”. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Select “Fuel pressure” from the list. with respect to the correctness of information in this document. Copyright by AUDI AG.
– To activate basic setting, perform Operating instructions func‐

tion.
– Observe fuel pressure displayed on vehicle diagnostic tester .
• Fuel pressure will drop to a specified value.
– Switch off engine with pedals depressed.

WARNING
There is a risk of injury: avoid skin contact with fuel.

♦ Wear safety goggles and protective clothing when open‐
ing the fuel system.
♦ Before opening the high-pressure section of the fuel sys‐
tem, place a clean cloth around the connection to catch
escaping fuel.
– The high-pressure system must be opened »immediately« af‐

ter reducing the fuel pressure; wrap a clean cloth around the
connection. Catch the escaping fuel.
Note
The pressure will increase again due to the effect of residual heat
if the high-pressure system is not opened immediately.
Final steps
© satelettronica
– Erase event memory and generate readiness code in engine
control unit in “Guided Functions” mode.

renewed.
– Then check high-pressure system again for leaks.

2 Air cleaner
1 - Air duct
2 - Sealing element
3 - Rubber grommet
© satelettronica
stalling air cleaner hous‐
ing”, page 285
parts catalogue
Maintenance tables
let 411
6 - Air pipe
hose clips
⇒ Fig. ““Installing air
pipes and hoses with
screw-type clips”“ , page
285
7 - Lid
its or dirt
8 - Air duct
❑ 1.5 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Installing air pipes and hoses with screw-type clips
Note


2- Hose clip with width -b- = 9 mm: 3.4 Nm

housing
© satelettronica
Removing
ments .
Note
Disregard -item 1-.


page 64 .
2. Air cleaner 285


-arrow-.
Installing
Note
© satelettronica
♦ When cleaning the air cleaner housing with compressed air,
cover the critical components of the engine intake system such
as intake pipes etc. with a clean cloth to avoid malfunctions.

note the following:
ments .
page 64 .
Tightening torques
page 285

3 Intake manifold
⇒ “3.2 Exploded view - intake manifold (bottom section) with fuel
rail”, page 291
page 294
⇒ “3.5 Removing and installing intake manifold (bottom section)”,
page 296
298

⇒ “3.1.1 Exploded view - intake manifold, vehicles with 2.5 ltr.
engine”, page 287
⇒ “3.1.2 Exploded view - intake manifold, vehicles with 2.8 ltr.
engine”, page 289
© satelettronica
3.1.1 Exploded view - intake manifold, vehicles with 2.5 ltr. engine
1 - Actuator for intake manifold

change-over
2 - Bolt
❑ 2.5 Nm
3 - Variable intake manifold
change-over valve - N156-
4 - Bolt
❑ 8 Nm
5 - Intake manifold
stalling intake manifold”,
page 292
6 - Seal
❑ Renew
J338-
stalling throttle valve
module J338 ”,
page 298
9 - Bolt
❑ 3 Nm
10 - Bracket
❑ On vehicles from model
year 2013 onwards,
secondary air inlet valve
- N112- is secured to

bracket For fitting loca‐

tion refer to ⇒ page 288 .
11 - Bolt
❑ 6 Nm
13 - O-ring
❑ Renew
14 - Bolt
❑ 2.5 Nm
16 - O-ring
❑ Renew
17 - Gaskets
❑ Renew
18 - Seal
© satelettronica
❑ When renewing lever out with screwdriver
❑ Press in by hand
20 - Bolt
❑ 2.5 Nm
Fitting location of secondary air inlet valve - N112-
Note
Secondary air inlet valve - N112- is fitted on vehicles from model

year 2013 onwards.

3 - Vacuum line to vacuum supply
4 - Control pipe to combination
with respectvalves for secondary
to the correctness air
of information inlet

3.1.2 Exploded view - intake manifold, vehicles with 2.8 ltr. engine
1 - Vacuum hose
2 - Variable intake manifold
change-over valve - N156-
3 - Bolt
❑ For variable intake
manifold position send‐
er - G513-
❑ 2.5 Nm
4 - Bolt
❑ 2.5 Nm
5 - Actuator for intake manifold
change-over
toothed segments for in‐
take manifold change-
over
© satelettronica
sition of toothed seg‐
ments for intake mani‐
fold change-over”“ ,
page 291
❑ Replacement part is
supplied together with
-item 26-
6 - Seal
❑ When renewing lever

out with screwdriver

7 - Ball stud
❑ 2.5 Nm
8 - Intake manifold (top sec‐
tion)
❑ Removing and installing ⇒ “3.4 Removing and installing intake manifold (top section)”, page 294
9 - Seal
❑ Renew
11 - Bracket
12 - Bolt
❑ 6 Nm
14 - Hose
© satelettronica
15 - Bolt
❑ 3 Nm
17 - O-ring
❑ Renew
❑ 2.5 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

20 - O-ring
❑ Renew
21 - Bolt
❑ 8 Nm
22 - Washer
24 - Gaskets
❑ Renew
25 - Seal
26 - Lever with toothed segment
27 - Seal
28 - Vacuum hose

Installation position of toothed segments for intake manifold

change-over
• The lower edges of the toothed segments must be flush
-arrow-.
3.2 Exploded view - intake manifold (bottom section) with fuel rail
1 - Intake manifold (bottom

section)
(left and right)
stalling intake manifold
© satelettronica
(bottom section)”,
page 296
2 - Distance sleeve
G247-
installing fuel pressure
sender G247 - vehicles
with 2.8 ltr. engine”,
❑ 20 Nm
4 - Bracket
5 - Bolt
❑ 9 Nm
WARNING
The fuel system oper‐
ates at extremely high
pressure. This can
cause injury.
The
♦ fuel pressure in the
high-pressure section of
the injection system must
be reduced to a residual
pressure prior to opening
the system.
❑ Reducing fuel pressure in high-pressure system

⇒ “1.2 Reducing fuel pressure in high-pressure section”, page 282
❑ Do not alter shape
❑ Do NOT bend open retainer for fuel pipe
❑ If retainer has been bent open or fuel pipe has to be renewed, retainer must also be renewed
❑ 25 Nm

7 - Bolt
❑ 9 Nm
❑ 40 Nm
❑ Renew
9 - Stud
10 - Nut
❑ 9 Nm
11 - Retainer for fuel rail
12 - Bolt
❑ 2.5 Nm
15 - Fuel rail
16 - Gaskets
© satelettronica
❑ Renew
17 - Support ring
❑ Make sure it is correctly seated
❑ Via this support ring, the fuel rail exerts the force which holds the injector in the cylinder head.
18 - O-ring
❑ Renew
❑ Lubricate lightly with clean engine oil
19 - Spacer ring
20 - Combustion chamber ring seal
❑ Renewing ⇒ “4.3.2 Removing and installing injectors - vehicles with 2.8 ltr. engine”, page 305
21 - Radial compensation element
❑ Clip onto support ring -item 17-
22 - Injector
Removing and installing ⇒ “4.3.2 Removing and installing injectors - vehicles with 2.8 ltr. engine”, page 305
Note
The description applies for vehicles with 2.5 ltr. engine.
Removing
Note


page 64 .

© satelettronica
Note
Disregard -item 1-.
– If fitted, unplug electrical connector -2- and disconnect vac‐

uum hoses -3- and -4-.
– Disengage secondary air inlet valve - N112- from bracket.
– Unplug electrical connectors at front of intake manifold.

– Move clear vacuum hoses -arrows-.

– Move clear vacuum hose -arrow-.

– Press retaining tab -2- up slightly and detach crankcase
breather hose from intake manifold.
– Remove bolts -arrows- and detach intake manifold.
Caution

♦ Block off the openings in the cylinder heads with clean
cloths to prevent small items from dropping through the
intake ports into the engine.
© satelettronica
Installing
Note
♦ Renew gaskets and O-rings.

Tightening torques
♦ ⇒ “3.1.1 Exploded view - intake manifold, vehicles with 2.5 ltr.
engine”, page 287
page 285

(top section)
Note
The description applies for vehicles with 2.8 ltr. engine.
Removing
Note
– Remove engine cover panels

page 64 .

– Detach vacuum hose -2-.
Note
Ignore -arrow-.
© satelettronica
Unplug following electrical connectors:
3 - Intake air temperature sender - G42- / intake manifold pressure
sender - G71-
– Take activated charcoal filter solenoid valve 1 - N80- out of
bracket and move to side with hose attached.
– Unplug electrical connectors at front of intake manifold.

3 - Variable intake manifold positionpermitted
sender - G513-

– Move vacuum hose clear -arrow-.

– Press retaining tab -2- up slightly and detach crankcase
breather hose from intake manifold.
– Unscrew bolts -arrows- and remove intake manifold (top sec‐

tion).
Note
Seal intake ports on cylinder heads with clean cloths.
Installing
© satelettronica
Note

Tightening torques
♦ ⇒ “3.1.2 Exploded view - intake manifold, vehicles with 2.8 ltr.
engine”, page 289 with respect to the correctness of information in this document. Copyright by AUDI AG.

page 285

(bottom section)
Note
♦ The description applies for vehicles with 2.8 ltr. engine.

♦ The intake manifold (bottom section) and fuel rail are removed
and installed together.
Removing
Note
The following description shows the removal and installation of

the bottom section of the intake manifold (left-side). The proce‐
dure for the other side is more or less identical.

WARNING

cause injury.
prior to opening the system
page 282 .
dissipate.
– Remove intake manifold (top section) ⇒ page 294
permitted . authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
-item 2-.
– Unscrew bolts and nuts -arrows- and detach intake manifold
(bottom section) with fuel rail.
© satelettronica
Note
Seal intake ports on cylinder heads with clean cloths.
Installing
Note
♦ If an injector has been pulled out of the cylinder head, the tef‐
lon ring seal must be renewed.
♦ Lubricate O-rings of injectors lightly with clean engine oil.
– Press intake manifold (bottom section) with fuel rail evenly on‐
to injectors.
– Tighten bolts and nuts -arrows- for intake manifold (bottom

section) in diagonal sequence and in stages.
– Plug in electrical connector -2- at fuel pressure sender -
G247- .
– Fit high-pressure pipe on fuel rail
⇒ Fig. ““Installing high-pressure pipe on fuel rail”“ ,
page 318 .
Tightening torques
♦ ⇒ “3.2 Exploded view - intake manifold (bottom section) with
fuel rail”, page 291


module - J338-
Removing
page 64 .
– Release hose clips -arrows- and remove air pipe.
© satelettronica
J338- with intermediate flange.
Caution

♦ Block off the openings in the cylinder heads with clean
cloths to prevent small items from dropping through the
intake ports into the engine.
Installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
page 64 .
Tightening torques

4 Injectors
Note
This exploded view applies for vehicles with 2.5 ltr. engine.

G247-
installing fuel pressure
sender G247 - vehicles
with 2.5 ltr.forengine”,
© satelettronica
Protected by copyright. Copying private or commercial purposes, in part or in whole, is not
permitted unlesspage 311by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
❑ 20 Nm
2 - Bracket
3 - Bolts
❑ 9 Nm
WARNING
pressure. This can
cause injury.
The
the system.
❑ Reducing fuel pressure

in high-pressure system
⇒ “1.2 Reducing fuel
pressure in high-pres‐
sure section”, page 282
❑ Do NOT bend open re‐
tainer for fuel pipe
❑ If retainer has been bent
open or fuel pipe has to be renewed, retainer must also be renewed
❑ Tightening ⇒ Fig. ““Installing high-pressure pipe on fuel rail”“ , page 318
5 - Bolt
❑ 9 Nm
6 - Union nut
❑ Lubricate threads lightly with clean engine oil
❑ 25 Nm
4. Injectors 299
7 - Union nut
❑ 25 Nm
❑ 40 Nm
9 - Nut
❑ 9 Nm
10 - Bolt
❑ 9 Nm
11 - Fuel rail
12 - Support ring
❑ Make sure it is correctly seated
❑ Via this support ring, the fuel rail exerts the force which holds the injector in the cylinder head.
13 - O-ring permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renew with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
14 - Spacer ring
15 - Injector
Removing and installing ⇒ “4.3.2 Removing and installing injectors - vehicles with 2.8 ltr. engine”, page 305
16 - Sealing washer
❑ Renewing ⇒ “4.3.1 Removing and installing injectors - vehicles with 2.5 ltr. engine”, page 301
Note
♦ The description applies for vehicles with 2.5 ltr. engine.

♦ The following instructions describe the removal and installa‐
tion procedures for the fuel rail on the left side. The procedure
for the right side is similar.
Removing
WARNING

cause injury.
page 282 .
dissipate.


-item 5-.
– Remove bolts -1, 4 and 6- and nut -3- and detach fuel rail.
Installing
Note
♦ If an injector has been pulled out of the cylinder head, the tef‐
lon ring seal must be renewed.
– Press fuel rail evenly onto injectors.
© satelettronica
– Fit high-pressure pipe on fuel rail
⇒ Fig. ““Installing high-pressure pipe on fuel rail”“ ,
page 318 .
Tightening torques
♦ ⇒ “4.1 Exploded view - fuel rail with injectors”, page 299

⇒ “4.3.1 Removing and installing injectors - vehicles with 2.5 ltr.
engine”, page 301
⇒ “4.3.2 Removing and installing injectors - vehicles with 2.8 ltr.
engine”, page 305
4.3.1 Removing and installing injectors - ve‐

hicles with 2.5 ltr. engine
♦ Tool set for FSI engines - T10133 C-
4. Injectors 301
Removing
WARNING

cause injury.
page 282 .
dissipate. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Remove fuel rail
If injectors cannot be pulled out of cylinder head by hand, proceed
© satelettronica
as follows:
– Pull support ring -4- off injector -1-.
– Guide puller -T10133/2A- into groove on injector.

– Then attach removal tool -T10133/16- and pull out injector by
turning bolt -1-.

– Carefully remove old combustion chamber ring seal -arrow-.

To do so, cut open combustion chamber ring seal using knife
or prise open with small screwdriver and then pull off forwards.
Note
Take care not to damage groove on injector. Injector must be re‐

newed if groove is damaged.
Installing
Note
♦ Renew combustion chamber ring seals and O-rings.

♦ Renew spacer ring and radial compensation element if dam‐
aged.
♦ Lightly lubricate O-rings for injectors with clean engine oil.
♦ The injector pipes must be re-installed on the same cylinders.
© satelettronica
– Clean bore in cylinder head with nylon cylinder brush -
T10133/4- .
– When re-installing an injector, clean any combustion residue
off groove for combustion chamber ring seal andwithinjector
respect to stem
with a clean cloth.
– Fit assembly cone -T10133/5- with new combustion chamber

ring seal -1- from repair kit onto injector -2-.
– Using assembly sleeve -T10133/6- , push combustion cham‐

ber ring seal onto assembly cone -T10133/5- as far as it will
go.
– Turn round assembly sleeve -T10133/6- and slide combustion
chamber ring seal into groove.
4. Injectors 303
Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. After pushing it on, it therefore has to be com‐
pressed again. This is done in two stages, as described below.
– Push calibration sleeve -T10133/7- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again by turning it in the
opposite direction.

opposite direction. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
© satelettronica
– Fit parts from repair kit onto injector -1-:
2 - Spacer ring
3 - O-ring
4 - Support ring
5 - Sealing washer
– To make it easier to install injector in fuel rail, lubricate new O-
ring lightly with clean engine oil before installing it.
Note
The combustion chamber ring seal -6- must not be lubricated.
– Push injector by hand as far as it will go into aperture in cylin‐

der head (do not use oil or grease). Ensure that the injector is
properly seated in the cylinder head.
Note
♦ It should be possible to insert injector easily. If necessary wait

until the combustion chamber ring seal has contracted suffi‐
ciently.
♦ Note correct installation position and ensure that injectors are
properly seated in cylinder head.
♦ If the injector cannot be pushed in by hand, use puller -
T10133/2A- -2- with striker - T10133/3- to insert the injector.

Installation position of support ring:

• Lug -1- on support ring must engage in recess -arrow- in cyl‐
inder head.
note the following:
– Install fuel rail

hicles with 2.8 ltr. engine
© satelettronica
Note
Special tool T10133/2 (puller) has been modified and now
permitted unless hasbythe
authorised AUDI AG. AUDI AG does not guarantee or accept any liability
designation puller T10133/2 A . If you havewith
notrespect
yet received the
new tool you can make the modification yourself.
Modifying special tool T10133/2 (puller) to make it equivalent to

puller T10133/2 A
♦ Round file, approx. 6 mm
– File out a semi-circular recess as shown in the illustration. The
recess allows the tool to be pushed further onto the injector so
the contact surface is increased.
– For identification purposes, mark the modified tool with the
letter “A” after the tool number.
4. Injectors 305
Injector - exploded view

1- Injector
2- Spacer ring (renew if damaged)
3- O-ring (renew; apply thin coating of clean engine oil prior to
installation)
4- Support ring (via the support ring the fuel rail exerts force
which secures injector in cylinder head)
5- Radial compensation element (renew if damaged)
6- Combustion chamber ring seal (teflon ring seal) - renew;
when fitting, do not grease ring or use any other lubricant.
Removing
WARNING

cause injury.
© satelettronica
page 282 .
dissipate.
Note
Injectors must only be installed when engine is cold.

page 294 .
– Remove intake manifold (bottom section) on relevant side
tion)”, page 296 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If injectors cannot be pulled out of cylinder head by hand,
with proceed
as follows:
– Use a screwdriver to bend retainer tabs -1- of radial compen‐
sation element to side -arrow- and pull support ring -2- off
injector.

– Slide stop sleeve -T10133/18- over injector.
– Carefully knock against stop sleeve several times to loosen

injector.
Note
♦ Use a torque wrench to pull out injector.

♦ Adjust torque wrench to 5 Nm.
© satelettronica
– Guide puller -T10133/2A- into groove on injector.
– Then apply puller T10133/16A .
– Pull out injector by turning bolt with torque wrench -1-.
– If injector does not come loose after limit torque of 5 Nm is
reached, remove puller and repeat procedure using stop
sleeve to loosen injector.
Note
♦ Observe correct torque to avoid irreparable damage to injec‐

tor. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The combustion chamber ring seal must always be renewed

prior to reinstalling the injector.
4. Injectors 307
– Carefully remove old combustion chamber ring seal -arrow-.

To do so, cut open combustion chamber ring seal using knife
or prise open with small screwdriver and then pull off forwards.
Note

Installing
Note
♦ Renew combustion chamber ring seals and O-rings.

♦ Renew spacer ring and radial compensation element if dam‐
aged.
♦ Lightly lubricate O-rings for injectors with clean engine oil.
♦ The injector pipes must be re-installed on the same cylinders.
© satelettronica
T10133/4- .
off groove for combustion chamber ring seal and injector with
stem
with a clean cloth.


go.

Note


opposite direction.

opposite direction.
© satelettronica
2 - Spacer ring
3 - O-ring
4 - Support ring
5 - Sealing washer
Note

4. Injectors 309
Note

ciently.
• Electrical connector of injector must engage in recess in cyl‐

inder head.
note the following:
– Install intake manifold (bottom section)
– Protected
Install intake manifold
by copyright. Copying for(top section)
⇒ “3.4 Removing
permitted and
unless authorised installing
by AUDI AG. AUDIintake manifold
AG does not guarantee(top section)”,
© satelettronica
page 294 .to the correctness of information in this document. Copyright by AUDI AG.
with respect


311

sender - G247-
⇒ “5.1.1 Removing and installing fuel pressure sender G247 - ve‐
hicles with 2.5 ltr. engine”, page 311
⇒ “5.1.2 Removing and installing fuel pressure sender G247 - ve‐
hicles with 2.8 ltr. engine”, page 311
5.1.1 Removing and installing fuel pressure

sender - G247- - vehicles with 2.5 ltr.
engine
Removing
© satelettronica
– Unscrew fuel pressure sender - G247- .
Installing
Tightening torques
5.1.2 Removing and installing fuel pressure

sender - G247- - vehicles with 2.8 ltr.
engine
Removing
page 294 .
-4-.
– Unscrew fuel pressure sender - G247- -4-.
Installing
– Install intake manifold (top section)
page 294 .
Tightening torques

⇒ “6.3 Removing and installing high-pressure pipe”, page 317
1 - Fuel pressure sender for

low pressure - G410-
❑ 15 Nm
2 - Not fitted Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.

sequence
⇒ Fig. ““High-pressure
pump - tightening torque
page 313
© satelettronica
- N290-
stalling high-pressure
pump”, page 314
❑ Connections must not
be damaged
❑ 27 Nm
❑ Low-pressure section
WARNING
pressure. This can
cause injury.
The
the system
⇒ “1.2 Reducing fuel
pressure in high-pres‐
sure section”, page 282 .
❑ Removing and installing ⇒ “6.3 Removing and installing high-pressure pipe”, page 317
❑ Check for damage before re-installing
❑ Lubricate thread of union nut with clean engine oil
❑ 25 Nm

8 - Gasket
❑ Renew
9 - Housing
11 - Bolt
12 - O-ring
❑ Renew
13 - Protective plate
❑ For high-pressure pipe
❑ Different versions available
⇒ Fig. ““Guard plate for high-pressure pipe - tightening torque”“ , page 313 ; for allocation refer to ⇒
14 - Nut
❑ 9 Nm
15 - Threaded pin
© satelettronica
❑ 9 Nm
16 - Roller tappet
❑ Lubricate lightly with clean engine oil before installing
17 - O-ring
❑ Renew
High-pressure pump - tightening torque and sequence

1. -arrows- Screw in by hand until contact is made
2. -arrows- 5 Nm
3. -arrows- Tighten in stages and alternately; final
torque 20 Nm
Guard plate for high-pressure

with respect topipe - tightening torque
– Tighten bolts -arrows- securing guard plate -1-.

• Tightening torque: 9 Nm


pump
♦ Wrench, 21 mm - T40263-
© satelettronica
Removing
WARNING

cause injury.
page 282 .
dissipate.
Note
♦ The high-pressure pump should only be removed and installed

when the engine is cold.
♦ When installing the high-pressure fuel pump, it is essential to
ensure that no dirt enters the fuel system.
♦ Use a cloth to catch escaping fuel.
♦ The O-ring must always be renewed.


282 .
page 285 .
– Unscrew nuts -arrows- and remove guard plate -1-.

– Remove bolt -3- on retaining clip.
© satelettronica
– Unscrew connections -2- and -5-.
– Carefully pull out high-pressure pump. It is possible that the
roller tappet may remain lodged inside.
Note

♦ Do not bend fuel pipes to a different shape.
♦ Do NOT bend open retaining clamps for fuel pipe.
♦ If one of the retaining clamps has been bent open or the fuel
pipe has to be renewed, the retaining clamps must also be
renewed.
– Pull roller tappet -1- out of housing.

Installing
Note
♦ The connections of the high-pressure pipe must not be dam‐

aged.
♦ Do not bend fuel pipes to a different shape.
renewed.
– Renew O-ring for high-pressure pump.

– Check roller tappet -1- for damage and renew if necessary.

– Lightly lubricate roller tappet with oil and insert it so that lug
-arrow A- slides into guide notch -arrow B-.
Note
The roller tappet must be positioned at the lowest point when in‐
stalling the high-pressure pump.

T40263- .
– Rotate crankshaft in direction of normal engine rotation
-arrow- using wrench (21 mm) - T40263- and turning-over tool
- T40272- , and at the same time press roller tappet into hous‐
© satelettronica
ing until it reaches lowest point.
– Only lift high-pressure pipe slightly to fit high-pressure pump.
– Insert high-pressure pump into housing.
– Press high-pressure pump down by hand as far as possible
onto stop.
– Hand-tighten the bolts -arrows- as far as the flange.

– Then initially tighten securing bolts alternately to 5 Nm
Protected by copyright. (do not
tilt high-pressure pump). permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
The high-pressure pump can be damaged if it is tightened too

much on one side (keep it straight).
• Final tightening torque for securing bolts

– Tighten union nut -5- on fuel supply line hand-tight. Align so
that parts are free of tension.
– Connect fuel supply hose -2- again.

– Tighten bolt -3- on retaining clip.

– Plug in electrical connectors -1- and -6-.
Note
Disregard -item 4-.
– Tighten high-pressure pipe to specified torque

⇒ Fig. ““Installing high-pressure pipe at high-pressure pump”“ ,
page 318 .
– Install guard plate -1-.

page 285 .
– Check fuel system for leaks
⇒ “1.3 Checking fuel system for leaks”, page 283 .
© satelettronica
pipe
Special tools and workshop equipment
Protected by copyright.required
♦ Torque wrench - V.A.G 1331-
♦ Tool insert (open-end ring spanner, 17 mm) -V.A.G 1331/2-

♦ Socket SW 14 - 3150- or flared ring spanner tool insert AF 14

- V.A.G 1331/8-
Procedure
Note
♦ The connections of the high-pressure pipes must not be dam‐

aged.
♦ Do not bend the high-pressure pipes out of shape.
© satelettronica
renewed.
– Lubricate threads of union nuts with clean engine oil.

– Hand-tighten union nuts on high-pressure pipes (ensure that
pipes are not under tension).
Installing high-pressure pipe at high-pressure pump
– Tighten union nut on high-pressure pipe hand-tight initially.
– Ensure that high-pressure pipe is not under tension.
– To tighten union of high-pressure pipe at high-pressure pump,
use torque wrench - V.A.G 1331- with ratchet - V.A.G 1331/1-
and socket, 14 mm - 3150- .
Installing high-pressure pipe on fuel rail Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten union nut on high-pressure pipe hand-tight initially.

– To tighten high-pressure pipe on fuel rail, use torque wrench
- V.A.G 1331- with tool insert (open-end ring spanner, 17 mm)
-V.A.G 1331/2- .
– Do not install retaining tabs until high-pressure pipes have
been tightened.
Tightening torques

7 Lambda probes
⇒ “7.1 Exploded view - Lambda probes”, page 319
7.1 Exploded view - Lambda probes
Note
♦ New Lambda probes are coated with an assembly paste.

♦ In the case of a used Lambda probe, coat only the thread with
high-temperature paste; refer to ⇒ Electronic parts catalogue
for high-temperature paste.
♦ The assembly paste / high-temperature paste must not make
contact with the slots on the Lambda probe body.

❑ With Lambda probe
© satelettronica
heater - Z19-
installing Lambda probe
G39 ”, page 320
❑ 55 Nm
ic converter - G130-
❑ With Lambda probe 1
heater after catalytic

converter - Z29-
after catalytic converter
G130 ”, page 323
❑ 55 Nm
heater 2 - Z28-
2 G108 ”, page 321
❑ 55 Nm
converter - Z30-
2 G108 ”, page 321
❑ 55 Nm
7. Lambda probes 319


page 320
⇒ “7.2.2 Removing and installing Lambda probe 2 G108 ”,
page 321
⇒ “7.2.4 Removing and installing Lambda probe 2 after catalytic

- G39-
© satelettronica
Removing
Note

page 64 .
clear at air pipe.

– Unplug electrical connector -4- for Lambda probe - G39- .

Note

the engine removed.
© satelettronica
Installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note

body.
♦ When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into

page 64 .
Tightening torques
♦ ⇒ “7.1 Exploded view - Lambda probes”, page 319
page 285

2 - G108-

Removing
Note
© satelettronica
page 64 .
– Push coolant expansion tank to one side with coolant hoses
-arrows- attached.
– Unplug electrical connector -2- for Lambda probe 2 - G108- .

– Unscrew Lambda probe 2 - G108- -1- using tool from Lambda

Note

the engine removed.
Installing
Installation is carried out in the reverse
Protected order;
by copyright. noteforthe
Copying following:
Note

body.
© satelettronica

page 64 .
Tightening torques

after catalytic converter - G130-
Removing
Note


page 64 .

lytic converter - G130- .
© satelettronica

– Unscrew Lambda probe after catalytic converter - G130- -2-

using tool from Lambda probe open ring spanner set - 3337- .
Note

the engine removed.
Installing
Note

body.
© satelettronica

page 64 .
Tightening torques
page 285

2 after catalytic converter - G131-
Removing
Note


page 64 .
-arrows- attached.
© satelettronica
– Unplug electrical connector -1- for Lambda probe 2 after cat‐
alytic converter - G131- .

– Unscrew Lambda probe 2 after catalytic converter - G131-

-2- using tool from Lambda probe open ring spanner set -
3337- .
Note

the engine removed.
Installing
Note

body.
© satelettronica
tached at the same locations to prevent it from coming to theinto

with respect correctness of information in this document. Copyright by AUDI AG.

page 64 .
Tightening torques


page 330

© satelettronica
♦ Test box - V.A.G 1598/42-


Note
♦ The test box - V.A.G 1598/42- has 105 sockets. It can be con‐
nected to the engine control unit via 2 different adapter cables.
♦ The engine control unit is connected to the vehicle's wiring
harness via two connectors, one of which has 60 pins, the
other has 94 pins.
-A- on the test box. For components connected to 60-pin wiring
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.
and to the engine control unit itself at the same time. The ad‐
© satelettronica
vantage of this is that the electronic engine control system
remains fully functional when the test box is connected (for
example, for measuring signals when the engine is running).
♦ Always use auxiliary measuring set - V.A.G 1527B- to connect
test equipment (e.g. voltage tester - V.A.G 1526E- , hand-held
multimeter - V.A.G 1594C- etc.).
Caution

♦ Select the appropriate measuring range before connect‐
ing the test leads and observe test requirements.
– Remove engine control unit - J623-

”, page 330 .
– Connect test box - V.A.G 1598/42- to wiring harness connec‐
tor. The earth clip on the test box must be connected to the
negative battery terminal. The instructions for performing the
individual tests indicate whether or not the engine control unit
- J623- itself also needs to be connected to the test box.
Installing engine control unit
The procedure required after connecting the new engine control
unit is described in the Guided Fault Finding or Guided Functions.
Note
After completion of the Guided Fault Finding routine, the tester

will attempt to erase the event memories of all control units. If this
is not successful, the remaining events saved in the memories
must be dealt with so that all event memory entries can be erased.


Note
© satelettronica
locking fluid.
♦ The metal locking plate has to be removed before the con‐
nectors can be unplugged from the engine control unit (e.g. to
Removing
vehicle diagnostic tester .
chamberProtected
coverby. copyright. Copying for private or commercial purposes, in part or in whole, is not


-item 1-.
Note
Disregard -item 2-.
Caution
Wiring, connectors, insulation and control units can be burnt

and damaged.
♦ Keep exactly to the following procedure. Observe the in‐
structions for operating the hot air blower.

© satelettronica
plate -2-.
air blower.
WARNING
The shear bolts and protective housing also become very hot
when heating the threads of the locking mechanism. 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.


– Unscrew shear bolts using mole grips (see arrow in illustra‐
tion).
heated.
nectors.
Installing
© satelettronica
– After installation, the protective housing must be re-fitted on
the engine control unit - J623- .
chamber cover .
must be performed:
– Activate engine control unit via a vehicle diagnostic
Protected testerforinprivate or commercial purposes, in part or in whole, is not
by copyright. Copying
“Guided Functions” mode, “Replace permitted
engineunless
control unit”.

1 - Bolt
❑ 20 Nm
2 - Mounting
❑ Check preload
© satelettronica
⇒ “1.4 Stress-free
by AUDI AG. align‐
permitted unless authorised AUDI AG does not guarantee or accept any liability
with respectment of exhaust
to the correctness sys‐ in this document. Copyright by AUDI AG.
of information
tem”, page 339
3 - Centre silencer
for repair purposes
❑ Remove diagonal struts
prior to removal
⇒ Fig. ““Diagonal struts
(Audi A7)”“ , page 336
❑ Cutting point
⇒ “1.2 Separating ex‐
haust pipes/silencers”,
page 336
tem”, page 339
4 - Rear silencer
❑ Combined as one unit
with centre silencer as
original equipment
❑ Centre silencer and rear
silencer can be renewed
separately
prior to removal ⇒ Fig. ““Diagonal struts (Audi A7)”“ , page 336
❑ Cutting point: centre silencer / rear silencer ⇒ “1.2 Separating exhaust pipes/silencers”, page 336
❑ Align exhaust system so it is free of stress ⇒ “1.4 Stress-free alignment of exhaust system”, page 339
5 - Gasket
❑ Renew
6 - Nut
❑ 23 Nm

❑ Renew
❑ Removing and installing ⇒ “2.1 Removing and installing catalytic converters”, page 341
❑ Mounting components:
♦ Vehicles with multitronic gearbox 0AW (front-wheel drive)
⇒ Fig. ““Components of mountings for catalytic converter - vehicles with multitronic gearbox 0AW (front-
wheel drive)”“ , page 335
♦ Vehicles with manual gearbox or 7-speed dual clutch gearbox 0B5
⇒ Fig. ““Components of mountings for catalytic converter - vehicles with manual gearbox or 7-speed dual
clutch gearbox 0B5”“ , page 336
8 - Nut
❑ 23 Nm
❑ Renew
9 - Gasket
❑ Renew
© satelettronica
10 - Front silencer
❑ Removing and installing ⇒ “1.3 Removing and installing front silencer”, page 338
11 - Clamp (front)
❑ Installation position ⇒ Fig. ““Installation position of front clamps”“ , page 335
❑ Push onto front silencer as far as stop
❑ Before tightening, align exhaust system so it is free of stress
12 - Nut
❑ 23 Nm
13 - Trim
❑ For tailpipe
❑ Slide onto tailpipe as far as stop
14 - Mounting
15 - Nut
❑ Renew
❑ 20 Nm
16 - Clamp (rear)
❑ Installation position ⇒ Fig. ““Installation position of rear clamps”“ , page 335
17 - Nut
❑ 23 Nm
18 - Bolt
❑ 23 Nm

19 - Mounting
Installation position of front clamps

bottom of clamp.
• Installation position: bolted connections face outwards.

bottom of clamp.
© satelettronica
Components of mountings for catalytic converter - vehicles with

multitronic gearbox 0AW (front-wheel drive)
1- Nut, 23 Nm
2- Spacer sleeve
4- Washer
5- Bolt
6- Bolt, 23 Nm
7- Spacer sleeve
8- Buffer
9- Bracket
10 - Bolt, 23 Nm
11 - Bracket
Note
The illustration shows the right-side mounting. The mountings

(left-side) are symmetrically reversed.

Components of mountings for catalytic converter - vehicles with

manual gearbox or 7-speed dual clutch gearbox 0B5
1- Nut, 23 Nm
2- Spacer sleeve
4- Washer
5- Bolt
6- Bolt, 23 Nm
7- Spacer sleeve
8- Buffer
9- Bracket
10 - Bolt, 23 Nm
11 - Bracket
Note
© satelettronica
Diagonal struts (Audi A7)

– Remove diagonal struts -1- and -2- when removing centre si‐
lencer and rear silencer unit.
– Install diagonal struts ⇒ Running gear, axles, steering; Rep.
gr. 42 ; Subframe; Exploded view - subframe . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability


Procedure
– Audi A7: Remove bolts on both sides and detach diagonal
struts -1- and -2-.
© satelettronica


bottom of clamp.
– Align the exhaust system so it is free of stress
⇒ “1.4 Stress-free alignment of exhaust system”, page 339 .
Tightening torques
♦ Diagonal struts ⇒ Running gear, axles, steering; Rep. gr. 42 ;

Removing
noise insulation .
© satelettronica

Caution

than 10°.
– Release and push back clamp -1- or -2- and detach relevant
front silencer.
Installing
Note
♦ Renew gaskets and self-locking nuts.

♦ Coat threads of nuts with high-temperature paste; for high
temperature paste refer to ⇒ Electronic parts catalogue .
© satelettronica
Tightening torques
1.4 Stress-free alignment

Protected by copyright. Copying forof exhaust
private system
Procedure with respect to the correctness of information in this document. Copyright by AUDI AG.

ers
6 ... 10 mm.

Note


6 ... 10 mm.
– Tighten bolted connections on front clamps evenly.

ded by -a- = 11 ... 15 mm.
© satelettronica
Aligning tailpipes
• Tightening torque
Tightening torques

– Plug tailpipes during leak test (e.g. with cloth or plugs).
– Listen for noise at connections between cylinder head/exhaust
manifold, exhaust manifold/front exhaust pipe, etc. to locate
any leaks.


⇒ “2.1 Removing and installing catalytic converters”, page 341

verters
⇒ “2.1.1 Removing and installing catalytic converter (left-side) -
vehicles with manual gearbox”, page 341
vehicles with multitronic gearbox 0AW”, page 343
vehicles with dual clutch gearbox 0B5”, page 343
⇒ “2.1.4 Removing and installing catalytic converter
Protected by copyright.(right-side) - or commercial purposes, in part or in whole, is not
Copying for private
vehicles with manual gearbox/multitronic gearbox
permitted 0AW”,by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
⇒ “2.1.5 Removing and installing catalytic converter (right-side) -

vehicles with dual clutch gearbox 0B5”, page 347
© satelettronica
verter (left-side) - vehicles with manual
gearbox
Removing
Note
– Remove Lambda probe 2 after catalytic converter - G131-

⇒ “7.2.4 Removing and installing Lambda probe 2 after cata‐
lytic converter G131 ”, page 325 .
cross brace .
Caution

– Remove front silencer (left-side)

⇒ “1.3 Removing and installing front silencer”, page 338 .
move clear by sliding splines together ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and instal‐
ling intermediate steering shaft .

– Remove bolts -arrows- and detach heat shield (left-side) -1-

on subframe.
– Remove nuts -arrows- and bolt -1-.

– Detach catalytic converter (left-side).
Installing
Note
© satelettronica
– Install intermediate steering shaft ⇒ Running gear, axles,

– Install front silencer
– Install Lambda probe 2 after catalytic converter - G131-
Tightening torques
♦ ⇒ Fig. ““Components of mountings for catalytic converter - ve‐
hicles with manual gearbox or 7-speed dual clutch
gearbox 0B5”“ , page 336
♦ Subframepermitted
crossunless
brace ⇒ Running
authorised by AUDI AG.gear,
AUDI axles,
AG does notsteering; Rep.
gr. 40 ; Subframe;
with respect toExploded view
the correctness - subframe


verter (left-side) - vehicles with multi‐
tronic gearbox 0AW
Removing
gearbox; Removing gearbox
Note
Disregard items -2, 3, 4- and -arrows-.
– Unscrew nuts -arrows- and detach catalytic converter (left-

side).
© satelettronica
Note

the engine removed.
Installing
Note


Tightening torques

verter (left-side) - vehicles with dual
clutch gearbox 0B5
♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Gearbox support - T10337-
Removing
Note
© satelettronica
cross brace .
Caution


– Unscrew bolts -arrows- and remove cover -1- from side of

gearbox.

– Loosen bolted connection -2- and swivel bracket -1- to rear

-arrow-.
Note
Disregard -item 1-.
© satelettronica
– Fit gearbox support - T10337- ontotoengine
with respect and ofgearbox
the correctness information jack
- V.A.G 1383 A- and position underneath gearbox.
– Raise gearbox slightly using engine and gearbox jack.
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 under the vehicle.
– Remove bolts -arrows- for tunnel cross member.

– Lower tunnel cross member as far as distance -a- using engine

and gearbox jack - V.A.G 1383 A- .
• Distance -a- = 70 mm (maximum)
Installing
Note


© satelettronica
Tightening torques
♦ Subframe cross brace ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Exploded view - subframe
♦ Tunnel cross-piece ⇒ Rep. gr. 34 ; Assembly mountings; Ex‐
ploded view - assembly mountings
♦ Cover on gearbox ⇒ Rep. gr. 34 ; ATF circuit; Exploded view
- ATF circuit


verter (right-side) - vehicles with manual
gearbox/multitronic gearbox 0AW
Removing
– Take electrical connector -1- for Lambda probe after catalytic
converter - G130- out of bracket, unplug and move clear.
Note
– Detach catalytic converter (right-side).

Installing
© satelettronica
Note

Tightening torques
2.1.5 Removing and installing catalytic

Protectedcon‐
verter (right-side) - vehicles with dual
clutch gearbox 0B5

Removing
Note
– Remove front silencer (right-side)
© satelettronica
cross brace .
Caution


page 298 .
– Remove coolant pipe from right side of gearbox
gearbox”, page 248 .
– Remove Lambda probe after catalytic converter - G130-
converter G130 ”, page 323 .
– Detach electrical connectors -1 ... 4- from bracket.
– Remove bolts -arrows- and detach bracket.

– Remove nuts -arrows- and bolt -1- and move catalytic con‐
verter (right-side) towards rear.
– Remove bolts and detach retainer -1- for bracket for exhaust
system.
© satelettronica
– Remove bolts -arrows- and detach heat shield.
– Remove bolts -2-, detach combination valve (right-side) for

secondary air system and press it to left side with secondary
air hose connected.
Note
Disregard -item 1-.

– Release fasteners -arrows- and detach heat shield -1- for tun‐
nel (top right).
– Fit gearbox support - T10337- onto engine and gearbox jack

WARNING
Risk of accident.
© satelettronica

• Distance -a- = 60 mm (maximum) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Secure gearbox in position using retaining tool - VW 785/1 B- ,

– Lift off catalytic converter (right-side).
Installing
Note

– Install combination valve for secondary air (right-side)

– Install Lambda probe after catalytic converter - G130-
converter G130 ”, page 323 .
– Install coolant pipe (right-side) on gearbox
© satelettronica
⇒ “3.2.5 Removing and installing coolant pipe (left-side) on
– Install throttle valve module - J338-
page 298 .
Tightening torques
♦ ⇒ Fig. ““Components of mountings for catalytic converter - ve‐
hicles with manual gearbox or 7-speed dual clutch
gearbox 0B5”“ , page 336 with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Strips / trim
panels / extensions; Exploded view - heat shield


”, page 353
⇒ “3.3 Checking combination valve for secondary air system”,
page 355

Secondary air pump motor - V101-
Note
The illustration shows the version for the 2.8 ltr. engine.

- V101-
❑ Fitting location: At front
© satelettronica
right of engine compart‐
ment below longitudinal
member
stalling secondary air
pump motor V101 ”,
page 353
agnostic tester
2 - Bolt
❑ 9 Nm
❑ 3x
4 - Bracket
❑ For secondary air pump
motor - V101-
5 - Nut
❑ 9 Nm
6 - Hose
❑ From air cleaner
7 - O-rings
❑ Renew
8 - Hose
❑ To combination valves
for secondary air inlet
Combination valves for secondary air system

1 - Hose
❑ From secondary air
pump motor - V101-
2 - Gasket
❑ Renew
3 - Bolts
❑ 9 Nm
4 - Combination valve for sec‐
ondary air system (right-side)
❑ Check operation and
check for leaks
⇒ “3.3 Checking combi‐
nation valve for secon‐
dary air system”,
page 355
installing combination
valve (right-side)”,
page 360
© satelettronica
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 9 Nm
ondary air system (left-side)
check for leaks
nation valve for secon‐
dary air system”,
page 355
⇒ “3.4.1 Removing and installing combination valve (left-side)”, page 358
8 - Bolts
❑ 9 Nm
9 - Gasket
❑ Renew

pump motor - V101-
Removing
Note
– Remove wheel spoiler (front right) ⇒ General body repairs,

exterior; Rep. gr. 66 ; Wheel housing liners; Exploded view
-
wheel housing
correctnessliner (front)in.this document. Copyright by AUDI AG.
with respect to the of information

– Vehicles with auxiliary heater: Release clamp -arrow- and

swivel exhaust pipe for auxiliary heater -1- to rear.
– Remove air intake grille (right-side) from bottom section of
bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 ;

V101- .
– Press release tabs and detach secondary air hoses -1- and
-4-.
– Remove nuts -3- and detach secondary air pump.
© satelettronica

V101- .
-2-.
Installing
Note
Fit new O-rings.
– Install tailpipe for auxiliary heater ⇒ Auxiliary heater, supple‐

mentary heater; Rep. gr. 82 ; Auxiliary/supplementary heater;
Removing and installing exhaust system .
Tightening torques

3.3 Checking combination valve for secon‐

dary air system
⇒ “3.3.1 Checking combination valve for secondary air system -
vehicles up to model year 2013”, page 355
⇒ “3.3.2 Checking combination valve for secondary air system -
vehicles from model year 2013 onwards”, page 356
3.3.1 Checking combination valve for secon‐

dary air system - vehicles up to model
year 2013
Procedure
• No leaks in hose connections.
Combination valve for secondary air system (left-side):
body brace .
Combination valve for secondary air system (right-side):
© satelettronica
page 298 .
– Remove bolts -2- and press secondary air hoses to side.
Note
Disregard -item 1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Connect suitable hose -arrow- to combination valve for sec‐

ondary air, as shown in illustration.
– Blow lightly into test hose with your mouth (do not use com‐
pressed air).
• The combination valve for secondary air system should be
closed; it should not be possible to blow through the hose.
– Blow more firmly (i.e. with greater pressure) into test hose with
your mouth (do not use compressed air).
• The combination valve for secondary air system should open;
it should now be possible to blow through the hose.
Note
It is necessary to overcome slight initial resistance before it is

possible to blow through the hose.
– Renew combination valve for secondary air system if you can‐

not determine the switching point: (left-side)
side)”, page 358 , (right-side)
© satelettronica
Installing
Note

♦ Secure all hose connections withpermitted
the correct type ofbyhose
unless authorised clips
(same as original equipment) ⇒ Electronic parts
with respect to the catalogue
correctness . in this document. Copyright by AUDI AG.
of information


page 298 .
Tightening torques
♦ Body brace ⇒ Running gear, axles, steering; Rep. gr. 40 ;
Suspension strut, upper links; Exploded view - suspension
strut, upper links
3.3.2 Checking combination valve for secon‐

dary air system - vehicles from model
year 2013 onwards

• Vacuum hoses and hose connections do not leak.

• Vacuum hoses are not clogged.
– Remove engine cover panels
page 64 .
– Follow vacuum hose -4- downwards to Y-connector.
© satelettronica
– Disconnect vacuum hose for combination valve being checked
from Y-connector.
– Connect hand vacuum pump - VAS 6213- to vacuum hose of
combination valve to be checked.



– Press release tabs and detach secondary air hose -1- from
secondary air pump motor - V101- .


secondary air pump motor - V101- .
– Blow lightly into secondary air hose with your mouth (do not
use compressed air). Fit auxiliary hose if secondary air hose
is not long enough.
• The combination valves for secondary air should be closed; it
should not be possible to blow through the hose.
– Operate hand vacuum pump.
• The combination valve should open; it should now be possible
to blow through the hose.
Note

– Renew combination valve for secondary air system if it does
© satelettronica
not open: left-side
side)”, page 358 , right-side
3.4 Removing and installing combination

valve
⇒ “3.4.1 Removing and installing combination valve (left-side)”,
page 358
⇒ “3.4.2 Removing and installing combination valve (right-side)”,
page 360
3.4.1 Removing and installing combination

valve (left-side)
Removing
Note

body brace .


-1- on subframe.
– Take electrical connector -1- for Lambda probe 2 after catalytic

converter - G131- out of bracket, unplug and move clear.
Note
© satelettronica
– Remove nuts -arrows- and bolt -1-, detach catalytic converter
(left-side) from exhaust manifold and move to rear.

– Unscrew bolts -1- and -2- and remove combination valve for
secondary air system (left-side).
Installing
Note
Renew gasket.
– Install catalytic converter (left-side) and front silencer

Tightening torques
strut, upper links
♦ ⇒ Fig. ““Guide tube for oil dipstick - tightening permitted
torque”“ , authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
page 135
© satelettronica

valve (right-side)
Removing
Note

– Remove wheel housing liner (front right) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (front) .
-1- on subframe.
page 298 .

– Move clear electrical wiring for Lambda probe 2 after catalytic

converter - G131- .
– Remove bolt -1- and nuts -arrows-, detach catalytic converter
(right-side) from exhaust manifold and move to rear.
– If fitted, remove bolts -arrows- and detach heat shield -1-.
© satelettronica
– Remove bolts -2- and detach combination valve (right-side) for

secondary air system and bolts -1- for secondary air hose.
Installing
Note
Renew gasket.

page 298 .
– Install catalytic converter (right-side) and front silencer
Tightening torques

4 Exhaust manifolds
⇒ “4.1 Exploded view - exhaust manifolds”, page 362
⇒ “4.2 Removing and installing exhaust manifolds”, page 363
4.1 Exploded view - exhaust manifolds
1 - Nut
❑ Renew
parts catalogue
tightening sequence:
left-side
⇒ Fig. ““Exhaust mani‐
fold (left-side) - tighten‐
quence”“ , page 363 ;
© satelettronica
right-side permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ Fig. ““Exhaust mani‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
fold (right-side) - tight‐
ening torque and se‐
2 - Bracket for heat shield
stalling exhaust mani‐
folds”, page 363
4 - Gasket
❑ Renew
5 - Heat shield
6 - Bolt
❑ 10 Nm
7 - Lambda probe before cata‐
lytic converter
side): Lambda probe -
G39-
❑ Cylinder bank 2 (left-side): Lambda probe 2 - G108-
❑ Removing and installing ⇒ “7.2 Removing and installing Lambda probe”, page 320
❑ Exploded view ⇒ “1.1 Exploded view - silencers”, page 333
9 - Nut
❑ Renew
❑ 23 Nm
10 - Gasket
❑ Renew

Exhaust manifold (left-side) - tightening torque and sequence
Note
♦ Renew nuts.
– Tighten nuts in 3 stages in the sequence shown:

Stage Nuts Tightening torque
2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm
Exhaust manifold (right-side) - tightening torque and sequence
Note
© satelettronica
♦ Renew nuts.

2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm

folds
⇒ “4.2.1 Removing and installing exhaust manifold (left-side)”,
page 363
⇒ “4.2.2 Removing and installing exhaust manifold (right-side)”,
page 367
4.2.1 Removing and installing exhaust mani‐

fold (left-side)
Removing
Note

body brace .
noise insulation .
4. Exhaust manifolds 363


on subframe.
(left-side).
– Unbolt drive shaft (left-side) from gearbox flange shaft ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing
and installing drive shaft .
© satelettronica
Caution

than 10°.
– Loosen and push back clamp -1- and tie up front silencer (left-
side).
Note
Disregard -item 2-.
– Remove bolt -1- and nuts -arrows- and push catalytic convert‐
er (left-side) towards rear of vehicle.

– Take electrical connector -2- for Lambda probe 2 - G108- out

of bracket, unplug and move wiring clear.
Note
Disregard -items 1, 2, 3, 4- and -arrows-.
– Unscrew nuts -arrows- and move clear coolant pipe on longi‐

tudinal member.
© satelettronica
– Remove bolt -2- and push coolant expansion tank to side with
coolant hoses -arrows- connected.
– Release fasteners -1- and -arrows- and detach heat shield

from longitudinal member (left-side).

– Remove bolts -1 … 4- and detach heat shield.
– Remove nuts -1- and -8- and detach bracket for heat shield.
– Remove nuts -2 … 7- and -9- and detach exhaust manifold.
Installing
Note
© satelettronica
♦ Renew gasket and self-locking nuts.
– Fit exhaust manifold with gasket for catalytic converter and

tighten nuts
⇒ Fig. ““Exhaust manifold (left-side) - tightening torque and
– Install catalytic converter (left-side)

Tightening torques
♦ ⇒ Fig. ““Exhaust manifold (left-side) - tightening torque and
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Exploded view - drive shaft
strut, upper links


fold (right-side)
Removing
Note

noise insulation .
page 285 .
– Remove Lambda probe - G39-
page 320 .
-1- on subframe.
© satelettronica
– Remove front wheel (right-side) ⇒ Running gear, axles, steer‐
– Remove boltsauthorised
permitted unless -arrows- andAG.
by AUDI detach
AUDI AGheat shield
does not forordrive
guarantee acceptshaft
any liability
(right-side).
– Unbolt drive shaft (right-side) from gearbox flange shaft ⇒

Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Re‐
moving and installing drive shaft .

Caution

than 10°.
– Loosen and push back clamp -2- and tie up front silencer
(right-side).
Note
Disregard -item 1-.
Vehicles without auxiliary heater:

– Unscrew bolts -1 and 2- and place coolant pipe on longitudinal
member (right-side) to one side (coolant hoses remain con‐
nected).
© satelettronica
Vehicles Protected
with auxiliary heater:
– Loosen with
nutrespect
-1- and
to theremove
correctnessbolt -2-. in this document. Copyright by AUDI AG.
of information
– Release hose clips -arrows-, disconnect coolant hoses from

coolant pipe at longitudinal member (right-side) and detach
coolant pipe.


– Remove bolt -1- and nuts -arrows- and pull catalytic converter
off exhaust manifold.
Note

the engine removed.
© satelettronica
Installing
Note



tighten nuts
⇒ Fig. ““Exhaust manifold (right-side) - tightening torque and
– Install catalytic converter (right-side)
– Install Lambda probe - G39-
page 320 .
page 285 .
Tightening torques
♦ ⇒ Fig. ““Exhaust manifold (right-side) - tightening torque and
© satelettronica

1 Ignition system
⇒ “1.2 Test data, spark plugs”, page 374
page 374
⇒ “1.4 Removing and installing knock sensor”, page 376
⇒ “1.5 Removing and installing Hall senders”, page 380
381

⇒ “1.1.1 Exploded view - ignition system, vehicles with 2.5 ltr. en‐
gine”, page 371
⇒ “1.1.2 Exploded view - ignition system, vehicles with 2.8 ltr. en‐
© satelettronica
gine”, page 373
1.1.1 Exploded view - ignition system, vehicles with 2.5 ltr. engine
1 - Bolt
❑ 9 Nm
2 - Hall sender
side)
♦ Inlet side: Hall sender -
G40-
♦ Exhaust side: Hall sender 3
- G300-
stalling Hall senders”,
page 380
3 - O-ring
❑ Renew
4 - Knock sensor
❑ Contact surfaces be‐
tween knock sensor and
cylinder block must be
free of corrosion, oil and
grease.
♦ Cylinder bank 1 (right-side):
knock sensor 1 - G61-
♦ Cylinder bank 2 (left-side):
stalling knock sensor”,
page 376
5 - Bolt
❑ 25 Nm

6 - Spark plug
❑ Remove and install with spark plug socket and extension - 3122 B- ⇒ Maintenance ; Booklet 411
❑ Change interval ⇒ Maintenance tables
❑ 30 Nm
7 - Ignition coil
8 - Bolt
❑ 5 Nm
9 - Electrical wiring harness
10 - Bolt
❑ 9 Nm
© satelettronica
12 - O-ring
❑ Renew
13 - Hall sender
♦ Inlet side: Hall sender 2 - G163-
♦ Exhaust side: Hall sender 4 - G301-
14 - Bolt
❑ 9 Nm

1.1.2 Exploded view - ignition system, vehicles with 2.8 ltr. engine
1 - Bolt
❑ 9 Nm
2 - Hall sender
side)
❑ Inlet side: Hall sender -
G40-
❑ Exhaust side: Hall send‐
er 3 - G300-
page 380
3 - O-ring
❑ Renew
4 - Knock sensor
© satelettronica
grease.
side): knock sensor 1 -
G61-
❑ Cylinder bank 2 (left-
G66-
installing knock sensors
- vehicles with 2.8 ltr. en‐
gine”, page 378
5 - Bolt
❑ 25 Nm
6 - Spark plug
❑ 30 Nm
7 - Ignition coil
❑ Ignition coil 3 with
permitted output
unless stage
authorised - N291-
❑ Ignition coilwith 4 respect
with output stage - N292-

❑ Use puller - T40039- for removal
8 - Bolt
❑ 5 Nm


10 - Bolt
❑ 9 Nm
12 - O-ring
❑ Renew
13 - Hall sender
❑ Inlet side: Hall sender 2 - G163-
❑ Exhaust side: Hall sender 4 - G301-
1.2 Test data, spark plugs
© satelettronica
Engine data 2.5 ltr. / 2.8 ltr. / 4V FSI
Idling speed Cannot be adjusted; regulated by idling speed sta‐
bilisation
Ignition timing Not adjustable (determined by control unit)
Ignition system Multi-coil system with 6 ignition coils (output stages
integrated) connected directly to spark plugs via
spark plug connectors
Spark plugs Designations ⇒ Electronic parts catalogue
Removing and installing ⇒ Maintenance ; Booklet 411
Tightening torque

with output stages
♦ Puller - T40039-
Removing
page 64 .


– Only remove air cleaner housing on ignition coil for cylinder 1
page 285 .
– Move fuel line -1- and line -2- from activated charcoal filter
clear at air cleaner housing and air pipe.
– Unscrew bolts -arrows- and unplug electrical connectors at ig‐

nition coils.
– Move electrical wiring harness down slightly.
Note
© satelettronica
-arrows- attached.

nition coils.
Note
Disregard -items 1, 2, 3-.


– Pull ignition coils out of spark plug holes using puller -
T40039- .
Installing
– Fit all ignition coils loosely into spark plug holes.
– Align ignition coils with connectors and attach all connectors
onto coils simultaneously.
– Push ignition coils evenly onto spark plugs by hand (do NOT
quence.
Tightening torques
♦ ⇒ “1.1 Exploded view - ignition system”, page 371
page 285
1.4 Removing and installing knock sensor
© satelettronica
⇒ “1.4.1 Removing and installing knock sensor 1 G61 - vehicles
⇒ “1.4.2 Removing and installing knock sensor 2 G66 - vehicles
1.4.1 Removing and installing knock sensor 1

- G61- - vehicles with 2.5 ltr. engine
Removing
– Remove injector on cylinder 2
⇒ “4.3.1 Removing and installing injectors - vehicles with 2.5
ltr. engine”, page 301 .
– Take electrical connector -3- (cylinder bank 1) out of bracket.
Note
Disregard -item 1-.

– Unscrew bolt -1- for knock sensor 1 - G61- and detach knock
sensor.
Note
Disregard -item 2-.
Installing
– Install injector
Tightening
Protected by copyright.torques
♦ ⇒ “1.1.1 Exploded view - ignition
with respect to the correctness of information system,
in this document. vehicles
Copyright with 2.5
by AUDI AG. ltr.
engine”, page 371
1.4.2 Removing and installing knock sensor 2

- G66- - vehicles with 2.5 ltr. engine
© satelettronica
Removing
– Remove injector on cylinder 5
– Take electrical connector -2- (cylinder bank 2) for knock sen‐
sor 2 - G66- out of bracket and unplug connector.
Note
– Unscrew bolt -2- for knock sensor 2 - G66- and detach knock
sensor.
Note
Disregard -item 1-.
Installing
– Install injector
Tightening torques
♦ ⇒ “1.1.1 Exploded view - ignition system, vehicles with 2.5 ltr.
engine”, page 371

1.4.3 Removing and installing knock sensors

- vehicles with 2.8 ltr. engine
1 - To injectors on cylinder bank 1
2 - Injectors, cylinder bank 2, and for fuel pressure sender - G247-
© satelettronica
Knock sensor for cylinder bank (right-side)

Knock sensor for cylinder bank (left-side)

Removing
WARNING
♦ The fuel system operates under high pressure. The pres‐

sure in the high-pressure part of the injection system must
be reduced to a residual pressure prior to opening the
system
page 282 .
♦ A clean cloth must then be wrapped around the connec‐
tion and the residual pressure dissipated by carefully loos‐
ening the connection.
♦ Observe notes on procedure for disconnecting the battery
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting
and connecting battery .
© satelettronica
page 294 .
– Remove relevant intake manifold (bottom section) with fuel rail
Note
To reach the bolt on knock sensor 1 - G61- -4- you must first
remove injector 2. To reach the bolt on knock sensor 2 - G66-
-4- you must first remove injector 5.
– Remove bolt from corresponding knock sensor.

Installing
– Re-install whichever knock sensor was removed.
The tightening torque influences the function of the knock sensor.
• Tightening torque: refer to exploded view of ignition system.

– Install relevant intake manifold (bottom section) with fuel rail
Tightening torques
♦ ⇒ “1.1.2 Exploded view - ignition system, vehicles with 2.8 ltr.
engine”, page 373

1.5 Removing and installing Hall senders

⇒ “1.5.1 Removing and installing Hall senders G40 / G163 ”, page
380
⇒ “1.5.2 Removing and installing Hall senders G300 / G301 ”,
page 380
1.5.1 Removing and installing Hall senders -

G40- / -G163-
Removing
page 64 .
– Unplug electrical connector -1- (cylinder bank 1).
– Unscrew bolt -arrow- and remove Hall sender - G40- .
© satelettronica
– Remove bolt -arrow- and detach Hall sender 2 - G163- .
Installing
Note
Fit new O-rings.
Tightening torques
1.5.2 Removing and installing Hall senders -

G300- / -G301-
Removing
page 285 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


-arrows- attached.
© satelettronica
– Unscrew bolt -2- and detach Hall sender.
Note
The illustration shows Hall sender 4 - G301- on cylinder bank 2

(left-side). The other Hallbysenders
Protected are similar.
Installing
Note
Fit new O-rings.

page 285 .
Tightening torques

sender - G28-
Removing
noise insulation .


– Remove bolt -arrow- for coolant pipe on gearbox (right-side).
Vehicles with ATF cooler:

– Remove bolts -arrows- and push ATF cooler slightly to one
side.
Note
Disregard -item 1-.
© satelettronica
Continued for all vehicles: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unplug electrical connector -2-. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew bolt -1- and pull out engine speed sender - G28- .
Installing
Tightening torques
♦ ⇒ Rep. gr. 34 ; ATF circuit; Exploded view - ATF circuit / ⇒
Rep. gr. 37 ; ATF circuit; Exploded view - ATF circuit

Service
Workshop Manual
Audi A6 2011 ➤
6-cylinder direct injection engine with supercharger
(3.0 ltr. 4-valve TFSI)
© satelettronica
Engine ID
CGW CGX CHM CGW CTTA CTU
B B A D A
Edition 08.2018

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
© satelettronica

Copyright © 2018 Audi AG, Ingolstadt D3E802BB097

6-cylinder direct injection engine with supercharger (3.0 ltr. 4-valve TFSI) - Edition 08.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
© satelettronica

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Exploded view - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Removing and installing poly V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.4 Removing and installing idler roller for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Contents i
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.3 Exploded view - drive chain for balance shaft and oil pump . . . . . . . . . . . . . . . . . . . . . . . . 122
© satelettronica
2.7 Removing and installing drive chain for balance shaft and oil pump . . . . . . . . . . . . . . . . . . 138
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.2 Removing and installing crankcase breather hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.1 Exploded view - oil filter housing/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
ii Contents

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
© satelettronica
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.2 Fitting coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4 Radiators/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.1 Exploded view - radiators/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.2 Exploded view - auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.4 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 246
1 Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.1 Exploded view - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.2 Exploded view - drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.3 Removing and installing supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.4 Checking supercharger for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.5 Removing and installing drive unit and damper spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
1.6 Securing supercharger to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.4 Removing and installing charge pressure sender G31 / G447 . . . . . . . . . . . . . . . . . . . . . . 275

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
2.3 Removing and installing vacuum unit for actuating intake manifold flaps . . . . . . . . . . . . . . 290
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Contents iii

4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
4.2 Removing and installing intake manifold (bottom section) with fuel rail . . . . . . . . . . . . . . . . 300
4.5 Removing and installing regulating flap control unit J808 . . . . . . . . . . . . . . . . . . . . . . . . . . 305
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
6.1 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
© satelettronica
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
1.2 Test data - spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
iv Contents
1 Identification
(ARL005949; Edition 08.2018)

Engine number
Note
Pull off engine cover panel (front) to make the engine number
visible.

be found on the front of the cylinder block beneath the cylinder
head (right-side) -arrow-.
© satelettronica
number.
Note

For engine data refer to ⇒ Technical data for engines; Rep. gr.
00 ; Overview of engines .
1. Identification 1
tem”, page 2
page 3
page 3
page 3
page 4
2.1 Safety precautions when working on the fuel supply system

© satelettronica
may spray out.

fuel pump.
2.2 Safety precautions when working on vehicles with start/stop system

2.3 Safety precautions when using testers and measuring instruments during
a road test


test equipment which is not secured adequately may be catapult‐
ed through the vehicle with potentially serious consequences.
Or:
seat.

subframe
Caution
© satelettronica
2.5 Safety precautions when working on the cooling system

The cooling system is under pressure when the engine is hot. Risk
of scalding due to hot steam and hot coolant.
Caution

♦ The filler cap must engage positively and audibly when it
is closed.
2.6 Safety precautions when working on the ignition system

Risk of injury due to electric shock
When the engine is running, there are high voltage levels in the
ignition system. There is a risk of electric shock when touching
the ignition system!
– Never touch or disconnect ignition wiring when the engine is
running or being turned at cranking speed.
Risk of damage to components

Washing the engine or connecting/disconnecting electrical wiring
may result in components being damaged if the engine is running.
– Switch off ignition before connecting/disconnecting electrical
wiring.
– Switch off ignition before cleaning engine.

incorrectly.
© satelettronica

6

loosening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
© satelettronica


Contact corrosion can occur if unsuitable fasteners (bolts, nuts,
washers etc.) are used.
fitted.
Please note:

ranty.

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activat‐
ed charcoal filter and electrical wiring etc. before removal so

© satelettronica


47
1.1 Removing engine

⇒ “1.1.1 Removing engine - vehicles with dual clutch gearbox”,
page 7
⇒ “1.1.2 Removing engine - vehicles with automatic gearbox”,
page 22
1.1.1 Removing engine - vehicles with dual clutch gearbox
© satelettronica
equipment required


♦ Scissor-type assembly platform - VAS 6131 B- with support
set for Audi - VAS 6131/10- , support set -VAS 6131/11- and
supplementary set -VAS 6131/13-
© satelettronica
Procedure
Note

gearbox and subframe (with lock carrier installed).

WARNING
moved.
must be empty.
cause injury.
jection system must be dissipated prior to opening the
system.
Note
The electromechanical parking brake must be released before

disconnecting the battery so that the propshaft can be turned dur‐
ing removal.
© satelettronica
battery .
R134a .
ments .
– Pull engine cover panels -1- and -2- off upwards.

WARNING


© satelettronica
noise insulation .
gine.
tor.

Note
Disregard -item 2-.

– Release hose clips -1- and -3-, disconnect coolant hoses from
coolant pipes (front left) and drain off remaining coolant.
Note

the engine removed.

chamber cover .
Note
Disregard -item 2-.
© satelettronica
clear at air pipe.

-arrow-.

– Release hose clip -1- and disconnect vacuum hose from

plenum chamber partition panel.
– Unplug electrical connector -2- at activated charcoal filter
solenoid valve 1 - N80- and detach vacuum hose -3-.
WARNING

Caution
© satelettronica
supply system ⇒ page 5 .

Note

the engine removed.

– Lift retaining clip -2- and disconnect coolant line.

© satelettronica
Caution
Risk of damage to refrigerant lines and hoses

tioner compressor.
Note

body brace .


© satelettronica
– Release fasteners -arrows- and move clear cable guide -2- .



© satelettronica
trical wiring.
holder -3-.


-arrow B-.

- V188- and move clear.
Note
© satelettronica
– Unplug electrical connectors -1- and -2- for radiator fan (push
retainer to the rear -arrow- and press down release catch).

move hose clear.
Note

– Remove bolts -arrows- (left and right) and detach longitudinal

member (bottom front) -1-.

© satelettronica
Caution


housing -arrows-.


Note

ing; Rep. gr. 40 ; Subframe; Removing and installing sub‐
frame cross brace .
Caution

© satelettronica
-1- on subframe.
– Unscrew nuts -arrows- and detach front silencer (left-side).
– Unscrew nuts -arrows- and detach front silencer (right-side).


– Unplug electrical connector -2- at steering rack (release re‐

tainer -arrow- and press down release catch).

VAS 6131/13-
© satelettronica
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /10-11
G6 /10-1 /10-2 /10-5 /10-11
A8+C8 /13-6 – – /13-2
F8+H8 /13-5 – – /13-2
B14 /10-1 /10-3 /10-5 /11-1
G14 /10-1 /10-4 /10-5 /11-1
assembly platform.
zontally.
WARNING




© satelettronica
shown.


shown.


ber on longitudinal members with felt-tip pen.
© satelettronica
Caution



from gearbox.
Note
– Lower engine/gearbox assembly further.

1.1.2 Removing engine - vehicles with automatic gearbox

equipment required
© satelettronica



© satelettronica
Procedure
Note

WARNING
moved.
must be empty.
cause injury.
jection system must be dissipated prior to opening the
system.

Note

ing removal.

battery .
R134a .
ments .
– Pull engine cover panels -1- and -2- off upwards.
© satelettronica
WARNING




noise insulation .
gine.
tor.

Note
© satelettronica
Disregard -item 2-.
– Release hose clips -1- and -3-, disconnect coolant hoses from
Note

the engine removed.

chamber cover .
Note
Disregard -item 2-.

clear at air pipe.

-arrow-.
© satelettronica
– Release hose clip -1- and disconnect vacuum hose from
plenum chamber partition panel.
solenoid valve 1 - N80- and detach vacuum hose -3-.
WARNING

Caution



Note

the engine removed.
© satelettronica



Caution

© satelettronica
tioner compressor.
Note

body brace .



– Release fasteners -arrows- and move clear cable guide -2- .

© satelettronica



trical wiring.
holder -3-.
© satelettronica
-arrow B-.

Note


move hose clear.
Note
© satelettronica
– Remove bolts -arrows- (left and right) and detach longitudinal
member (bottom front) -1-.



Caution


housing -arrows-.
© satelettronica
Note

frame cross brace .
Caution


-1- on subframe.

– Unscrew nuts -arrows- and detach front silencer (left-side).
– Unscrew nuts -arrows- and detach front silencer (right-side).

© satelettronica
from gearbox.
Note



VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /10-11
G6 /10-1 /10-2 /10-5 /10-11
A8+C8 /13-6 – – /13-2
F8+H8 /13-5 – – /13-2
B14 /10-1 /10-3 /10-5 /11-1
G14 /10-1 /10-4 /10-5 /11-1
assembly platform.
© satelettronica
zontally.
WARNING




shown.

© satelettronica
shown.


Caution

© satelettronica
– Lower engine/gearbox assembly.


⇒ “1.2.1 Separating engine and gearbox - vehicles with dual
clutch gearbox”, page 36
⇒ “1.2.2 Separating engine and gearbox - vehicles with automatic
gearbox”, page 41
1.2.1 Separating engine and gearbox - vehi‐

cles with dual clutch gearbox


VAS 6131/13-
♦ Adapter - T40058-
© satelettronica
Procedure
Note
verter (left-side).

Caution

with your hands.

Note
Disregard -item 2-.
© satelettronica
– Remove electrical connector -1- for Lambda probe after cat‐
Note


pipe (top).
(left-side).
© satelettronica

– Insert guide pin of adapter -T40058- as follows:

• The larger-diameter section -arrow 1- faces towards the en‐
gine.
• The smaller-diameter section -arrow 2- faces the adapter.
– Counterhold crankshaft using adapter - T40058- and angled

ring spanner when loosening bolts for drive plate.
Note
Only rotate crankshaft in direction of engine rotation -arrow-.
© satelettronica
– Remove 6 bolts -arrow- for clutch module. Turn crankshaft 60°
in direction of engine rotation each time.

Note

VAS 6131/13-7-
F2 /13-7
B10 /10-1 /10-3 /10-5 /11-4
G10 /10-1 /10-3 /10-5 /11-4



© satelettronica
Note
Disregard -item A-.


cles with automatic gearbox


VAS 6131/13-
© satelettronica
Procedure
Note

verter (left-side).
– Remove bolts -arrows- and remove bracket.
Note
© satelettronica
Caution

with your hands.



Note

Note
© satelettronica

pipe (top).

(left-side).
Note

– Remove bolts -arrows- and tie up ATF cooler -1- to side with
coolant hose -2- attached.
© satelettronica

gine.


Note

© satelettronica
Note

VAS 6131/14-
F2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5




Note
Disregard -item A-.
© satelettronica


equipment required
© satelettronica
Audi A6 - VAS 6095/1-5-
♦ Lift arm extension/workshop hoist - VAS 6101-
Procedure
WARNING
Risk of accident!
• Engine/gearbox assembly removed; engine separated from

gearbox.
– Detach poly V-belt from air conditioner compressor ⇒
“1.2.2 Removing and installing poly V-belt for ancillaries”,
page 73 .


– Attach lifting tackle - 2024 A- to engine lifting eyes and work‐
shop hoist as shown in illustration.
Note

WARNING
Risk of accident.
© satelettronica
– Take electrical connectors -2- for electrohydraulic engine
mounting solenoid valves out of brackets and unplug (both
sides).
– Unscrew nut (right-side) -1- and detach bracket with electrical
wiring from subframe.
Note
Disregard -item 1-.



© satelettronica
side).

to engine and gearbox support - VAS 6095- as shown in illus‐
tration and tighten to 40 Nm.


♦ Assembly aid - T40169- for vehicles with 7-speed dual clutch

gearbox 0B5
© satelettronica
Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled, phos‐

phated or black-finished nuts and bolts.
Component Nm
Bolts/nuts M6 9
M7 15

Component Nm
M8 20
M10 40
M12 65
♦ Assembly mountings ⇒ “2.1 Exploded view - assembly mount‐
ings”, page 58
gearbox; Tightening torques for gearbox / ⇒ Rep. gr. 37 ;
box
Procedure
Note

and O-rings.
© satelettronica
♦ 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.

– Install engine supports and engine mountings ⇒ page 58 .
– Before installing gearbox, always clean threaded holes for en‐
gine/gearbox bolts in cylinder block using a thread tap.
and gearbox:
dual-mass flywheel and gearbox housing from below, as illus‐
trated.
Note


– Insert transport lock - T40170- into gearbox housing and dual-

mass flywheel from below and clamp onto flange shaft -1-.

© satelettronica
sleeves.
-1, 6 … 10-.
Vehicles with 8-speed automatic gearbox 0BK:

– Turn torque converter until hole is visible next to notch
-arrow- in recess in bottom of gearbox housing, as shown in
illustration.
Note
There is only one notch on the circumference; turn the torque

converter accordingly.


– Hold ATF lines in installation position when joining engine and
subframe.

© satelettronica
sleeves.
– Bring gearbox into position on engine (pay attention to starter).
– Tighten bolts -1 … 11-.
– Remove transport lock - T40170- .
Note

wheel/torque converter is straight and that it makes even contact
with the drive plate.
– Use assembly lever -1- to press dual-mass flywheel//torque

converter -2- slightly against drive plate -3- in direction of
-arrow-.
– Bolt dual-mass flywheel/torque converter onto drive plate as

follows:
Note


gine.
– Use adapter - T40058- and angled ring spanner to turn

crankshaft 180° further in direction of engine rotation -arrow-.
⇒ Rep. gr. 30 ; Clutch; Exploded view - flywheel and dual
clutch / ⇒ Rep. gr. 32 ; Torque converter; Exploded view -
torque converter .
© satelettronica
flywheel and dual clutch / ⇒ Rep. gr. 32 ; Torque converter;
Exploded view - torque converter .
installing ATF cooler / ⇒ Rep. gr. 37 ; ATF circuit; Removing
– Install drive shafts and heat shield for drive shaft ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Exploded view
- drive shaft .
– Install catalytic converters: left-side ⇒ page 334 , right-
side ⇒ page 337 .

and body is -a-.
lever cable .
– Raise engine/gearbox assembly further using scissor-type as‐
sembly platform - VAS 6131 B- .
– Align subframe and gearbox carrier on longitudinal members
according to markings made before removal.
WARNING



mountings; Exploded view - assembly mountings / ⇒ Rep. gr.
37 ; Assembly mountings; Exploded view - assembly mount‐
ings .
lever cable .
note the following:
gear, axles, steering; Rep. gr. 48 ; Steering column; Remov‐
ing and installing intermediate steering shaft .
© satelettronica
– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
– Install front silencers ⇒ page 326 .
– Align the exhaust system so it is free of stress ⇒ page
331 .
– Install subframe cross brace and anti-roll bar ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Exploded view - sub‐
frame .
carrier .
trical system; Rep. gr. 97 ; Relay carriers, fuse carriers, elec‐
tronic boxes; Overview of fitting locations - relay carriers, fuse
carriers, electronic boxes .
ing battery .

Caution

sive voltage.

ments .
chamber cover .
carrier .
411 .
© satelettronica
Note

R134a .
Wheels, tyres .
WARNING


insulation .


Engine mounting
1 - Engine mounting
❑ Depending on version,
left side may include left
- N144-
right side may include
right electrohydraulic
© satelettronica
engine mounting
ings”, page 61
2 - Bolt
❑ 20 Nm
3 - Retaining plate
❑ When renewing engine
mounting, also renew
retaining plate
4 - Bolt
❑ 40 Nm
5 - Bolt
❑ 20 Nm
6 - Engine support
❑ Left-side: with bracket
for air conditioner com‐
pressor
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ Renew
❑ 90 Nm +90°
10 - Subframe
11 - Bolt
❑ 55 Nm

1 - Bolt
mountings; Exploded
ings
bly mountings; Explod‐
ed view - assembly
mountings
3 - Stop
installing gearbox
mounting - vehicles with
dual clutch gearbox”,
page 65
© satelettronica
5 - Bolt
mountings; Exploded
ings
6 - Nut
mountings; Exploded
ings
7 - Bolt
8 - Gearbox support
❑ Removing and installing ⇒ “2.4.1 Removing and installing gearbox support with gearbox mounting - ve‐
hicles with dual clutch gearbox”, page 64
9 - Bolt
10 - Nut
Gearbox mounting for automatic gearbox 0BK
1 - Bolt
mountings; Exploded
ings
bly mountings; Explod‐
ed view - assembly
mountings
3 - Stop
installing gearbox
mounting - vehicles with
automatic gearbox”,
page 66
© satelettronica
5 - Bolt
mountings; Exploded
ings
6 - Nut
mountings; Exploded
ings
7 - Bolt
8 - Gearbox support
❑ Removing and installing ⇒ “2.4.3 Removing and installing gearbox support with gearbox mounting - ve‐
hicles with automatic gearbox”, page 65
9 - Bolt
10 - Nut

tion

Procedure
© satelettronica
– Engage spindles -10-222A/11- at engine lifting eyes (left and
right).

ings
Note

Removing
– Support engine in installation position ⇒ “2.2 Supporting en‐
gine in installation position”, page 60 .
noise insulation .
© satelettronica
– Remove bolts -arrows- and detach longitudinal member (bot‐
tom front) -1- on relevant side.

– Position used oil collection and extraction unit - VAS 6622A-
below engine.

– Remove bolts -1 and 2- and press coolant pipe (bottom left) to

the side.
Note
Disregard -arrows-.
Note
side remain fitted.
© satelettronica
subframe.

– Take relevant electrical connector -2- for electrohydraulic en‐
gine mounting solenoid valve out of bracket and unplug con‐
nector.
plate to one side.
Note
Disregard -item 2-.
– Using spindle - 10-222A/11- -item 1-, raise engine through

Installing
Note

– Install coolant pipe (bottom left) ⇒ page 226 .
– Install engine oil cooler ⇒ page 187 .
Tightening torques
© satelettronica
♦ Longitudinal member (bottom front) ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Exploded view - lock carrier
(front)

mounting
mounting - vehicles with dual clutch gearbox”, page 64
with dual clutch gearbox”, page 65
mounting - vehicles with automatic gearbox”, page 65
with automatic gearbox”, page 66

with dual clutch gearbox

Removing
Installing
Tightening torques
sembly mountings

mounting - vehicles with dual clutch
gearbox
Removing
© satelettronica
Installing
Tightening torques
sembly mountings

with automatic gearbox
Removing
Installing
Tightening torques
sembly mountings

mounting - vehicles with automatic gear‐
box
Removing
Installing
© satelettronica
Tightening torques
sembly mountings


⇒ “3.1 Removing and installing engine cover panel”, page
67

panel
Removing
– Pull off engine cover panel -1-/-2- upwards.
Installing
– Position engine cover panel on engine and use both hands to
press it down into retaining clips.
© satelettronica

⇒ “1.2 Removing and installing poly V-belts”, page 71
⇒ “1.3 Removing and installing tensioner for poly V-belt”, page
75
⇒ “1.4 Removing and installing idler roller for poly V-belt”, page
77
80

⇒ “1.1.1 Exploded view - poly V-belt drive, poly V-belt for super‐
charger”, page 68
© satelettronica
⇒ “1.1.2 Exploded view - poly V-belt drive, poly V-belt for ancil‐
laries”, page 69
1.1.1 Exploded view - poly V-belt drive, poly V-belt for supercharger

1 - Poly V-belt
❑ For supercharger
❑ Check for wear
installing poly V-belt for
supercharger”, page
71
on pulleys
2 - Bolt
❑ 40 Nm
❑ 37 Nm if using door
alignment tool - 3320-
3 - Washer
4 - Cover
5 - Supercharger
❑ Exploded view ⇒
© satelettronica
“1.1 Exploded view - su‐
percharger”, page
257
6 - Idler roller
❑ For poly V-belt
installing idler roller for
supercharger”, page
77
stalling vibration damper”, page 78
8 - Bolt
9 - Tensioner
❑ For poly V-belt
❑ Removing and installing ⇒ “1.3.1 Removing and installing tensioner for poly V-belt for supercharger”,
page 75
10 - Bolt
❑ 40 Nm
1.1.2 Exploded view - poly V-belt drive, poly V-belt for ancillaries

1 - Poly V-belt
❑ Check for wear
ancillaries”, page 73
❑ Do not kink
on pulleys
2 - Alternator
⇒ Electrical system;
Rep. gr. 27 ; Alternator;
alternator
3 - Bolt
© satelettronica
4 - Idler roller
❑ For poly V-belt
installing idler roller for
❑ 40 Nm
5 - Bolt
7 - Bolt
8 - Coolant pump
10 - Tensioner
❑ For poly V-belt
❑ Removing and installing ⇒ “1.3.2 Removing and installing tensioner for poly V-belt for ancillaries”, page
76
❑ 40 Nm


12 - Bolt
13 - Bolt
14 - Bolt
16 - Dowel sleeves
17 - Bolt
❑ Renew
❑ 20 Nm +90°
© satelettronica
nal torque 9 Nm.
1.2 Removing and installing poly V-belts

⇒ “1.2.1 Removing and installing poly V-belt for supercharger”,
page 71
⇒ “1.2.2 Removing and installing poly V-belt for ancillaries”, page
73
1.2.1 Removing and installing poly V-belt for

supercharger

♦ Locking pin - T10060 A-
Removing
WARNING

© satelettronica
– Remove engine cover panel (front) ⇒ “3.1 Removing and in‐
stalling engine cover panel”, page 67 .
noise insulation .
Caution


V-belt.
– Detach poly V-belt and lock tensioner with locking pin - T10060
A- .

Installing
– Fit poly V-belt on pulleys as shown in illustration:
1- Tensioner
2- Supercharger
3- Idler roller
4- Vibration damper
Note

pulleys.

Tightening torques
© satelettronica
ancillaries
♦ Special wrench, long reach -3320/2- (included with door align‐
ment tool - 3320- )

Removing
– Remove poly V-belt for supercharger ⇒ “1.2.1 Removing and
installing poly V-belt for supercharger”, page 71 .
– Remove bolt -arrow- using special wrench, long reach
-3320/2- .
– Push guide roller towards radiator cowl.
Note
♦ Audi A7:
♦ The guide roller cannot be detached.
– Remove bolt -2- for coolant pipe (front left).
Note

the engine removed.
© satelettronica
– Remove bolts -2- for coolant pipes (front left).
Note

the engine removed.
Caution

♦ Mark direction of rotation of poly V-belt with chalk or felt-
tip pen for re-installation.
– To slacken poly V-belt, turn tensioner clockwise -arrow- and

lock with locking pin - T10060 A- .

Installing
1- Alternator
2- Idler roller
3- Coolant pump
5- Tensioner for poly V-belt
6- Vibration damper
Note

pulleys.
– Install coolant pipes (front left) ⇒ “3.3.3 Removing and in‐

stalling coolant pipes (front left)”, page 228 .
© satelettronica
– Install idler roller for supercharger ⇒ “1.4.1 Removing and in‐
stalling idler roller for supercharger”, page 77 .
– Install poly V-belt for supercharger ⇒ “1.2.1 Removing and in‐
stalling poly V-belt for supercharger”, page 71 .
Tightening torques
♦ ⇒ “1.1.1 Exploded view - poly V-belt drive, poly V-belt for su‐
percharger”, page 68

poly V-belt
⇒ “1.3.1 Removing and installing tensioner for poly V-belt for su‐
⇒ “1.3.2 Removing and installing tensioner for poly V-belt for an‐
cillaries”, page 76
1.3.1 Removing and installing tensioner for

poly V-belt for supercharger

Removing
– Remove bolt -1- and take off poly V-belt tensioner -2-.
Installing
Tightening torques

poly V-belt for ancillaries
Removing
WARNING
© satelettronica
– Remove engine cover panel (front) ⇒ “3.1 Removing and in‐

stalling engine cover panel”, page 67 .
– Remove bolt -2- for coolant pipe (front left).
Note

the engine removed.

noise insulation .
Note

the engine removed.

– Detach coolant valve for cylinder head - N489- -arrow- from

bracket and move it clear to the side.

V-belt.
– Remove poly V-belt from tensioner and release tensioner.
Note
Ignore -T10060 A- .
© satelettronica
– Detach cover from tensioner.
– Remove bolt -1- and detach poly V-belt tensioner -2- from
cylinder block.
Installing
– Install poly V-belt ⇒ “1.2.2 Removing and installing poly V-belt
for ancillaries”, page 73 .
Tightening torques
♦ ⇒ “1.1.2 Exploded view - poly V-belt drive, poly V-belt for an‐
1.4 Removing and installing idler roller for

poly V-belt
⇒ “1.4.1 Removing and installing idler roller for supercharger”,
page 77
⇒ “1.4.2 Removing and installing idler roller for ancillaries”, page
78
1.4.1 Removing and installing idler roller for

supercharger
Removing
Audi A7

– Remove radiator cowl ⇒ “4.5.2 Removing and installing radi‐

ator cowl - Audi A7”, page 251 .
– Remove bolt -arrow- and detach together with idler roller.
Installing
– Audi A7: Install radiator cowl ⇒ “4.5.2 Removing and installing
radiator cowl - Audi A7”, page 251 .
Tightening torques
1.4.2 Removing and installing idler roller for
© satelettronica
ancillaries
Removing
– Remove poly V-belt tensioner for supercharger ⇒ “1.3.1 Re‐
moving and installing tensioner for poly V-belt for supercharg‐
er”, page 75 .
– Remove idler roller for poly V-belt of supercharger ⇒
“1.4.1 Removing and installing idler roller for supercharger”,
page 77 .
– Unscrew bolt -2- and remove idler roller.
Installing
1.5 Removing and installing vibration

damper

Removing
– Remove bolt -2- for coolant pipes (front left).
Note
© satelettronica
the engine removed.
Note

V-belt.
– Remove poly V-belt from vibration damper and release ten‐
sioner.
Note
Ignore -T10060 A- .

– Remove bolts -1- for vibration damper using counterhold tool

- 3036- .
– Remove vibration damper.
Installing
Note

♦ Can only be installed in one position (holes are off-set)

– Install poly V-belt ⇒ “1.2.2 Removing and installing poly V-belt
for ancillaries”, page 73 .
Tightening torques
© satelettronica
(pulley end)
♦ Assembly tool - T40048A-

♦ Safety goggles

Procedure
– Loosen bolts -arrows- for coolant pump pulley (counterhold
with pin wrench - 3212- ).

– Release sealing flange (pulley end) from bonded joint and take
off sealing flange.
Note
Renew sealing flange (pulley end).
© satelettronica
Caution

WARNING
Risk of eye injury due to sealant residue.


Note

mm).

Caution


with sealant.
sealing surface.
Note

© satelettronica
– First position sealing flange (with assembly sleeve -T40048/2-

inserted) on crankshaft.
ing surface. Then bolt on ⇒ page 71 .
note the following:
– Install poly V-belt pulley for coolant pump ⇒ page 213 .


⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page
83
Note
When performing assembly work, secure engine to engine and gearbox support - VAS 6095- ⇒ page 47 .
1 - Drive plate
© satelettronica
holes for clutch module
for cracks and scoring.
page 84
2 - Bolt
❑ Renew
❑ 60 Nm +90°
3 - Needle bearing
closed side towards en‐
gine
⇒ “2.6 Renewing needle
bearing in drive plate”,
page 88
4 - Sender wheel
❑ For engine speed
sender - G28-
stalling sender wheel”,
page 85
❑ Checking ⇒ “2.4 Check‐
ing sender wheel”, page
85
Caution
causing irreparable
damage to sender
wheel.

The
loudspeaker).
stallation ⇒ “2.4 Check‐
ing sender wheel”, page
85 .
5 - Crankshaft
6 - Dowel pin
7 - Oil seal
❑ For crankshaft (gearbox end)
❑ Renewing ⇒ “2.5 Renewing crankshaft oil seal (gearbox end)”, page 87
© satelettronica
Removing
Caution

drive plate.
Installing

Note

bolts.
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page
83

Removing
© satelettronica
Caution

wheel.
is operating correctly before installation ⇒ page 85 .

Installing


♦ Sensor gauge - T10473-
Procedure
Caution

wheel.
© satelettronica
is operating correctly before installation.
– Check entire circumference of sender wheel using sensor

gauge - T10473- , as shown in illustration.

A - Sender wheel OK


end)

♦ Extractor hook - T20143/2-
© satelettronica
Procedure


© satelettronica
ing bolts -arrows-.
Caution

♦ Slide oil seal onto crankshaft by hand to prevent sealing
lip on oil seal from folding over.

hand.

T10122/5- .
oil seal.


♦ Thrust plate - VW 402-
♦ Tube - VW 418 A-
© satelettronica
♦ Tube - VW 421-
♦ Support - 40-103-

Procedure
– Place support - 40-103- under drive plate when pressing out
bearing.

gine.
© satelettronica

3 Crankshaft
Note

❑ Renewing ⇒ “1.6 Re‐
moving and installing
sealing flange (pulley
end)”, page 80
© satelettronica
2 - Bolt
sequence ⇒ Fig. ““Seal‐
ing flange (pulley end) -
tightening torque and
3 - Crankshaft
ance ⇒ “3.3 Measuring
axial clearance of
crankshaft”, page
95
ance ⇒ “3.4 Measuring
radial clearance of
crankshaft”, page
95
4 - Dowel sleeve
❑ 4x
frame ⇒ Fig. ““Applying
sealant to retaining
frame, position of dowel
5 - Seal
❑ Renew
6 - Bolt
7 - Bolt
3. Crankshaft 91

❑ Renew
❑ Use old bolts when measuring radial clearance
8 - Bolt
9 - Retaining frame
❑ With valve for oil pressure control - N428- ⇒ Fig. ““ Valve for oil pressure control -N428- ”“ , page
93
❑ Removing and installing valve for oil pressure control - N428- ⇒ “4.6 Removing and installing valve for
oil pressure control N428 ”, page 198
10 - Seal
❑ Renew
11 - Thrust washer
© satelettronica
12 - Bearing shell
❑ Install new bearing shells for retaining frame with correct coloured markings ⇒ Fig. ““Matching crankshaft
bearing shells to bearings in retaining frame”“ , page 94
13 - Thrust washer
14 - Bearing shell
❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ Fig. ““Matching
crankshaft bearing shells to bearings in cylinder block”“ , page 94
15 - Cylinder block

Note
Fit new O-ring.

2- O-ring - renew
3- Bolt, 9 Nm
© satelettronica
with sealant.
sealing surface.
3. Crankshaft 93
Note

1. -1 … 16- 50 Nm
2. -1 … 16- Turn 90° further
3. -17 … 31- 20 Nm
4. -17 … 31- Turn 90° further
© satelettronica
shell thickness.
R = Red
G = Yellow
B = Blue
S = Black

flywheel flange on the crankshaft. The first letter in the se‐
“2”, etc.
R = Red
G = Yellow
B = Blue
S = Black

Honing di‐ Main bearing journal ∅ Conrod journal ∅

mension mm mm
Basic dimen‐ 65.000 – 0.022 56.000 – 0.022
sion – 0.042 – 0.042

© satelettronica
Procedure
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
3.4 Measuring radial clearance of

crankshaft
♦ Plastigauge
Procedure
3. Crankshaft 95

ing shell.
– Fit retaining frame, secure with old bolts and tighten to final
torque ⇒ Item 7 (page 91) without rotating crankshaft.
Radial clearance:
• New: 0.015 ... 0.055 mm.
– Renew bolts for retaining frame which are tightened by turning
through specified angle.
© satelettronica

4 Balance shaft
1 - Balance shaft
page 97
2 - Bolt
❑ Use locating pin -
T40116- as counterhold
when loosening and
tightening
❑ 60 Nm
3 - Balance weight (gearbox
© satelettronica
end)
sition.
4 - Bearing plate
5 - Bolt
❑ 13 Nm
sition.
7 - Bolt
when loosening and
tightening
❑ 60 Nm

4. Balance shaft 97
Removing
– Remove timing chain cover (bottom) ⇒ page 112 .
© satelettronica
– Remove drive chain for auxiliary drives ⇒ page 138 .
– Use locating pin -T40116- to lock balance weight -1- in position
at rear of engine.
– Unscrew bolt -2- and detach balance weight from balance
shaft.
– Unscrew bolt -2- (counterhold balance weight -1- with a suit‐

able pin) and detach balance weight at front of engine from
balance shaft.


shaft at rear of engine.
Installing
T40069- .
Note
© satelettronica
tion.
– Install drive chain for auxiliary drives ⇒ page 138 .

– Install timing chain cover (bottom) ⇒ page 112 .
Tightening torques
4. Balance shaft 99

⇒ “5.4 Checking radial clearance of conrod bearings”, page
104
Note

1 - Bolts
❑ Renew
© satelettronica
ance
contact surface
❑ 50 Nm +90°
in colour ⇒ Fig. ““Mark‐
ing conrods”“ , page
101
conrod pairs ⇒ Fig.
““Conrod installation po‐
sition”“ , page 102
3 - Bearing shells
ed.
shells
❑ There are oversized
bearings available for
machined crankshaft
❑ Lugs on conrod bear‐
ings must be on the
same side
4 - Conrod
❑ Mark cylinder allocation in colour ⇒ Fig. ““Marking conrods”“ , page 101

5 - Circlip
❑ Renew
6 - Piston pin
7 - Piston
❑ Checking ⇒ Fig. ““Checking piston”“ , page 103
❑ Install using piston ring clamp
❑ Piston and cylinder dimensions ⇒ “5.3 Checking pistons and cylinder bores”, page 103
❑ Measuring cylinder bore ⇒ Fig. ““Measuring cylinder bore”“ , page 104
8 - Piston rings
© satelettronica
Caution

number on the piston crown using paint. Do not attempt
to mark the piston crown with a centre punch or by making
a notch or similar.
• Arrows on piston crowns point to pulley end.
Marking conrods
Note
Only renew conrods as a complete set.




2- Oil spray jet with spray nozzle valve (opening pressure:
2 ... 2.4 bar)
Caution
© satelettronica
Risk of damage to oil spray jets due to deformation.
• Never bend oil spray jets.

♦ Pin - VW 222 A-

Removing
⇒ page 47
– Remove sump (top section) ⇒ page 183 .
to cylinder and to conrods for re-installation ⇒ page 101 .
Note


Installing
Note

© satelettronica
– Install sump (upper section) ⇒ page 183 .
Tightening torques

Checking piston
Piston ∅ mm
Nominal dimension 84.491)
• 1) Dimensions including coating (thickness approx. 0.02 mm).
The coating will wear down in service.


points in transverse direction -A- and in longitudinal
direction -B-.
© satelettronica
of cylinder.
mm mm
1. Compression ring 0.20 … 0.30 0.80
Oil scraper ring 0.25 … 0.50 – 1)
• 1) Specification not yet available.

mm mm

bearings
♦ Plastigauge
Procedure

– Fit conrod bearing cap and tighten to final torque with old bolts
⇒ Item 1 (page 100) . Do not rotate crankshaft when doing so.
Radial clearance:
• New: 0.010 ... 0.052 mm.
© satelettronica


1 - Bolt
❑ Renew
sequence ⇒ Fig. ““Tim‐
ing chain cover (bottom)
- tightening torque and
sequence”“ , page
108
2 - Oil seal
© satelettronica
end)
newing crankshaft oil
seal (gearbox end)”,
page 87
3 - Bolt
❑ Renew
sequence ⇒ Fig. ““Tim‐
ing chain cover (bottom)
- tightening torque and
sequence”“ , page
108
4 - Dowel sleeve
❑ 2x
5 - Threaded pin
❑ Tightening torque ⇒ Fig.
““Timing chain cover
(bottom) - tightening
page 108
6 - Cylinder head gasket (left-
side)
7 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ Fig. ““Timing chain cover (left-side) - tightening torque and se‐
8 - Bracket
❑ For heat shield
❑ Removing and installing ⇒ “1.2.1 Removing and installing timing chain covers (left and right)”, page
109
10 - Retainer
❑ For wiring harness

11 - Bolt
❑ Renew
12 - Bracket
13 - Bolt
14 - Seals
❑ Renew
15 - Bracket
16 - Bolt
17 - Bolt
© satelettronica
❑ Tightening torque and sequence ⇒ Fig. ““Timing chain cover (right-side) - tightening torque and se‐
18 - Bracket
❑ Removing and installing ⇒ “1.2.1 Removing and installing timing chain covers (left and right)”, page
109
21 - Bracket
❑ For heat shield
22 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ Fig. ““Timing chain cover (right-side) - tightening torque and se‐
23 - Dowel sleeve
❑ 2x
24 - Bolt
❑ Tightening torque and sequence ⇒ Fig. ““Timing chain cover (bottom) - tightening torque and sequence”“ ,
page 108
❑ Removing and installing ⇒ “1.2.2 Removing and installing timing chain cover (bottom)”, page 112
27 - Bolt

Note


1. -1 … 8- 5 Nm
Note
© satelettronica

1. -1 … 8- 5 Nm
Timing chain cover (bottom) - tightening torque and sequence
Note
Securing with aluminium bolts:

1. -arrows- 3 Nm
3. -1, 2, 4, 5, 7- Turn 90° further
4. -arrows- 9 Nm
5. -8, 9, 10- 8 Nm
6. -8, 9, 10- Turn 90° further
7. -3- 16 Nm
8. -6- 20 Nm
Securing with steel bolts:


1. -arrows- 3 Nm
3. -1, 2, 4, 5, 7- and 9 Nm
-arrows-
4. -8, 9, 10- 20 Nm
5. -3- 16 Nm
6. -6- 70 Nm

cover
right)”, page 109
page 112

covers (left and right)
© satelettronica
♦ Safety goggles
Removing
Note
– Remove engine cover panel (rear) ⇒ page 67 .

– Remove corresponding combination valve for secondary air
system: left-side ⇒ page 348 , right-side ⇒ page 351 .
Timing chain cover (left-side):
to one side.
Note


joint and detach.
Timing chain cover (right-side):

5 - For Lambda probe after catalytic converter - G130-
Note
© satelettronica
Disregard -items 1, 2 and 3-.

to one side.
Note

joint and detach.
Installing
Note

Caution


WARNING

– Remove remaining sealant on timing chain covers -1-, cylinder

Note
© satelettronica
2 mm).
Caution

– Apply sealant bead -arrow- onto the clean sealing surface of

the timing chain cover (left-side) as illustrated.
Note

applying sealant.
– Install timing chain cover (left-side) and tighten bolts ⇒ Fig.

““Timing chain cover (left-side) - tightening torque and se‐

– Install timing chain cover (right-side) and tighten bolts ⇒ Fig.

““Timing chain cover (right-side) - tightening torque and se‐
note the following:
– Install combination valve for secondary air system: left-side ⇒
page 348 , right-side ⇒ page 351 .
Tightening torques

cover (bottom)
♦ Safety goggles
© satelettronica
Removing
Note
– Remove coolant pipe (top) ⇒ page 232 .

– Remove timing chain covers (left and right) ⇒ page 109 .
– Remove oil filter housing ⇒ page 196 .
Note


cover (bottom).
Installing
© satelettronica
Note

• Dimension -x- = 6.5 mm
• Dimension -y- = 8 mm
Note
Caution


WARNING

– Remove remaining sealant on timing chain cover -1-, cylinder

Note
© satelettronica
Caution

and do not kink.
Note
renewed.
– Carefully bend the ends of the cylinder head gaskets down

very slightly -arrows-, just far enough to be able to clean the
upper sealing surface on the cylinder head gasket and cylinder
head.

Note

2 mm).
Note
The sealant must be applied at several points on the engine as

described below.

© satelettronica
sealant.

Note
Depending on version, a second sleeve -2- may be fitted between

sealing flange and cylinder block on left side of engine.
Caution
Risk of sealant entering hole for gearbox bolt.

♦ Appropriate sleeve -1- ⇒ Electronic parts catalogue must
be fitted before installing timing chain cover (bottom).
♦ Projection of sleeve -a- = 3 mm above the sealing surface.
Note
Sleeves -1- and -2- have different diameters and are not inter‐
changeable.
© satelettronica
Timing chain cover (bottom), version 1
Caution


with sealant.
sealing surface.
Note
The timing chain cover must be installed within 5 minutes after

applying sealant.

tom).

Timing chain cover (bottom), version 2
Caution


with sealant.
sealing surface.
Note
© satelettronica

tom).
All versions (continued):

– Fit timing chain cover (bottom), guiding it towards the sealing
surface on cylinder block and cylinder head at an angle and
from below.
ting the cover.
– Tighten bolts for timing chain cover (bottom) ⇒ page 108 .
note the following:
– Install crankshaft oil seal (gearbox end) ⇒ page 87 .
– Install oil filter housing ⇒ page 196 .
– Install timing chain covers (left and right) ⇒ page 109 .
– Install coolant pipe (top) ⇒ page 232 .
– Install supercharger ⇒ page 259 .
411 .
Tightening torques
♦ ⇒ Electrical system; Rep. gr. 27 ; Starter; Exploded view -
starter

2 Chain drive
⇒ “2.3 Exploded view - drive chain for balance shaft and oil
pump”, page 122
123
⇒ “2.5 Removing and installing camshaft timing chain”, page
135
page 137
⇒ “2.7 Removing and installing drive chain for balance shaft and
oil pump”, page 138

© satelettronica
1 - Bolt
❑ Renew
❑ 80 Nm +90°
2 - Bolt
❑ Renew
❑ 80 Nm +90°
3 - Camshaft chain sprocket
⇒ “2.4 Removing
camshaft timing chain
from camshafts”, page
123
❑ Identification “Intake”
⇒ “2.4 Removing
123
Note
Depending on the version, the

camshaft adjuster may have three
or four recesses. The illustration
shows a camshaft adjuster with four
recesses.

side)
with a paint marker

6 - Bolt
❑ 9 Nm
7 - Slide
8 - Chain tensioner
9 - Bearing plate
10 - Bolt
❑ For drive chain sprocket for camshaft timing chain (left-side)
13 - Bolts
© satelettronica
2. Chain drive 119

1 - Bolt
❑ Renew
❑ 80 Nm +90°
⇒ “2.4 Removing
123
3 - Bolt
❑ Renew
❑ 80 Nm +90°
❑ Identification “Intake”
⇒ “2.4 Removing
© satelettronica
123
Note
Depending on the version, the

camshaft adjuster may have three
or four recesses. The illustration
shows a camshaft adjuster with four
recesses.
5 - Bolt
Item 15 (page 122)
❑ Installation position ⇒ Fig. ““Installation position: bearing mounting for drive sprocket for camshaft timing
chain (right-side)”“ , page 122
9 - Thrust washer

11 - Slide
12 - Bolt
❑ 9 Nm
1 - Guide rail
2 - Bolt
❑ Renew
❑ 10 Nm +90°
3 - Bolts
❑ Renew
❑ 5 Nm +60°
© satelettronica
❑ For timing chain (left-
side)
6 - Bolt
❑ Renew
❑ 10 Nm +90°
7 - Drive chain
with a paint marker
valve gear”, page
137
8 - Bolt
❑ Renew
❑ 10 Nm +90°
9 - Guide rail
10 - Bolt
❑ Renew
❑ 8 Nm +45°
11 - Bearing plate
❑ For timing chain (right-side)
13 - Thrust washer
2. Chain drive 121

15 - Bolt
❑ Renew
❑ 30 Nm +90°
16 - Seal
❑ Renew
18 - Bolt
❑ 9 Nm
19 - Crankshaft
© satelettronica
20 - Bolt
❑ Renew
❑ 10 Nm +90°
Installation position: bearing mounting for drive sprocket for

camshaft timing chain (right-side)
• Dowel pins in bearing mounting -3- for drive sprocket for
camshaft timing chain (right-side) must engage in drillings in
thrust washer -1- and in cylinder block drillings.
4 - Bolt
2.3 Exploded view - drive chain for balance shaft and oil pump

1 - Crankshaft
2 - Drive chain
❑ For auxiliary drives
with a paint marker
balance shaft and oil
pump”, page 138
❑ For oil pump
engine
4 - Bolt
❑ Renew
❑ 30 Nm +90°
© satelettronica
6 - Bolt
❑ Renew
❑ 15 Nm +90°
shaft
gearbox
8 - Chain tensioner
❑ With guide rail
9 - Bolt
❑ Renew
❑ 10 Nm +45°
2. Chain drive 123


equipment required
© satelettronica
♦ Socket - T10035-
♦ Counterhold tool - T10172- with -T10172/2-

♦ Special wrench - T40269- for camshaft adjuster with three re‐

cesses
♦ Special wrench - T40079- for camshaft adjuster with 4 recess‐

es
© satelettronica
Removing
WARNING

Note

on the engine.
– Remove timing chain covers (left and right) ⇒ page 109 .
2. Chain drive 125

– Remove cylinder head cover (left and right) ⇒ page 151 .

noise insulation .
– Detach poly V-belt from tensioner ⇒ “1.2.2 Removing and in‐
stalling poly V-belt for ancillaries”, page 73 .
below engine.
© satelettronica
WARNING

Caution

– Detach air conditioner compressor from bracket and tie up on

longitudinal member (left-side) with lines/wiring connected.
Note
Disregard -item 1-.

gine.


crankshaft in direction of engine rotation -arrow- to “TDC”.

wards.
© satelettronica
Note
– Remove plug -arrow- for crankshaft “TDC” marking from cylin‐

der block.
2. Chain drive 127


Note
Chain tensioners for camshaft timing chain are oil-damped and

can only be compressed slowly by applying constant pressure.

(left-side) inwards as far as the stop using a screwdriver -1-.
© satelettronica
T40071- .
Camshaft adjusters with four recesses
Caution
Risk of damage to camshaft if handled incorrectly

• Never use camshaft clamp as a counterhold tool.
– Counterhold at corresponding camshaft adjuster by applying

special wrench - T40079- with torque wrench - V.A.G 1332-
and open ring spanner insert - V.A.G 1332/9- , and loosen bolt
-2-.
Note
Disregard -item 1- and -arrow-.
• Perform the same procedure on the opposite cylinder bank.

Camshaft adjusters with three recesses
Caution
Risk of damage to camshaft if handled incorrectly

• Never use camshaft clamp as a counterhold tool.
– Counterhold at corresponding camshaft adjuster by applying

special wrench - T40269- with torque wrench - V.A.G 1332-
and open ring spanner insert - V.A.G 1332/9- , and loosen bolt
-2-.
Note
Disregard item -1- and -arrow-.
© satelettronica
– Counterhold at corresponding camshaft sprocket by applying
counterhold tool - T10172A- with adapter - T10172/10- and
loosen bolt with special wrench - T10035- .
Note
Disregard -arrow-.
Caution

engine.
– Use paint to mark allocation of camshaft adjuster and

camshaft sprocket to corresponding cylinder head for re-in‐
stallation.
– Unscrew bolts -1- and -2- on cylinder head (left-side) and re‐
move camshaft adjuster and camshaft sprocket.
2. Chain drive 129

– Unscrew bolts -1- and -2- on cylinder head (right-side) and

remove camshaft adjuster and camshaft sprocket.
Installing
• Tightening torques ⇒ “2.1 Exploded view - camshaft timing
chains”, page 118
Note
Caution

• Drive chain for valve gear installed ⇒ “2.6 Removing and in‐
© satelettronica
stalling drive chain for valve gear”, page 137
T40069- .
• Camshafts on both cylinder heads locked in “TDC” position

-arrows- with camshaft clamp - T40133- (25 Nm).
Note
When assembling, note the following:
Caution

♦ The camshaft sprockets MUST be installed as described
in the following work steps:
• Fit camshaft sprockets according to marks applied when re‐

moving.

• When fitting camshaft sprockets, make sure that the lugs on

the camshaft sprockets engage in the slots on the
camshafts -arrows-.
Note
• Turn camshaft sprocket on camshaft anti-clockwise onto stop

-arrow-.
Note
© satelettronica
• Dot -1- should align with adjustment window -2-.
Note
♦ Illustration shows the cylinder head for cylinder bank 2 (left-

side).
♦ Disregard the camshaft timing chain in the illustration.
Caution

♦ The camshaft adjusters MUST be installed as described
• Fit camshaft adjusters according to marks applied during re‐

moval.
• Groove -1- on camshaft adjuster should align with adjustment
window -2-.
Note
♦ Illustration shows the cylinder head for cylinder bank 1 (right-

side).
♦ Disregard the camshaft timing chain in the illustration.
2. Chain drive 131

Installation (continued)
– Re-install camshaft adjusters on cylinder head (left-side) in the
same position as before (pay attention to marks applied when
removing).
– Fit camshaft timing chain (left-side) onto drive sprocket,
camshaft adjuster and camshaft sprocket and fit bolts -1- and
-2- without tightening.
• It should just be possible to turn the camshaft adjuster and
camshaft sprocket on the camshaft without axial movement.
– Re-install camshaft adjuster on cylinder head (right-side) in

the same position as before (pay attention to marks applied
when removing).
– Fit camshaft timing chain (right-side) onto drive sprocket,
camshaft adjuster and camshaft sprocket and fit bolts -1- and
-2- without tightening.
• It should just be possible to turn the camshaft adjuster and
camshaft sprocket on the camshaft without axial movement.
© satelettronica
– Apply counterhold tool - T10172A- with adapter - T10172/10-

to camshaft sprocket of exhaust camshaft (right-side).
– Have a 2nd mechanic apply tension to camshaft timing chain
by pressing camshaft sprocket in direction of -arrow-.
– Tighten bolts as follows while keeping camshaft sprocket un‐
der tension:
1. On exhaust 80 Nm
camshaft
1. On inlet 80 Nm
camshaft
Camshaft adjusters with four recesses

– Fit special wrench - T40079- onto camshaft adjuster of inlet
camshaft (left-side).
insert - V.A.G 1332/9- to special wrench - T40079- .
– Have a second mechanic apply approx. 40 Nm of tension to
camshaft timing chain by pressing torque wrench - V.A.G
1332- in direction of -arrow-.

Camshaft adjusters with three recesses

– Fit special wrench -T40269- onto camshaft adjuster of inlet
camshaft (left-side).
insert - V.A.G 1332/9- to special wrench -T40269- .
– Have a second mechanic apply tension to camshaft timing
chain by pressing torque wrench - V.A.G 1332- in direction of
-arrow-.
der tension:
1. -1- On exhaust camshaft: 80 Nm
1. -2- On inlet camshaft: 80 Nm
– Tighten bolts securing camshaft adjuster and camshaft

sprocket on cylinder head (left-side) as follows:
© satelettronica
2. -1- Tighten on exhaust camshaft to final
tightening torque ⇒ Item 2 (page 118)
2. -2- Tighten on inlet camshaft to final tight‐
ening torque ⇒ Item 1 (page 118)
– Tighten bolts securing camshaft adjuster and camshaft

sprocket on cylinder head (right-side) as follows:
2. -1- Tighten on inlet camshaft to final tight‐
ening torque ⇒ Item 3 (page 120)
2. -2- Tighten on exhaust camshaft to final
tightening torque ⇒ Item 1 (page 120)
– Remove camshaft clamps - T40133- from both cylinder heads

-arrows-.
Note
2. Chain drive 133

– Using adapter - T40058- and angled ring spanner, turn

crankshaft 2 revolutions in normal direction of rotation
-arrow- until crankshaft is at “TDC” again.
Note

© satelettronica
wards.



– Remove locking pin.
note the following:
– Install cylinder head covers: left-side ⇒ page 152 ; right-side
⇒ page 152 .
– Install timing chain covers (left and right) ⇒ page 109 .
Tightening torques
© satelettronica

ing chain
Removing
– Remove cylinder head covers: left-side ⇒ page 152 ; right-
side ⇒ page 152 .
– Remove timing chain from camshafts on relevant side ⇒ page
123 .
Caution


chain (left-side).
2. Chain drive 135

– Remove bolts -1- and -2- and take off chain tensioner (right-
side).
– Press guide rail of chain tensioner for drive chain for valve gear
in direction of -arrow- and lock chain tensioner by inserting
– Remove bolt -1- securing drive sprocket.
– Pull off drive sprocket with bearing mounting and lift off
camshaft timing chain (right-side).
Installing
© satelettronica
Note

Caution

– Position timing chain (left-side) as shown in the illustration

T40071- .

– Guide camshaft timing chain upwards to cylinder head (note

marks applied during removal).
– Install drive sprocket ⇒ page 122 .
– Tighten bolt -1- securing bearing mounting for drive chain
sprocket.
Note
Disregard -arrow-.
– Fit chain tensioner on cylinder head (right-side) and position

timing chain.
© satelettronica
note the following:
Tightening torques

valve gear
Removing
– Remove timing chains from camshafts ⇒ page 123 .
– Remove drive chain for auxiliary drives ⇒ page 138 .
2. Chain drive 137


of -arrow- and lock chain tensioner by inserting locking pin -
T40071- .
Caution


Installing
© satelettronica
Note

of -arrow- and remove locking pin - T40071- .
– Install drive chain for auxiliary drives ⇒ page 138 .
Tightening torques

balance shaft and oil pump

♦ Key - T40049-
© satelettronica
2. Chain drive 139

Removing
Caution
Risk of damage to drive chain if thread of bolt exceeds speci‐

fied length.
not exceed 22 mm.
– Attach key - T40049- at rear end of crankshaft using 2 bolts

-arrows-.
© satelettronica
– Remove plug -arrow- for crankshaft “TDC” marking from cylin‐
der block.
– Rotate crankshaft in normal direction of rotation to “TDC”.


– Press guide rail of chain tensioner in direction of -arrow- and

lock chain tensioner by inserting locking pin - T40071- .
Caution

– Unscrew bolts -3- and detach chain sprocket from balance

shaft.
– Remove bolts -1- and -2- and take off chain tensioner with
chain.
Installing
T40069- .
© satelettronica
– Install chain tensioner with chain and balance shaft sprocket.
– Lock balance shaft in “TDC” position using locating pin -
T40116- .
• The elongated holes in the balance shaft sprocket must be
aligned centrally over the threaded holes in the balance shaft.
If necessary move chain one tooth further.
– Tighten bolts for chain tensioner.
– Fit bolts -1- for chain sprocket without tightening.
• It should just be possible to turn the sprocket on the balance
– Pull out locking pin - T40071- to release chain tensioner.
– Press against guide rail of chain tensioner -arrow- using a
screwdriver, and at the same time tighten bolts -1- securing
chain sprocket.
– Pull locating pin -T40116- out of balance shaft.
note the following:
Tightening torques
♦ ⇒ “2.3 Exploded view - drive chain for balance shaft and oil
pump”, page 122
2. Chain drive 141

3 Cylinder head
⇒ “3.3 Removing and installing cylinder head cover”, page
151
Note

cylinder head”, page
© satelettronica
145
part number must face
cylinder head
2 - Cylinder head
⇒ page 145
⇒ Fig. ““Checking cylin‐
page 144
❑ Machining limit ⇒ Fig.
““Cylinder head machin‐
ing limit”“ , page 145
3 - O-ring
❑ Renew
4 - Hall sender
side): Hall sender - G40-
side): Hall sender 2 -
G163-
⇒ page 366
5 - Bolt
Item 1 (page 362)
6 - Bolt
❑ Renew
❑ Bolts have been gradually converted from Polydrive to multi-point socket
❑ Note correct sequence when loosening ⇒ page 149

❑ Tightening torque and sequence ⇒ Fig. ““Cylinder head - tightening torque and sequence”“ , page
144
7 - Ignition coil
❑ Removing and installing: left-side ⇒ page 152 , right-side ⇒ page 152
9 - Seal
10 - Filler cap
11 - Hose
❑ Removing and installing ⇒ “3.2 Removing and installing crankcase breather hoses”, page 189
Caution
Risk of violating emis‐
sion legislation applying
to USA models.
Do
♦ NOT open hose con‐
© satelettronica
nection.
12 - O-ring
❑ Renew
13 - Bolt
❑ Renew if gasket is damaged
❑ Tightening torque and tightening sequence: cylinder head cover (left-side) ⇒ page 144 , cylinder head
cover (right-side) ⇒ page 144
14 - Bolt
15 - Connector rail
❑ For ignition coils
16 - Gasket
❑ For cylinder head cover
17 - Camshaft control valve
❑ Cylinder bank 2 (left-side): camshaft control valve 2 - N208-
18 - Bolt
❑ 5 Nm
19 - O-ring
❑ Renew



© satelettronica
Note

2. -1 … 8- 40 Nm

• Max. distortion: 0.05 mm.



© satelettronica
♦ Special wrench, long reach - T10070- for vehicles up to ► July
2011
♦ Bit XZN 12 - T40270- , for vehicles from July 2011 ► onwards
Removing

Note

heads together.
– To remove cylinder head (right-side), first remove coolant pipe

(top) ⇒ page 232 .
– Remove oil filter housing ⇒ page 196 .
– Remove intake manifold (bottom sections) ⇒ page 300 .
© satelettronica
– Remove timing chain from camshafts on relevant side ⇒ page
123 .
– Remove locking pin - T40071- from cylinder head (left-side).
– Remove bolts -1- and -2- and detach chain tensioner from
cylinder head (right-side).
Note
Locking pin - T40071- remains in place.

– Unplug electrical connectors on cylinder head (left-side).

3 - For camshaft control valve 2 - N208-
Note
– Unplug electrical connector -1- for coolant temperature sender

- G62- .
WARNING
© satelettronica

one side.
– Remove bolt -1- for earth wire.
Note
Disregard -item 2-.

– Unplug electrical connectors on cylinder head (right-side).

2- Hall sender - G40-
Note
Disregard -arrows-.
© satelettronica
Note
Disregard -arrows-.


Note
♦ Depending on the version, different camshafts (with or without

recesses) and cylinder head bolts (with or without collar) are
fitted.
♦ Distinguishing features:
♦ Cylinder head bolts without a collar have a Polydrive head.
♦ Cylinder head bolts with a collar have a multi-point socket
head.
♦ Camshafts with assembly clearance feature have tool recess‐
es -arrows-; the cylinder head bolts without a collar can be
removed without any further preparation. Those with a collar
cannot be removed without further preparation (camshafts
must be removed ⇒ page 160 before cylinder head bolts can
be unscrewed).
♦ Camshafts without tool recesses must be removed ⇒ page
160 before the cylinder head bolts can be removed.
© satelettronica
– Unscrew bolts, detach cylinder head and set it down on a soft
surface (foam plastic).
Installing
Caution

cylinder block.
surfaces.
terial.
gasket.
valve gear.
erated.

Note

head bolts.
♦ After renewing the cylinder head or cylinder head gasket,
change the coolant and engine oil.
Cylinder head with camshafts installed

• Camshafts on both cylinder heads locked in “TDC” position
-arrows- with camshaft clamp - T40133- (25 Nm).
© satelettronica
• The camshaft clamp - T40133- is positioned correctly if the

T40069- .
– Renew seals and O-rings for coolant pipe (front).

• Installation position: the word “oben” (top) or the Part No.
should be visible.
• Pay attention to dowel sleeves -arrows- in cylinder block.

– Tighten cylinder head bolts ⇒ Fig. ““Cylinder head - tightening

torque and sequence”“ , page 144 .
Cylinder head with camshafts removed

– Tighten bolts -arrows- for timing chain cover (bottom) ⇒ Fig.
““Timing chain cover (bottom) - tightening torque and se‐
© satelettronica
Note

after repair work.

note the following:
– Install coolant pipe (front) ⇒ page 229 .
– Install camshaft timing chains ⇒ page 135 .
– Install intake manifold (bottom sections) ⇒ page 300 .
– Connect coolant hose with plug-in connector ⇒ Fig. ““Con‐
necting coolant hose with plug-in connector”“ , page 240 .
– Install oil filter housing ⇒ page 196 .
Tightening torques
page 145
♦ ⇒ Fig. ““Cylinder head - tightening torque and sequence”“ ,
page 144

cover
⇒ “3.3.1 Removing and installing cylinder head cover (left-side)”,
page 152

⇒ “3.3.2 Removing and installing cylinder head cover (right-

side)”, page 152
3.3.1 Removing and installing cylinder head

cover (left-side)
Removing
– Remove ignition coils ⇒ page 363 .
Rest-of-world vehicles:
lease tabs.
head cover (left-side).
USA models:
Caution
Risk of violating emission legislation applying to USA models.

♦ Do NOT open hose connection -arrow-.
© satelettronica
– Remove bolts in the sequence -12 ... 1- and move cylinder
head cover (left-side) clear to one side with crankcase
breather hose -arrow- still connected.
Installing
Note

aged.
♦ Fit new O-ring.

– Tighten bolts for cylinder head cover (left-side) ⇒ page 144 .
– Install ignition coils ⇒ page 363 .
Tightening torques

cover (right-side)
Removing

Rest-of-world vehicles:
lease tabs.
head cover (right-side).
USA models:
Caution

♦ Do NOT open hose connection -arrow-.
– Remove bolts in the sequence -12 ... 1- and move cylinder

head cover (right-side) clear to one side with crankcase
breather hose -arrow- still connected.
Installing
© satelettronica
Note

aged.
♦ Fit new O-ring.

– Tighten bolts for cylinder head cover (right-side) ⇒ page 144 .
Tightening torques


Procedure
head (left-side).
© satelettronica
Note

head (right-side).
Note

– Check compression pressure with compression tester -
V.A.G 1763- .
Note

pletely and at the same time operate the starter until the
pressure on the tester display no longer increases.
When new 11.0 … 14.0
Wear limit 10.0

Assembling
– Erase any entries in event memory resulting from testing
⇒ Vehicle diagnostic tester, Guided Functions , then In-
terrogate event memory .
© satelettronica

4 Valve gear
⇒ “4.5 Checking hydraulic compensation elements”, page
166
⇒ “4.6 Removing and installing valve stem oil seals”, page
168
Note
cracked.
© satelettronica
♦ Illustration shows the cylinder head for cylinder bank 2 (left-side).

1 - Sealing plug
2 - Cylinder head
guides”, page 175
head installed ⇒
“4.6.1 Removing and in‐
stalling valve stem oil
seals (cylinder head in‐
stalled)”, page 168
head removed ⇒
“4.6.2 Removing and in‐
seals (cylinder head re‐
moved)”, page 171
© satelettronica
4 - Valve spring
❑ Installation position ⇒
Fig. ““Installation posi‐
tion of valve spring”“ ,
page 158
ement
finger -item 8-
ing hydraulic compen‐
sation elements”, page
166
❑ Lubricate contact surface before installing
7 - Valve cotters
❑ Assembly: attach to hydraulic compensation element -item 5- using securing clip -item 9-
9 - Securing clip
10 - Inlet camshaft
11 - Bolt
❑ Renew
4. Valve gear 157

❑ Tightening torque and sequence ⇒ Fig. ““Retaining frame for camshafts - tightening torque and se‐
❑ One or two fitted depending on version; for allocation, refer to ⇒ Electronic parts catalogue
16 - Oil strainer
❑ Not fitted on all versions; for allocation, refer to ⇒ Electronic parts catalogue
17 - Inlet valve
❑ Must not be machined; only grinding-in is permissible
© satelettronica
❑ Checking ⇒ “5.2 Checking valves”, page 176
18 - Exhaust valve

head.

Retaining frame for camshafts - tightening torque and sequence
Note
♦ The illustration shows the retaining frame for the camshafts of

the left-hand cylinder head. The procedure is symmetrically
opposite on the right-hand cylinder head.

the full surface
2. -1 … 21- 8 Nm
3. -1 … 21- Turn 90° further
© satelettronica
4. Valve gear 159

Procedure
clean surface.
– Re-insert camshafts, install retaining frame ⇒ Fig. ““Retaining
frame for camshafts - tightening torque and sequence”“ , page
159 and tighten with old bolts to 8 Nm.

© satelettronica
♦ Plastigauge
Procedure
clean surface.
ing.
– Re-insert camshafts, fit retaining frame, secure with old bolts
and tighten to final torque without rotating camshafts ⇒
page 159 .
Radial clearance:
• 24 mm bearing ∅: 0.024 ... 0.066 mm
• 36 mm bearing ∅: 0.032 ... 0.078 mm



engines - T10133 C-
© satelettronica
♦ Safety goggles
Removing
– Remove timing chains from camshafts ⇒ page 123 .
– To remove camshafts in cylinder head (left-side), remove vac‐
uum pump ⇒ Brake system; Rep. gr. 47 ; Vacuum system;
Removing and installing vacuum pump .
– To remove camshafts in cylinder head (right-side), first re‐
move high-pressure pump and housing for high-pressure
pump drive ⇒ page 313 .
– Remove bolt -arrow- and detach camshaft control valve.
4. Valve gear 161

– Unplug electrical connector -1- at Hall sender.
Note
Disregard -arrow-.
Note
Perform the same procedure (laterally reversed) on retaining

frame (right-side).
© satelettronica
joint and set it down on a soft surface on workbench.

– Mark and remove camshafts.
Installing
Note
Renew seals/gaskets and sealing plugs.

T40069- .
stalled.
Caution


tion.
WARNING


– Check strainer -arrow- for dirt and clean as necessary.
© satelettronica
Note
Strainer -arrow- is not fitted on all versions; for allocation refer to

⇒ Electronic parts catalogue .

Note
One or two rectangular section seals are installed on the exhaust

camshaft -2 and/or 3- (depending on version). For allocation, re‐
fer to ⇒ Electronic parts catalogue .
– Turn retaining frame over with camshafts fitted, holding

camshafts firmly in position.
4. Valve gear 163



© satelettronica
Note

2 mm).
Caution


Note


plying the sealant.

head.
– Tighten bolts securing retaining frame for camshafts ⇒ page

159 .
Note
© satelettronica
sealant to dry.
– Clean bore for outer sealing plug in cylinder head (left and
right); it must be free of oil and grease.
– Drive in sealing plug until flush.
4. Valve gear 165


pins -T10133/3- .
note the following:
sure pump ⇒ page 313 .
Caution

valve gear.
erated.
Tightening torques
© satelettronica
♦ ⇒ Fig. ““Retaining frame for camshafts - tightening torque and
♦ ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded
view - vacuum pump

ments
Note


♦ Feeler gauge
♦ Adapter - T40058- for vehicles with 7-speed dual clutch gear‐

box 0B5
Procedure


WARNING

– Remove cylinder head cover: left-side ⇒ page 152 ; right-side

⇒ page 152 .
– Turn crankshaft until cam of hydraulic compensation element
to be tested is at top:
noise insulation .
© satelettronica
gine.

crankshaft in direction of engine rotation -arrow-.

element ⇒ “4.4 Removing and installing camshaft”, page
160 .
– Install cylinder head cover: left-side ⇒ page 152 ; right-side ⇒
page 152 .
Tightening torques
4. Valve gear 167



seals

equipment required
© satelettronica

5161/19B-

Procedure
– Apply drift -VAS 5161/3A- to valve spring plate and use plas‐
tic-headed hammer to release sticking valve cotters.
© satelettronica
– Screw adapter - T40012- with seal hand-tight into the corre‐
sponding spark plug thread.

4. Valve gear 169

If the puller -3364- cannot be used on some of the valve stem oil
seals due to the confined space, proceed as follows:
© satelettronica
lustration.
-arrow-.
Caution
Make sure valve stem oil seals are not damaged when in‐
stalling.


If valve cotters had been removed from assembly cartridge they

• Installation position of valve spring ⇒ page 158 .
– Secure guide plate back onto cylinder head.

cotters.
tion.
© satelettronica
Assembling
Caution

valve gear.
erated.
4. Valve gear 171


equipment required
© satelettronica
5161/19B-
Procedure


supply.
with valve heads.
– Apply drift -VAS 5161/3A- to valve spring plate and use plas‐
tic-headed hammer to release sticking valve cotters.
© satelettronica

4. Valve gear 173

Caution
Make sure valve stem oil seals are not damaged when in‐
stalling.
© satelettronica

• Installation position of valve spring ⇒ page 158 .
– Secure guide plate back onto cylinder head.

cotters.
tion.
Assembling



© satelettronica
Procedure
Note


new valves.

Note
5.2 Checking valves

– Visually inspect for scoring on valve stems and contact sur‐
faces.
Note

is permitted.
© satelettronica
∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.0 ± 0.2 101.9 ± 0.2
α ∠° 45 45
WARNING
♦ Care must be taken when disposing of old sodium-cooled

exhaust valves.
valves must not come into contact with water. After
preparing the valves, throw a maximum of ten into a buck‐
et of water. Then step away immediately, since a chemical
reaction will occur in which the sodium filling burns.
♦ After performing these steps the valves can be disposed

17 – Lubrication
1 Sump/oil pump
⇒ “1.3 Removing and installing sump (bottom section)”, page
181
⇒ “1.6 Removing and installing oil level and oil temperature
sender G266 ”, page 186
Note
© satelettronica

1 - Nut
❑ 9 Nm
sender - G266-
temperature sender
G266 ”, page 186
3 - Seal
❑ Renew
5 - Bolt
❑ Steel bolts:
♦ 9 Nm
© satelettronica
❑ Aluminium bolts:
♦ Renew
♦ 3 Nm +90°
7 - Bolt
❑ Renew
sequence ⇒ Fig. ““Sump
(top section) - tightening
page 180
❑ Removing and installing ⇒ “1.4 Removing and installing sump (top section)”, page 183
9 - Dowel sleeve
❑ 2x
10 - O-ring
❑ Renew
11 - Bolt
❑ Clean threaded holes for bolts
❑ Steel bolts:
♦ 9 Nm
❑ Aluminium bolts:
♦ Renew
♦ 3 Nm +90°
13 - Seal
❑ Renew

14 - Gasket
❑ Renew
15 - Bolt
❑ Renew
❑ 3 Nm +90°
❑ With oil cooler bypass valve
❑ Removing and installing ⇒ “2.1 Removing and installing engine oil cooler”, page 187
17 - Bolt
❑ 9 Nm
18 - Drive shaft
❑ For oil pump
20 - Sleeve
❑ 2x
© satelettronica
21 - Mounting bracket
22 - Bolt
❑ 9 Nm
23 - Chain sprocket
❑ For oil pump
24 - Bolt
❑ Renew
❑ To loosen and tighten, use pin wrench - 3212- to counterhold chain sprocket
❑ 30 Nm +90°
25 - O-ring
❑ Renew
26 - Seal
❑ Renew
27 - O-ring
❑ Renew
28 - Oil pump
29 - Bolt
❑ 20 Nm
30 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ Fig. ““Sump (bottom section) - tightening torque and sequence”“ ,
page 180
31 - Seal
❑ Renew
32 - Oil drain plug
❑ 30 Nm

Note

For steel bolts
For aluminium bolts
© satelettronica
Note
– Tighten bolts in the following sequence:

For steel bolts
Thread of bolt Tightening torque
M7 -1 … 6- Screw in by hand until they make con‐
tact, tighten in stages and in diagonal
sequence (final torque: 16 Nm)
M8 -1 … 6- Screw in by hand until they make con‐
tact, tighten in stages and in diagonal
sequence (final torque: 20 Nm)
For aluminium bolts
2. -1 … 6- 8 Nm
1.2 Engine oil

nance tables .
Caution

dipstick.


section)
♦ Safety goggles
Removing
Note
Lay a cloth under the engine oil cooler to catch escaping engine
oil.
© satelettronica
– Remove bolts for sump (bottom section) -1-.
– Release sump (bottom section) from bonded joint, taking care
not to bend sump.
Installing
Note
♦ Renew seals.
Caution

tion.

WARNING

– Remove remaining sealant on bottom section and top section

of sump -1- with a rotating plastic brush or similar.
Note
Take care not to damage the coating on the sump (bottom sec‐
tion).
Note
© satelettronica

1 mm).
Caution


sump (bottom section) as illustrated.
Note


– Fit sump (bottom section) and tighten bolts ⇒ page 180 .

note the following:
411 .
Tightening torques

tion)
♦ Safety goggles
© satelettronica
Removing
• Engine secured to engine and gearbox support ⇒ page 47
– Remove oil pump ⇒ page 185 .
– Remove bolts -arrows- and detach baffle plate (bottom).
– Remove bolt -arrow- for coolant pipes (left-side).

– Remove bolts -1 ... 6- for sump (top section).

Installing
Note
Caution

tion.

© satelettronica
WARNING

– Remove sealant residue from sump (top section) -1- and cylin‐
der block using rotating plastic brush or similar.
Note

1.5 mm).

Caution


• The grooves on the sealing surfaces must be completely filled
with sealant.
sealing surface.
Note

© satelettronica
– Fit seal -1- and O-ring -2- in retaining frame.
tighten bolts ⇒ page 180 .
note the following:
– Secure coolant pipes (left-side) ⇒ page 225 .
– Install oil pump ⇒ page 185 .
Tightening torques

Removing
– Remove sump (bottom section) ⇒ page 181 .
– Pull oil pump forwards off drive shaft.
Installing
Note
– Fit oil pump onto drive shaft and tighten bolts.

– Install sump (bottom section) ⇒ page 181 .
411 .
Tightening torques
© satelettronica
Removing
Installing
Note
Renew seal -4-.
411 .
Tightening torques

2 Engine oil cooler


er
© satelettronica
Removing
noise insulation .
– Detach coolant hose -1- and, if necessary, -2- from engine oil
cooler; release hose clip to do so.
below engine.
Installing
Note
♦ Renew gasket.
Note

Tightening torques

⇒ “3.1 Exploded view - crankcase breather system”, page
188
⇒ “3.2 Removing and installing crankcase breather hoses”, page
189
1 - Plug
❑ 20 Nm
2 - Gasket
❑ Renew
3 - Cover with oil separator
crankcase breather
© satelettronica
page 190
4 - Bolt
❑ 9 Nm
5 - O-ring
❑ Renew
❑ USA models: 2x
6 - Connection
❑ Installation position ⇒
Fig. ““Installing connec‐
tion for crankcase
breather”“ , page 189
7 - O-ring
❑ Renew
❑ USA models: 2x
8 - Bolt
❑ 2.5 Nm
9 - Bolt
❑ 2.5 Nm
❑ Removing and installing ⇒ “3.2 Removing and installing crankcase breather hoses”, page 189
11 - O-rings
❑ Renew
❑ To air pipe
13 - Hose clip
14 - Plug
❑ 20 Nm

Installing connection for crankcase breather

– Insert connection -1- for crankcase breather with new O-rings
in cover for oil separator.
• Installation position: lug -2- must engage in guide -arrow-.

breather hoses
⇒ “3.2.1 Removing and installing crankcase breather hoses, rest-
of-world vehicles”, page 189
⇒ “3.2.2 Renewing crankcase breather hoses, USA vehicles”,
page 189
© satelettronica
3.2.1 Removing and installing crankcase
breather hoses, rest-of-world vehicles
Removing
Note
– Remove supercharger ⇒ page 259 .

covers.
breather hoses.
Installing
Note
Fit new O-rings.

Tightening torques
♦ ⇒ “3.1 Exploded view - crankcase breather system”, page
188
3.2.2 Renewing crankcase breather hoses,

USA vehicles
Caution

♦ Crankcase breather hoses cannot be removed without

being irreparably damaged. Once removed, they must be
renewed.
Removing
Note

covers.
breather hoses.
Installing
© satelettronica
Note
Fit new O-rings.

Tightening torques
188

Removing
– Remove crankcase breather hoses ⇒ page 189 .
– Remove intake manifold (bottom section, left-side) ⇒ page
300 .


– Detach bracket for high-pressure pipes and cover -1- with oil
separator.
Installing
Note
Renew gasket.
– Install intake manifold (bottom section) ⇒ page 300 .

– Install crankcase breather hoses ⇒ page 189 .
Tightening torques
188
© satelettronica


⇒ “4.1 Exploded view - oil filter housing/oil pressure switch”, page
192
193
”, page 198
4.1 Exploded view - oil filter housing/oil pressure switch
1 - Bolt
❑ 13 Nm
© satelettronica
sure 2.5 ... 3.2 bar
❑ With grey insulation
agnostic tester
switch F22 ”, page
193
❑ 20 Nm
3 - Seal
❑ Renew
4 - Flange nut
❑ 13 Nm
5 - Bolt
❑ 9 Nm
6 - Sleeve
7 - Rubber grommet
❑ With oil retention valve
❑ The oil retention valve
cannot be renewed
9 - O-ring
❑ Renew
❑ Fitting ⇒ Fig. ““Installing O-ring on oil filter housing”“ , page 193
10 - Sealing cap
❑ 25 Nm
11 - Seal

❑ Renew
❑ Removing and installing ⇒ Fig. ““Renewing seal on sealing cap”“ , page 193
13 - Bolt
❑ Tightening torque ⇒ Fig. ““Timing chain cover (bottom) - tightening torque and sequence”“ , page 108
14 - Gasket
❑ Renew
Renewing seal on sealing cap

– Take hold of tab -arrow A- and pull seal -2- out of sealing cap
-1-.
– Install new seal so that semi-circular profile fits in groove
-arrow B- in sealing cap.
• Lug -arrow A- must point upwards.
© satelettronica
Installing O-ring on oil filter housing
– Fit O-ring -2- in groove -arrow- on oil filter housing -1-.

♦ Opening/closing pressure 0.75 ... 1.05 bar
♦ With grey insulation
♦ Check in Guided Fault Finding ⇒ Vehicle diagnostic tester
♦ Removing and installing ⇒ page 194
♦ 20 Nm

switch - F22-

♦ Socket, 24 mm - T40284-
Removing
Note
© satelettronica
– Unscrew oil pressure switch - F22- .
Installing
Note
♦ Renew seal.
mediately to avoid loss of oil.

Tightening torques
♦ ⇒ “4.1 Exploded view - oil filter housing/oil pressure switch”,
page 192


Removing
– Take out noise insulation.
-2-.
© satelettronica
Note

the supercharger removed.
Installing
Note
Renew seal.
Tightening torques
♦ ⇒ Fig. ““ Oil pressure switch for reduced oil pressure -F378-
”“ , page 193

Procedure
• Oil level OK


sure switch.
– Screw oil pressure switch - F22- into oil pressure tester.
– Start engine.
Assembling

© satelettronica
Removing
– Extract engine oil from oil filter housing using used oil collec‐
tion and extraction unit - VAS 6622A- .
solenoid valve 1 - N80- and detach vacuum hose -2- (press
release tabs).

Note
Mark position of vacuum hoses for re-installation.
– Disconnect vacuum hoses -4 ... 7-.
– Move clear vacuum hose -2- leading to brake servo at bracket

-1-.
© satelettronica
– Remove bolts -arrows- and move bracket -1- with change-over
valves to one side.

to one side.
Note

Note

F22- .
– Remove bolts -3- and push secondary air hose to rear.
Note
© satelettronica
– Remove nut -1- and unscrew centre hex stud.
– Remove oil filter housing with centre hex stud.
Installing
Note
Renew seals, gasket and O-ring.

Tightening torques
page 192
♦ ⇒ “1.1 Exploded view - supercharger”, page 257
4.6 Removing and installing valve for oil

pressure control - N428-


Removing
noise insulation .
below engine.
© satelettronica

N428- -item 4-.
Installing
Note
Fit new O-ring -2-.

Tightening torques
♦ ⇒ Fig. ““ Valve for oil pressure control -N428- ”“ , page 93

19 – Cooling

Note
© satelettronica
♦ Orange = Coolant circuit for charge air cooler.

1 - Water radiator (front) for

charge air cooling circuit
2 - Radiator
sender - G62-
4 - Thermostat
5 - Coolant pump
6 - Charge air cooler (right-
side)
❑ In supercharger hous‐
ing
7 - Bleeder screw
8 - Cylinder head
side)
9 - Bleeder screw
© satelettronica
V50-
Coolant circuit;
Overview of fitting loca‐
tions - coolant circuit
12 - ATF cooler
14 - Cylinder head
15 - Bleeder screw
16 - Charge air cooler (left-side)
❑ In supercharger housing
17 - Filler cap

23 - Water radiator (left-side) for charge air cooling circuit

24 - Charge air cooling pump - V188-
25 - Bleeder screw
Note

1 - Water radiator (front) for
© satelettronica
charge air cooling circuit
2 - Radiator
sender - G62-
4 - Thermostat
V55-
tary heater; Rep. gr.
82 ; Auxiliary/supple‐
mentary heater; Re‐
auxiliary/supplementary
heater
6 - Coolant pump
side)
ing
8 - Bleeder screw
9 - Cylinder head
side)
valve - N279-
Coolant circuit;
Overview of fitting loca‐
tions - coolant circuit
11 - Bleeder screw

13 - ATF cooler
15 - Cylinder head
16 - Bleeder screw
18 - Filler cap
© satelettronica
26 - Bleeder screw


equipment required
© satelettronica
Procedure
WARNING



• The pressure should not drop more than 0.2 bar within 10
minutes.
inate fault.
Note

engine is cold.
© satelettronica
1.4 ... 1.6 bar.
scribed.


equipment required
© satelettronica
♦ ⇒ Vehicle diagnostic tester
Draining
WARNING


WARNING


noise insulation .
gine.
© satelettronica
Note
Disregard -item 2-.

Note
Disregard -item 2-.
– Release hose clips -1 and 3-, disconnect coolant hoses from

Note

the engine removed.
Filling

Caution

Note

♦ Use only coolant additives listed in the ⇒ Electronic parts cat‐
alogue (ETKA) . If you use other coolant additives, this can
© satelettronica
ical climates.
♦ Only use water/coolant additive as a lubricant for coolant
hoses.


Procedure
– Connect coolant hose to coolant pipe (bottom left) with hose

clip -1-.
© satelettronica
– Connect coolant hoses to coolant pipes (front left) with hose
clips -1 and 3-.
Note

the engine removed.

12 litres of premixed coolant (according to recommended ratio
⇒ page 208 ).
V.A.G 1274/8- .
Note

rection of flow).

– Connect ⇒ Vehicle diagnostic tester to vehicle.

– Select following menu options on ⇒ Vehicle diagnostic tester:
♦ Guided Functions mode
♦ 01 - Simos fuel injection and ignition system
♦ Functions - engine
♦ 01 - Coolant circuit vent routine
– Follow instructions shown on vehicle diagnostic tester .

• The suction jet pump generates a vacuum in the cooling sys‐
tem. The needle on the gauge should move into the green
zone.
© satelettronica
• The suction jet pump will continue generating a vacuum in the
cooling system. The needle on the gauge should remain in the
green zone.
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the pro‐
cess.
tained.

– Open valve -A-.
drawn out of the reservoir of the cooling system charge unit -
VAS 6096- ; the cooling system is then filled.


cedure.
Note
© satelettronica
– Open bleeder screws -1- and -2- one after the other until
coolant flows out.
– Close bleeder screws.
chamber cover .

hose.
clip.

it engages).
– Start engine.
– Set temperature to “HI” for all zones and select lowest blower
speed (= 0).
– Allow engine to run at idling speed until both large coolant
hoses at radiator become warm.


insulation .

gine is cold.
engine is warm.
© satelettronica


⇒ “2.2 Removing and installing electric coolant pump”, page
214
”, page 217
1 - Bolt
❑ 9 Nm
© satelettronica
2 - Bolt
❑ 20 Nm
4 - Coolant pump
❑ With seal
stalling coolant pump”,
page 215
5 - Bolt
❑ 9 Nm
6 - Bolt
Item 2 (page 69)
7 - Washer
8 - Idler roller
❑ For poly V-belt
9 - Connection
10 - Gasket
❑ Renew
11 - Seal
12 - Thermostat
page 217
Note
When removing and installing the

thermostat, make sure that the nee‐

dle is fitted correctly (conical end

fitted in wax expansion element of
thermostat). If necessary, push ther‐
mostat needle as far as possible into
wax expansion element.
13 - Bolt
❑ 9 Nm
14 - Coolant valve for cylinder head - N489-
Charge air cooling pump - V188- - tightening torque

– Tighten nut -2- to 9 Nm.
© satelettronica
Temperature sender for engine temperature regulation - G694- -
tightening torque
– Tighten temperature sender for engine temperature regulation
- G694- -item 1- to 3 Nm.

pump

Removing
– Remove front left wheel spoiler ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Removing and
installing wheel housing liner (front) .
– Unscrew nuts -arrows- and remove bracket.
© satelettronica
– Clamp off coolant hoses at charge air cooling pump - V188-
using hose clamps, up to 25 mm - 3094- , release hose
clips -1- and disconnect coolant hoses.
Installing
Note

Tightening torques
♦ ⇒ Fig. ““ Charge air cooling pump -V188- - tightening torque”“ ,
page 214
♦ Front wheel spoiler ⇒ General body repairs, exterior; Rep. gr.
66 ; Wheel housing liners; Exploded view - wheel housing liner
(front)

Removing


– Remove poly V-belt for supercharger ⇒ page 71 .
– Detach poly V-belt from air conditioner compressor, but do not
remove completely ⇒ “1.2.2 Removing and installing poly V-
belt for ancillaries”, page 73 .
ments .
Note
Disregard -item 2-.
© satelettronica
Note
– Remove bolts -arrows- and detach coolant pump to the side.

Installing
ments .
Note

Tightening torques
♦ ⇒ “3.2 Removing and installing air cleaner housing”, page
295

Removing
– Remove coolant pipe (front) ⇒ page 229 .
Note
Place a cloth underneath to catch any escaping coolant.

© satelettronica
Installing
Note
When removing and installing the thermostat, make sure that the
needle is fitted correctly (conical end fitted in wax expansion el‐
ement of thermostat). If necessary, push thermostat needle as far
as possible into wax expansion element.
Note
Renew gasket.

Note

Tightening torques
2.5 Removing and installing coolant tem‐


Removing
• Engine cold.
– Remove engine cover panel (front) ⇒ page 67 .

- G62- .
Note
– Pull off retaining clip -2- and detach coolant temperature
© satelettronica
sender - G62- .
Note
Disregard -arrow-.
Installing
Note
♦ Fit new O-ring.


tion - G694-
Removing
– Remove intake manifold (bottom section, right-side) ⇒ page
300 .


Installing
– Install intake manifold (bottom section, right-side) ⇒ page
300 .
Tightening torques
♦ ⇒ Fig. ““ Temperature sender for engine temperature regula‐
tion -G694- - tightening torque”“ , page 214

© satelettronica
Removing
noise insulation .


Installing
Note

Tightening torques
© satelettronica

3 Coolant pipes
⇒ “3.2 Fitting coolant hoses”, page 224

1 - Bolt
❑ 9 Nm
2 - Bolt
❑ 9 Nm
3 - Coolant pipes (front left)
(front left)”, page 228
© satelettronica
4 - Retainer
5 - Bolt
❑ 22 Nm
6 - Bolt
❑ 2.5 Nm
7 - Bolt
❑ 9 Nm
(front)”, page 229
9 - Seal
❑ Renew
10 - O-rings
❑ Renew
sender - G62-
ature sender G62 ”, page 217
12 - Bolt
❑ 5 Nm
13 - Coolant pipe (bottom) on supercharger
❑ Remove and install together with -item 20- ⇒ page 234
14 - Bolt
❑ 5 Nm
15 - Dowel sleeve
16 - Seal

❑ Renew
17 - Bolt
❑ 5 Nm
18 - Seal
❑ Renew
19 - Coolant pipe (top) on supercharger
❑ Remove and install together with -item 14- ⇒ “3.3.6 Removing and installing coolant pipes on super‐
charger”, page 234
20 - Dowel sleeve
21 - Bolt
❑ 5 Nm
22 - Seals
❑ Renew
23 - O-ring
❑ Renew
© satelettronica
25 - Bolt
❑ 9 Nm
26 - Seal
❑ Renew
27 - Bolt
❑ 9 Nm
28 - O-ring
❑ Renew
29 - Bolt
❑ Renew
❑ 3 Nm +90°
30 - Bolt
❑ Renew
❑ 3 Nm +90°
31 - Coolant pipes (left-side)
❑ Removing and installing ⇒ “3.3.1 Removing and installing coolant pipes (left-side)”, page 225
32 - Retaining clip
Coolant pipes to 7-speed dual clutch gearbox 0B5

1 - Bolt
❑ 22 Nm
(bottom left)”, page
226
N509-
page 219
4 - Bolt
❑ 9 Nm
5 - Heat shield
6 - Bolt
❑ 9 Nm
© satelettronica
gearbox
page 235
8 - Bolt
❑ 9 Nm
9 - Bracket
valve - N509-
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 22 Nm
Coolant pipes to 8-speed automatic gearbox 0BK

1 - Bolt
❑ 22 Nm
(bottom left)”, page
226
N509-
page 219
4 - Bolt
❑ 9 Nm
5 - Heat shield
6 - Bolt
❑ 9 Nm
© satelettronica
gearbox
page 235
8 - Bolt
❑ 9 Nm
9 - Bracket
valve - N509-
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 22 Nm
3.2 Fitting coolant hoses

– Fit coolant hose on connection as follows:
• Push coolant hose -6- onto connection -1- as far as stop -3-.
• If stop is not fitted, push coolant hose 28 mm onto connection.
• Arrow marking -4- on coolant hose must align with arrow mark‐
ing -2- on connection. Some parts have line markings instead
of arrows.
• Use only undamaged hose clips -5- (same as original equip‐
ment).
• Position hose clips between coloured markings -7-.
• Position lugs of hose clips for maximum clearance from sur‐
rounding parts.


page 225
226
⇒ “3.3.3 Removing and installing coolant pipes (front left)”,
page 228
⇒ “3.3.4 Removing and installing coolant pipe (front)”, page
229
⇒ “3.3.5 Removing and installing coolant pipe (top)”, page
232
⇒ “3.3.6 Removing and installing coolant pipes on supercharger”,
page 234

(left-side)
© satelettronica
Removing
page 73 .
– Remove bolts -arrows- and detach engine support with brack‐

et for air conditioner compressor.


– Release hose clips -1- and -2- and disconnect coolant pipes
from coolant hoses.
Installing
Note
♦ Fit new O-ring.


– Install engine support with bracket for air conditioner com‐
pressor and engine mounting (left-side) ⇒ page 58 .
© satelettronica
Note

Tightening torques

(bottom left)

© satelettronica
Removing
Note

3094- , release hose clips -arrows- and disconnect coolant
hoses from coolant pipe (bottom left).
– Detach coolant pipe (bottom left).
Note
Installing
Note
– Install engine mounting (left-side) ⇒ page 61 .
Note


Tightening torques

(front left)
© satelettronica
Removing
noise insulation .

WARNING

gine.
Note
© satelettronica
the bumper removed in this and the following illustration.

3094- , release hose clips -1- and -3- and disconnect coolant
hoses from coolant pipes (front left).
– Release hose clips -1- and detach coolant hoses from coolant
pipes at supercharger.
– Detach coolant pipes (front left) from below.
Installing
Note

Tightening torques

(front)

© satelettronica
Removing
ments .
Note
Disregard -item 2-.
– Remove coolant pipes (front left) ⇒ page 228 .

page 73 .


– Detach coolant valve for cylinder head - N489- -arrow- from

bracket and move it clear to the side.
– Press release tabs and move clear -2- secondary air hose
-1-, take it out of bracket towards front and disconnect it.
© satelettronica
- G62- .
– Lift retaining clips and disconnect coolant hoses -1 and 4-.
– Release hose clip -2- and detach coolant hose (top).
– Release hose clip -5-.
– Unscrew bolts -arrows- and remove coolant pipe (front).
Installing
Note

– Clean or smoothen sealing surfaces for seals and O-rings.

– Lubricate seals and O-rings with coolant and slide onto coolant
pipe.
– Install coolant pipes (front left) ⇒ page 228 .
ments .
Note


Tightening torques
♦ Air pipe ⇒ “3.1 Exploded view - air cleaner housing”, page
295

(top)
Removing
Note
© satelettronica
– Remove intake manifold (bottom section, right-side) ⇒ page
300 .
– Remove nuts -arrows- and detach guard plate -1- for high-
pressure pipe.
– Press release tabs and move clear -2- secondary air hose
-1-, take it out of bracket towards front and disconnect it.

– Unscrew connection -1-.
WARNING

– Unscrew union nuts -2- and -3- (counterhold connection).

– Unscrew bolts -arrows- on retaining clips and detach high-
pressure pipe.
Note
The threaded connection on the fuel rail must be renewed if it has
© satelettronica
been loosened or removed at union nuts -2- and -3-.
Note
– Lift retaining clip -2- and disconnect coolant hose from coolant
pipe.
block -arrow-.
Installing
Note
Fit new O-rings.

Note

Tightening torques


on supercharger
© satelettronica
Removing
noise insulation .

WARNING


gine.

3094- , release hose clips -1- and disconnect coolant hoses
from coolant pipes at supercharger.
© satelettronica
Note
Disregard -item 2-.
– Remove bolts -1- and -2- and take off coolant pipes.
Installing
Note


Tightening torques


© satelettronica
Removing
clear at air pipe.


-1- on subframe.
WARNING

© satelettronica

noise insulation .
tion.

– Clamp off coolant hose -1- with hose clamp, up to 25 mm -
3094- .
– Clamp off coolant hose -3- using hose clamp up to 25 mm -
3094- , release hose clip and disconnect coolant hose from
coolant pipe on right side of gearbox.

– Clamp off coolant hose -1- with hose clamp, up to 25 mm -
3094- .
– Clamp off coolant hose -3- using hose clamp up to 25 mm -
3094- , release hose clip and disconnect coolant hose from
coolant pipe on right side of gearbox.
Installing

Note

Tightening torques
295
© satelettronica

4 Radiators/radiator fans
⇒ “4.1 Exploded view - radiators/radiator fans”, page 239
⇒ “4.2 Exploded view - auxiliary radiator”, page 241
⇒ “4.4 Removing and installing water radiator for charge air cool‐
ing circuit”, page 246
4.1 Exploded view - radiators/radiator fans

Radiator and water radiator (front) for charge air cooling circuit
1 - Air duct
2 - Coolant hose
© satelettronica
tach
❑ Connecting to radiator ⇒
Fig. ““Connecting
in connector”“ , page
240
3 - O-ring
❑ Renew
4 - Radiator
gether with radiator cowl
stalling radiator”, page
242
5 - O-ring
❑ Renew
6 - Coolant hose
tach
Fig. ““Connecting
in connector”“ , page
240
7 - Coolant hose
tach
Fig. ““Connecting coolant hose with plug-in connector”“ , page 240
8 - O-ring
❑ Renew
9 - Rubber bush
4. Radiators/radiator fans 239

❑ For radiator
10 - Retaining pin
11 - Air duct
12 - Coolant hose
13 - Bolt
❑ 4.5 Nm
14 - Condenser
15 - Water radiator (front) for charge air cooling circuit
❑ Removing and installing ⇒ “4.4 Removing and installing water radiator for charge air cooling circuit”, page
246
16 - Coolant hose
17 - Air duct
18 - Rubber bush
❑ For radiator
© satelettronica
20 - Bolt
❑ 5 Nm
21 - Washer
22 - Bolt
❑ 4.5 Nm
23 - O-ring
❑ Renew
24 - Coolant hose

– Lightly lubricate new O-ring with coolant and fit O-ring in
coolant hose.
bly.
Radiator cowl and radiator fans


❑ With radiator fan control
unit 2 - J671-
page 254
unit - J293-
page 254
3 - Radiator cowl
installing radiator cowl -
Audi A6”, page 249
© satelettronica
installing radiator cowl -
Audi A7”, page 251
4 - Bolt
❑ 3.5 Nm
5 - Fan wheel
❑ Pin must engage in hole
6 - Bolt
❑ 5 Nm
7 - Fan wheel
8 - Bolt
❑ 5 Nm
9 - Bolt
❑ 3.5 Nm
4.2 Exploded view - auxiliary radiator

1 - Air duct
2 - Bolt
❑ 9 Nm
3 - Washer
4 - Rubber bush
❑ For radiator
5 - Nut
❑ 9 Nm
6 - Bolt
❑ 22 Nm
7 - Bracket
8 - Nut
❑ 22 Nm
9 - Rubber bush
❑ For radiator
10 - Charge air cooling pump -
© satelettronica
V188-
stalling electric coolant
pump”, page 214
11 - Coolant hose
12 - Coolant hose
13 - Nut
❑ 9 Nm
14 - Bracket
❑ For charge air cooling
pump - V188-
15 - Bracket
❑ For charge air cooling pump - V188-
16 - Coolant hoses
❑ Removing and installing ⇒ “4.7 Removing and installing auxiliary radiator”, page 254
Note
gether as one unit.

© satelettronica
Removing
noise insulation .
bumper cover .
– Remove water radiator (front) for charge air cooling circuit ⇒
page 246 .
gine.
tor.

WARNING

radiator cowl.
© satelettronica
diator.
Note
Disregard -item 2-.

– Release catches -arrows A- and detach air duct -1- on left and
right -arrow B-.
upwards -arrows-.
© satelettronica
-arrows B-.
Caution

hoses.



– Slightly lower radiator.
Installing
Note
© satelettronica

– Install water radiator (front) for charge air cooling circuit ⇒
page 246 .
cover .
Note

Tightening torques
♦ ⇒ “4.1 Exploded view - radiators/radiator fans”, page 239
♦ Air duct ⇒ “3.1 Exploded view - air cleaner housing”, page
295
4.4 Removing and installing water radiator

for charge air cooling circuit

© satelettronica
Removing
ments .

wards slightly.
Note
Disregard -item 1-.
Note
For illustration purposes, the installation position is shown in the

following illustrations with the bumper removed.
© satelettronica
– Place drip tray for workshop hoist - VAS 6208- beneath water
radiator (front) for charge air cooling circuit.
– Clamp off coolant hose using hose clamp up to 25 mm - 3094- ,
release hose clip -arrow- and disconnect hose.
– Clamp off coolant hose using hose clamp up to 25 mm - 3094- ,

release hose clip -1- and disconnect hose.
– Push catch down -arrow A- and move water radiator (front) for
charge air cooling circuit slightly in direction of -arrow B-.

– Lift water radiator (front) for charge air cooling circuit off radi‐
ator -arrows A- and swivel in direction of -arrow B-.
– Detach water radiator (front) for charge air cooling circuit from
right side downwards -arrow C-.
Installing
Note
♦ If there are slight impressions on the fins, refer to ⇒ page 6 .


Note
© satelettronica

Tightening torques

⇒ “4.5.1 Removing and installing radiator cowl - Audi A6”, page
249
⇒ “4.5.2 Removing and installing radiator cowl - Audi A7”, page
251

Audi A6
Removing
ments .

Note
Disregard -item 2-.

© satelettronica
noise insulation .
– Remove water radiator for charge air cooling circuit ⇒ “4.4 Re‐
moving and installing water radiator for charge air cooling
circuit”, page 246 .
gine.
tor.

WARNING

radiator cowl.

© satelettronica
from below.
Installing
– Connect coolant hose with plug-in connector ⇒ Fig. ““Con‐
necting coolant hose with plug-in connector”“ , page 240 .
Note

Tightening torques

Audi A7
Removing
noise insulation .

WARNING

radiator cowl.
ments .
Note
© satelettronica
Disregard -item 2-.
– Detach air duct -1-.

wards slightly.


© satelettronica

Installing
Tightening torques

V7-
© satelettronica
Removing
Note

– Remove bolts -1- or -2- and detach corresponding fan wheel.
– Remove bolts -arrows- on radiator fan.
– Move electrical wiring harness clear and detach radiator fan.
Installing
– Note installation position of fan wheel.
• Pin -2- must engage in hole -1-.
Tightening torques

tor

© satelettronica
Removing
noise insulation .

Note

the bumper removed in the following illustration.
– Detach air duct -1- -arrow-.
– Place drip tray for workshop hoist - VAS 6208- beneath water
radiator (left-side) for charge air cooling circuit.
– Lift water radiator (left-side) -1- for charge air cooling circuit off
bracket.
© satelettronica
Installing
Note

Note

Tightening torques
♦ ⇒ “4.2 Exploded view - auxiliary radiator”, page 241
(front)

1 Supercharger
⇒ “1.1 Exploded view - supercharger”, page 257
⇒ “1.2 Exploded view - drive unit”, page 259
⇒ “1.3 Removing and installing supercharger”, page 259
⇒ “1.4 Checking supercharger for leaks”, page 263
⇒ “1.5 Removing and installing drive unit and damper spring”,
page 265
⇒ “1.6 Securing supercharger to engine and gearbox support”,
page 267
1.1 Exploded view - supercharger

2 - Bolt
© satelettronica
❑ 27 Nm
3 - Supercharger
❑ With charge air coolers
supercharger ⇒
“1.3 Removing and in‐
stalling supercharger”,
page 259
❑ Exploded view - charge
air system ⇒ “2.1 Ex‐
ploded view - charge air
system”, page 271
❑ Secure to engine and
gearbox support - VAS
6095- when performing
assembly work ⇒
“1.6.1 Securing super‐
charger to engine and
gearbox support for as‐
sembly work”, page
268
6095- when checking
for leaks ⇒ “1.6.2 Secur‐
ing supercharger to en‐
gine and gearbox sup‐
port for leak test”, page
269
4 - Insulating plate
5 - Bolt
❑ 5 Nm
6 - Rubber grommet
❑ 2x
7 - Intermediate flange
8 - Bolt
1. Supercharger 257
❑ Tightening torque ⇒ Fig. ““ Throttle valve module -J338- - tightening torque”“ , page 299
10 - O-rings
❑ Renew
11 - Connection
12 - Bolt
❑ Tightening torque and sequence ⇒ Fig. ““ Regulating flap control unit -J808- - tightening torque and
13 - Bracket
❑ For change-over valves
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ Tightening torque and sequence ⇒ Fig. ““ Regulating flap control unit -J808- - tightening torque and
© satelettronica
17 - Regulating flap control unit - J808-
❑ Removing and installing ⇒ “4.5 Removing and installing regulating flap control unit J808 ”, page 305
18 - Bleeder screw
❑ For charge air cooler (left-side)
❑ 1.5 … 3.0 Nm
19 - Bolt
❑ Tightening torque ⇒ Fig. ““ Intake air temperature sender -G42- / intake manifold pressure sender -G71-
- tightening torque”“ , page 299
❑ Removing and installing ⇒ “6.1 Removing and installing intake air temperature sender G42 / intake man‐
ifold pressure sender G71 ”, page 311
21 - O-rings
❑ Renew
22 - Nut
❑ 20 Nm
23 - O-ring
❑ Renew
24 - Threaded pin
❑ 17 Nm
25 - Bolt
❑ Self-locking
❑ Renew
❑ Before assembly, always remove residues from threaded holes using a thread tap
❑ 10 Nm
26 - Charge pressure sender
❑ Cylinder bank 1 (right-side): charge pressure sender - G31-
❑ Cylinder bank 2 (left-side): charge pressure sender 2 - G447-
❑ Removing and installing ⇒ “2.4 Removing and installing charge pressure sender G31 / G447 ”, page
275
27 - Seals

❑ Renew
28 - O-ring
❑ 2x on USA versions
❑ Renew
29 - Connection
❑ Installation position ⇒ Fig. ““Installing connection for crankcase breather”“ , page 189
30 - O-ring
❑ Renew
1.2 Exploded view - drive unit
1 - Bolt
❑ Self-locking
❑ Renew
© satelettronica
❑ Before assembly, al‐
ways remove residues
from threaded holes us‐
ing a thread tap
❑ 25 Nm
2 - Drive unit
stalling drive unit and
damper spring”, page
265
3 - Damper spring
stalling drive unit and
damper spring”, page
265
4 - Supercharger housing
1.3 Removing and installing supercharger

1. Supercharger 259
© satelettronica

Removing
– Remove poly V-belt for supercharger ⇒ page 71 .
gine.
Note

the engine removed.
clear at air pipe.
© satelettronica

release tabs).
Note
Disregard -item 1-.
– Unplug electrical connector -arrow- at throttle valve module -

J338- .
1. Supercharger 261
– Unplug electrical connector -arrow- at regulating flap control

unit - J808- .
Note
Mark position of vacuum hoses for re-installation.
– Disconnect vacuum hoses -4 ... 7-.
© satelettronica
– Unplug electrical connector -1- at intake air temperature
sender - G42- / intake manifold pressure sender - G71- .
Note
Disregard -arrows-.
– Move clear vacuum hose -1-.

– Remove bolts -arrows- on both sides and detach cover -2-.

– Move clear vacuum hose -2- leading to brake servo at bracket

-1-.

– Remove nuts -arrows- and lift off supercharger with charge air
coolers.
– Seal openings on supercharger and all relevant ducts and
hoses of the charge air system with plugs from engine bung
set - VAS 6122- .
Installing
© satelettronica
Note

– Ensure that crankcase breather connection is positioned cor‐

rectly ⇒ page 189 when fitting supercharger.
– Install poly V-belt for supercharger ⇒ page 71 .
Note

Tightening torques
295
1.4 Checking supercharger for leaks

1. Supercharger 263
♦ Charge air system tester - V.A.G 1687- with adapters - V.A.G

1687/10- , -V.A.G 1687/13-1- , -V.A.G 1687/13-2- and -V.A.G
1687/13-3-
Procedure
• Supercharger secured to engine and gearbox support - VAS
6095- for leak test ⇒ page 268 .
• Regulating flap control unit - J808- installed ⇒ page 305 .
– Secure -V.A.G 1687/13-1- to bottom of supercharger housing.
– Secure hose connections with hose clips.
© satelettronica
Note
For illustration purposes the supercharger is shown without the

gearbox support.
– Secure -V.A.G 1687/13-3- to top of supercharger housing.

– Secure -V.A.G 1687/13-2- to supercharger housing with

adapter - V.A.G 1687/10- .


valves -3- and -4-.
• Make sure knob is pulled out before turning pressure control
valve.
– Connect charge air system tester - V.A.G 1687- as shown in

illustration, and connect to compressed air line using a com‐
mercially available connection piece -1-.
© satelettronica
– If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution


– Close valve -3-.
• Pressure must not drop by more than 0.1 bar for 30 seconds.
felt with the hand; apply commercially available leak detecting
Note

1.5 Removing and installing drive unit and

damper spring
1. Supercharger 265

♦ Oil for supercharger drive ⇒ Electronic parts catalogue
♦ Spreader tool (commercially available)
Removing
6095- ⇒ page 268 .
© satelettronica
– Detach coolant pipes from supercharger ⇒ page 234 .
– Position supercharger vertically in engine and gearbox sup‐
port.
• Drive unit faces upwards.
Caution
♦ To make sure bearing cover -1- does not come loose and
remains properly sealed, always use spreader tool
-arrows- to press off drive unit -2- as shown in illustration
(do not use a hammer).
– Carefully press off drive unit from bearing cover and detach.
– Detach damper spring.

– With the aid of used oil collection and extraction unit - VAS
6622A- , extract all oil for supercharger drive from bearing
cover (including oil chambers -arrows- between ribs).
Installing
Note
♦ Renew the drive unit bolts.

♦ Fit self-locking bolts or insert bolts with locking fluid ⇒ Elec‐

– Before assembly, always remove residues from threaded
holes for drive unit in bearing cover using a thread tap.
– Fill bearing cover with oil for supercharger drive.
Note
The container is filled with the required amount of oil. It is not
© satelettronica
possible to check the oil level at a later stage.
– Insert damper spring in damper element.

• End -1- of damper spring must engage in hole -arrow- in rear
damper element.
– Apply a thin layer of sealant to sealing surface of drive unit.
– Fit drive unit to supercharger housing (pay attention to dowel
sleeves).
Caution
Avoid damage to drive shaft.

♦ The drive unit must not be pulled in by screwing in the
bolts.
– Simultaneously turn drive pulley until opposite end of damper

spring engages in hole in drive unit.
note the following:
– Check supercharger for leaks ⇒ page 263 .
– Install coolant pipes on supercharger ⇒ page 234 .
Tightening torques
♦ ⇒ “1.2 Exploded view - drive unit”, page 259
1.6 Securing supercharger to engine and

gearbox support
⇒ “1.6.1 Securing supercharger to engine and gearbox support
for assembly work”, page 268
for leak test”, page 269
1. Supercharger 267
1.6.1 Securing supercharger to engine and

gearbox support for assembly work
Note
When performing assembly work, the openings in the bottom of

the supercharger housing make it possible for you to see and ac‐
cess the charge air coolers.

© satelettronica
♦ Gearbox support - T40206- with -T40206/1- and -T40206/2-
Procedure
• Supercharger removed ⇒ page 259 .
– Insert gearbox support -T40206- with -T40206/1- into engine
– Secure supercharger to gearbox support, as shown in illus‐
tration (use holes “1”, “4”, “9”, “11” and “13” for bolted connec‐
tions -1-).
– Attach mounting -T40206/2- directly to supercharger housing
at front right with bolt -2-.

Installation position of mountings -T40206/2- :

• Seals -arrow 1- of mountings should point downwards.
• Openings -arrow 2- in supercharger housing make it possible
for you to see and access charge air coolers.

gearbox support for leak test
Note
When checking for leaks, the seals on the mountings -T40206/2-

should seal off the openings in the supercharger housing.
© satelettronica
♦ Gearbox support - T40206- with -T40206/1- and -T40206/2-
1. Supercharger 269
Procedure
• Supercharger removed ⇒ page 259 .
– Insert gearbox support -T40206- with -T40206/1- into engine
– Secure supercharger to gearbox support, as shown in illus‐
tration (use holes “1”, “4”, “9”, “11” and “13” for bolted connec‐
tions -1-).
– Attach mounting -T40206/2- directly to supercharger housing
at front right with bolt -2-.
Installation position of mountings -T40206/2- :
© satelettronica
• Seals of mountings should seal off openings in supercharger
housing.

2 Charge air system

⇒ “2.4 Removing and installing charge pressure sender G31 /
G447 ”, page 275
Note
♦ Observe rules for cleanliness ⇒ page 5 .

♦ Check that all air pipes and hoses and vacuum lines are correctly fitted and that there are no leaks before
carrying out tests or repairs.
1 - Gasket
❑ Renew
© satelettronica
2 - O-ring
❑ Renew
❑ Coat with engine oil
when installing charge
air cooler
3 - O-ring
❑ Renew
air cooler
5 - Gasket
❑ Renew
side)
stalling charge air cool‐
er”, page 272
7 - Bolt
❑ Self-locking
❑ Renew
❑ 10 Nm
8 - Seal
❑ Must not be detached
from charge air cooler
air cooler
9 - Bolt
❑ Self-locking
❑ Renew

❑ 10 Nm
❑ Removing and installing ⇒ “2.3 Removing and installing charge air cooler”, page 272
11 - Seal
❑ Must not be detached from charge air cooler
❑ Coat with engine oil when installing charge air cooler

charge air system
Note

♦ Secure all hose connections with the correct type of screw-
type clips (same as original equipment) ⇒ Electronic parts
© satelettronica
catalogue .

1- Screw-type clip -a- = 13 mm wide: 5.5 Nm
2- Screw-type clip -b- = 9 mm wide: 3.4 Nm

er
♦ Fitting sleeve - 2033-

♦ Assembly device for valves - 2036-
♦ Tyre lever for aluminium rims - V.A.G 1942-

Removing
6095- for assembly work ⇒ page 268 .
Charge air cooler (left-side):
– Unclip bracket -1- for vacuum hose.
© satelettronica
Note
Disregard -item 2-.
– Remove charge pressure sender 2 - G447- ⇒ page 275 .

Charge air cooler (right-side):
– Remove charge pressure sender - G31- ⇒ page 275 .

– Remove bolts -1- and -2- and detach coolant pipes from su‐
percharger.
– Remove bolts -1, 2- for charge air cooler (left-side) and

bolts -3, 4- for charge air cooler (right-side).

– Attach valve assembly device - 2036- with -2036/1- to super‐

charger, as shown in illustration.
– Apply fitting sleeve - 2033- at front of charge air cooler.
– Using tyre lever - V.A.G 1942- , apply moderate pressure and
slowly press charge air cooler out of supercharger housing.
Installing
Note
♦ Renew seals, gaskets, O-rings and self-locking bolts.

♦ Before assembly, always remove residues from threaded
holes in supercharger housing using a thread tap.
© satelettronica
– Check gasket -5- on charge air cooler -4-.
• The gasket must not be cracked or damaged.
– Slide gasket -1- onto charge air cooler.
– Insert O-ring -2- into opening in supercharger housing -3-.
– Coat sealing surface -arrow A- and gasket -arrow B- of charge

air cooler -1- with engine oil.
– Also coat sealing surface inside supercharger housing with
engine oil.
– When fitting charge air cooler, make sure that seals align with
recesses in supercharger housing -arrows-.

Note
To make it easier to insert and press in the charge air cooler,

position the supercharger housing vertically in engine and gear‐
box support - VAS 6095- .
Caution
Risk of damage to charge air cooler.

♦ Only insert charge air cooler by hand.
– Insert charge air cooler in supercharger housing -arrow A- by

hand as far as stop, letting charge air cooler slide into hole
-arrow B- in front of supercharger housing.
– If necessary, guide charge air cooler by hand via openings

-arrows- in supercharger housing when inserting cooler.
– As soon as possible (due to length of bolts), screw in 2 bolts
© satelettronica
loosely by hand to guide charge air cooler additionally.
Caution

♦ The charge air cooler must not be pulled in by screwing in
the securing bolts.
♦ Insert charge air cooler by hand (without using tools) until
sealing flange with gasket makes contact with super‐
charger housing (maximum: 1 mm distance). Only then
tighten bolts, as described in the following.
– Tighten bolts -1, 2- for charge air cooler (left-side) and bolts
-3, 4- for charge air cooler (right-side) in diagonal sequence
and in small steps.
note the following:
– Install coolant pipes on supercharger ⇒ page 234 .
– Install throttle valve module - J338- ⇒ page 303 .
– Check supercharger for leaks ⇒ page 263 .
Tightening torques

sure sender -G31- / -G447-
Removing


– Remove bolts -arrows- and detach cover -2-.

– Unscrew bolts -arrows- and remove charge pressure sender.
Installing
© satelettronica
Note
♦ Renew self-locking bolts and O-ring.

holes for charge pressure senders in supercharger housing
using a thread tap.
Tightening torques


1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”, page
277


- V101-
❑ Fitting location ⇒ Fig.
““Fitting location of sec‐
ondary air pump motor -
V101- ”“ , page 287
G31- / intake manifold temper‐
© satelettronica
ature sender - G72-
““Fitting location of
charge pressure sender
-G31- / intake manifold
temperature sender -
G72- ”“ , page 284
3 - Ignition coils, cylinder bank
1
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
stalling ignition coils
with output stages”,
page 363
heater - Z19-
Lambda probes on
❑ Fitting location of connector ⇒ Fig. ““Electrical connectors at rear right of engine”“ , page 281
❑ Removing and installing ⇒ “8.2.1 Removing and installing Lambda probe G39 / Lambda probe after
catalytic converter G130 ”, page 319
❑ Fitting location ⇒ Fig. ““Fitting location of Hall sender and camshaft control valve on cylinder bank 1 (right-
❑ Assignment of connectors ⇒ Fig. ““Electrical connectors at rear left of engine”“ , page 282


❑ With Lambda probe 1 heater after catalytic converter - Z29-
❑ Removing and installing ⇒ “8.2.1 Removing and installing Lambda probe G39 / Lambda probe after
❑ Fitting location ⇒ Fig. ““Fitting location of throttle valve module -J338- ”“ , page 283
❑ Fitting location ⇒ Fig. ““Fitting location of intake air temperature sender -G42- / intake manifold pressure
sender -G71- ”“ , page 284
❑ Removing and installing ⇒ “6.1 Removing and installing intake air temperature sender G42 / intake man‐
ifold pressure sender G71 ”, page 311
❑ USA version only
❑ Fitting location ⇒ Fig. ““Fitting location of sender 1 for secondary air pressure -G609- ”“ , page 287
© satelettronica
❑ Fitting location ⇒ Fig. ““Fitting locations below intake manifold (bottom section) on cylinder bank 1 (right-
❑ Removing and installing ⇒ “5.1 Removing and installing injectors”, page 306
❑ Fitting location ⇒ Fig. ““Fitting location of temperature sender for engine temperature regulation -G694-
”“ , page 283
❑ Fitting location ⇒ Fig. ““Fitting location of intake manifold flap potentiometer -G336- ”“ , page 284
❑ Fitting location ⇒ Fig. ““Fitting location of Hall sender and camshaft control valve on cylinder bank 1 (right-

1 - Intake manifold flap poten‐

tiometer 2 - G512-
““Fitting location of in‐
take manifold flap po‐
tentiometer -G336- ”“ ,
page 284
sender - G62-
coolant temperature
sender -G62- ”“ , page
285
G247-
““Fitting locations below
intake manifold (bottom
section) on cylinder
bank 2 (left-side)”“ ,
page 283
© satelettronica
❑ Lubricate threads
❑ 22 Nm
““Fitting locations below
section) on cylinder
bank 2 (left-side)”“ ,
page 283
❑ Fitting location of con‐
nector ⇒ Fig. ““Electrical
connectors at rear left of
engine”“ , page 282
❑ Fitting location ⇒ Fig. ““Fitting location of regulating flap control unit -J808- ”“ , page 284
❑ Fitting location ⇒ Fig. ““Fitting location of secondary air inlet valves and intake manifold flap valve -N316-
”“ , page 286
”“ , page 286
9 - Secondary air inlet valve 2 - N320-
”“ , page 286
❑ Assignment of connectors ⇒ Fig. ““Electrical connectors at rear left of engine”“ , page 282
11 - Lambda probe 2 after catalytic converter - G131-

❑ With Lambda probe 2 heater after catalytic converter - Z30-

❑ Fitting location of connector ⇒ Fig. ““Electrical connectors at rear left of engine”“ , page 282
❑ Removing and installing ⇒ “8.2.2 Removing and installing Lambda probe 2 G108 / Lambda probe 2 after
12 - Engine fault warning lamp
❑ In instrument cluster
13 - Accelerator position sender - G79- / accelerator position sender 2 - G185-
❑ In accelerator pedal module; fitting location ⇒ Fig. ““Fitting location of accelerator position sender -G79- /
accelerator position sender 2 -G185- ”“ , page 281
❑ Fitting location ⇒ Fig. ““Fitting location of brake light switch -F- ”“ , page 281
Fitting location ⇒ Fig. ““Fitting location of Hall sender and camshaft control valve on cylinder bank 2 (left-side)”“ ,
page 285
© satelettronica
❑ With Lambda probe heater 2 - Z28-
❑ Fitting location of connector ⇒ Fig. ““Electrical connectors at rear left of engine”“ , page 282
❑ Removing and installing ⇒ “8.2.2 Removing and installing Lambda probe 2 G108 / Lambda probe 2 after
❑ Fitting location ⇒ Fig. ““Fitting location of charge air cooling pump -V188- ”“ , page 286
❑ Equipment version or country-specific version
❑ Fitting location ⇒ Fig. ““Fitting location of continued coolant circulation pump -V51- ”“ , page 286
22 - Intake manifold temperature sender 2 - G430- / charge pressure sender 2 - G447-
❑ Fitting location ⇒ Fig. ““Fitting location of charge pressure sender -G31- / intake manifold temperature
sender -G72- ”“ , page 284
❑ Fitting location ⇒ Fig. ““Fitting location of Hall sender and camshaft control valve on cylinder bank 2 (left-


♦ -Item 1- in plenum chamber (left-side)

Note

© satelettronica

-G185- .
Fitting location of brake light switch - F-

♦ In footwell on brake pedal
Electrical connectors at rear right of engine

1- For injectors on cylinder bank 1
4- For Lambda probe - G39- with Lambda probe heater - Z19-
5- For Lambda probe after catalytic converter - G130- with
Lambda probe 1 heater after catalytic converter - Z29-

Electrical connectors at rear left of engine

1- For Lambda probe 2 after catalytic converter - G131- with
Lambda probe 2 heater after catalytic converter - Z30-
2- For Lambda probe 2 - G108- with Lambda probe heater 2 -
Z28-
3- For injectors on cylinder bank 2 and for fuel pressure sender
- G247-
4- To knock sensor 2 - G66-
Fitting location of Lambda probes on cylinder bank 1 (right-side)

1- Lambda probe - G39- with Lambda probe heater - Z19-
2- Lambda probe after catalytic converter - G130- with Lambda
probe 1 heater after catalytic converter - Z29-
© satelettronica
Fitting location of Lambda probes on cylinder bank 2 (left-side)
1- Lambda probe 2 - G108- with Lambda probe heater 2 - Z28-
2- Lambda probe 2 after catalytic converter - G131- with Lamb‐
da probe 2 heater after catalytic converter - Z30-
Fitting locations at high-pressure pump

♦ On right side of cylinder head
1- Fuel pressure sender for low pressure - G410-
2- Fuel metering valve - N290-

Fitting locations below intake manifold (bottom section) on cylin‐

der bank 1 (right-side)
Fitting location of temperature sender for engine temperature

regulation - G694-
♦ -Item 1- below intake manifold (bottom section) on cylinder
bank 1 (right-side)
© satelettronica
Fitting locations below intake manifold (bottom section) on cylin‐
der bank 2 (left-side)
Fitting location of throttle valve module - J338-

♦ At rear of supercharger

Fitting location of regulating flap control unit - J808-

♦ -Item 3- at rear of supercharger
Fitting location of intake manifold flap potentiometer - G336-

♦ -Item 1- at front of intake manifold (right-side)
Note
The fitting location of the intake manifold flap potentiometer 2 -

G512- is symmetrically reversed.
© satelettronica
– Removing and installing ⇒ “2.3 Removing and installing vac‐
uum unit for actuating intake manifold flaps”, page 290
Fitting location of intake air temperature sender - G42- / intake

manifold pressure sender - G71-
♦ At rear of supercharger with charge air cooler
1- Electrical connector for intake air temperature sender -
G42- / intake manifold pressure sender - G71-
Fitting location of charge pressure sender - G31- / intake manifold

♦ At right side of supercharger with charge air cooler
1- Electrical connector for charge pressure sender - G31- / in‐
take manifold temperature sender - G72-
Note
Intake manifold temperature sender 2 - G430- / charge pressure

sender 2 - G447- are located symmetrically reversed.

Fitting location of Hall sender and camshaft control valve on cylin‐

der bank 1 (right-side)
2- Hall sender - G40-
Fitting location of Hall sender and camshaft control valve on cylin‐

der bank 2 (left-side)
1- Hall sender 2 - G163-
© satelettronica
Fitting location of valve for oil pressure control - N428-
♦ -Item 4- at bottom left of engine
Fitting location of coolant temperature sender - G62-

♦ At front of engine
1- Electrical connector for coolant temperature sender - G62-

Fitting location of charge air cooling pump - V188-

♦ In wheel housing (front left)
2 - Electrical connector for charge air cooling pump - V188-
Fitting location of continued coolant circulation pump - V51-

♦ At front left of engine
2 - Electrical connector for continued coolant circulation pump -
V51-
© satelettronica
♦ At bottom of timing chain cover (bottom)
2 - Electrical connector for engine speed sender - G28-
Fitting location of secondary air inlet valves and intake manifold

flap valve - N316-
♦ At rear of supercharger with charge air cooler
1- Secondary air inlet valve - N112-
2- Intake manifold flap valve - N316-
3- Secondary air inlet valve 2 - N320-


♦ In wheel housing (front right)
4 - Electrical connector for secondary air pump motor - V101-
Fitting location of sender 1 for secondary air pressure - G609-

1- Electrical connector for sender 1 for secondary air pressure
- G609-
© satelettronica
renewed.

2 Vacuum system
⇒ “2.3 Removing and installing vacuum unit for actuating intake
manifold flaps”, page 290
Note
♦ Observe rules for cleanliness ⇒ “3.1 Rules for cleanliness”,

page 5 .
♦ 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.
Caution
© satelettronica
Note
♦ Red = Vacuum supply line

♦ Blue = Control pipe to vacuum unit for actuating intake mani‐
fold flaps
♦ Orange = Control pipe to combination valve for secondary air
system (left-side)
♦ Brown = Control pipe to combination valve for secondary air
system (right-side)
♦ Green = Control pipe to switchable coolant pump

1 - Secondary air inlet valve -

N112-
2 - Intake manifold flap valve -
N316-
3 - Secondary air inlet valve 2
- N320-
Note
Not fitted on some USA vehicles
4 - To brake servo
5 - Connecting piece with seal‐
ing cap
ing combination valve”,
page 347
© satelettronica
8 - Vacuum pump
9 - Coolant valve for cylinder
head - N489-
10 - Vacuum unit
❑ For intake manifold flap
side)
installing vacuum unit
for actuating intake
manifold flaps, cylinder
bank 2 (left-side)”,
page 292
11 - Coolant pump
13 - Vacuum unit
❑ For intake manifold flap on cylinder bank 1 (right-side)
❑ Removing and installing ⇒ “2.3.1 Removing and installing vacuum unit for actuating intake manifold flaps,
cylinder bank 1 (right-side)”, page 290
14 - Combination valve for secondary air system (right-side)
❑ Checking ⇒ “3.3 Checking combination valve”, page 347


Procedure
♦ Cracks
© satelettronica
– If an entry is stored in the event memory, check the vacuum
lines leading to the corresponding component and also check
the other vacuum lines leading to other components.
hoses for leaks.
2.3 Removing and installing vacuum unit for

actuating intake manifold flaps
⇒ “2.3.1 Removing and installing vacuum unit for actuating intake
manifold flaps, cylinder bank 1 (right-side)”, page 290
⇒ “2.3.2 Removing and installing vacuum unit for actuating intake
manifold flaps, cylinder bank 2 (left-side)”, page 292
2.3.1 Removing and installing vacuum unit for

actuating intake manifold flaps, cylinder
bank 1 (right-side)
♦ Torx wrench or bit 10 with ball head (commercially available)
♦ Magnetic rod (commercially available)
Removing
– Remove engine cover panels ⇒ page 67 .

– Disconnect secondary air hose -1- at connection point -2- and

move clear at retainer.
– Remove bolts -2, 3- and detach intake manifold flap poten‐

tiometer - G336- .
© satelettronica
– Unclip operating rod -2- of vacuum unit from ball head.
– Disconnect vacuum hose -1- and detach vacuum unit.
Installing
The shaft for the intake manifold flaps on the intake manifold
(bottom section) and the mounting on the intake manifold flap po‐
tentiometer 2 - G512- are rectangular.
• Ensure that mounting on intake manifold flap potentiometer -
G336- is correctly positioned on shaft for intake manifold flaps
on intake manifold (bottom section).
Note
♦ Renew seals.

Tightening torques


2.3.2 Removing and installing vacuum unit for

actuating intake manifold flaps, cylinder
bank 2 (left-side)
© satelettronica
♦ Torx wrench or bit 10 with ball head (commercially available)

♦ Magnetic rod (commercially available)
Removing
noise insulation .
WARNING


25 mm - 3094- .
Note

The coolant hoses remain connected.

Note
Disregard -arrows-.
– Clamp off coolant hoses -1- using hose clamps (up to 25 mm)
- 3094- , release hose clips and disconnect coolant hoses from
coolant pipes at supercharger.
© satelettronica
- G62- .
Note
– Remove bolt -2- and detach bracket -3-.

– Swivel coolant pipe -1- to side.

– Remove bolts -2, 3- and detach intake manifold flap poten‐

tiometer 2 - G512- .
Note
It is recommended to use a magnet at this stage to prevent the

bolt from falling out.
– Unclip operating rod -1- of vacuum unit -2- from ball head.
– Disconnect vacuum hose -3- and detach vacuum unit.
© satelettronica
Installing
The shaft for the intake manifold flaps on the intake manifold
(bottom section) and the mounting on the intake manifold flap po‐
tentiometer 2 - G512- are rectangular.
• Ensure that mounting on intake manifold flap potentiometer 2
- G512- is correctly positioned on shaft for intake manifold
flaps on intake manifold (bottom section).
Note
♦ Renew seals.
– Install engine cover panels ⇒ page 67 .

Tightening torques

3 Air cleaner
⇒ “3.2 Removing and installing air cleaner housing”, page
295
1 - Air duct
2 - Sealing element
3 - Mounting
© satelettronica
ing”, page 295
parts catalogue
Maintenance tables
let 411
6 - Air pipe
screw-type clips ⇒ page
272
7 - Cover
❑ Remove any salt de‐
posits or dirt
let 411
8 - Air duct
9 - Bolt
❑ 1.5 Nm

housing
Removing
ments .
3. Air cleaner 295

Note
Disregard -item 1-.
© satelettronica
-arrow-.
Installing
Note

♦ To prevent malfunctions, cover all critical parts of the engine
air intake tract (intake pipes, etc.) with a clean cloth before

note the following:
ments .
Tightening torques

4 Intake manifold
rail”, page 297
⇒ “4.2 Removing and installing intake manifold (bottom section)
with fuel rail”, page 300
303
⇒ “4.5 Removing and installing regulating flap control unit J808 ”,
page 305
Note
Illustration shows components for cylinder bank 2 (left-side).
© satelettronica
1 - Bolts
❑ 2.5 Nm
tiometer 2 - G512-
side): intake manifold
flap potentiometer -
G336-
stalling vacuum unit for
actuating intake mani‐
fold flaps”, page 290
3 - Seal
❑ When renewing lever
out with screwdriver
4 - Sleeve
G247-
❑ Lubricate threads
❑ 22 Nm
6 - Bracket
7 - Bolt
❑ 9 Nm
pipe”, page 315
❑ To loosen and tighten high-pressure pipe, counterhold at pipe connection

❑ Re-tighten connection for fuel pipe before installing fuel pipe

❑ Lubricate threads of union nuts with fuel
❑ 25 Nm
9 - Bolt
❑ 9 Nm
10 - Nut
❑ Tightening torque and sequence ⇒ Fig. ““Intake manifold (bottom section) - tightening torque”“ , page
299
11 - Bolt
❑ Tightening torque and sequence ⇒ Fig. ““Intake manifold (bottom section) - tightening torque”“ , page
299
12 - Bolt
❑ 2.5 Nm
13 - Retainer
❑ For fuel rail
❑ 40 Nm
© satelettronica
❑ Check tightening torque of threaded connection before fitting union nut
15 - Fuel rail
16 - Seal
❑ Renew
17 - Intake manifold (bottom section)
❑ Removing and installing ⇒ “4.2 Removing and installing intake manifold (bottom section) with fuel rail”,
page 300
18 - Seal
❑ Renew
19 - Support ring
❑ Must be properly seated
❑ Via this support ring, the fuel rail exerts the force which holds the injector in the cylinder head
20 - O-ring
❑ Renew
21 - Spacer ring
22 - Injector
Removing and installing ⇒ “5.1 Removing and installing injectors”, page 306
23 - Sealing washer
❑ Renewing ⇒ “5.1 Removing and installing injectors”, page 306
25 - Seal
26 - Operating rod

❑ For vacuum unit

27 - Vacuum hose
❑ To intake manifold flap valve - N316-
28 - Vacuum unit
❑ For actuating intake manifold flaps
❑ Removing and installing ⇒ “2.3 Removing and installing vacuum unit for actuating intake manifold flaps”,
page 290
Intake air temperature sender - G42- / intake manifold pressure

sender - G71- - tightening torque
© satelettronica
Intake manifold (bottom section) - tightening torque
– Tighten bolts and nuts -arrows- in stages and in diagonal se‐
quence; final torque 9 Nm.
Throttle valve module - J338- - tightening torque

– Tighten bolts -arrows- in diagonal sequence to 10 Nm.

Regulating flap control unit - J808- - tightening torque and se‐

quence
1. -5, 6- Screw in by hand until contact is made
2. -6- 10 Nm
3. -5- 10 Nm

(bottom section) with fuel rail
© satelettronica
♦ Tool inserts - V.A.G 1331/2-
Removing
Note
The removal and installation procedures are described for cylin‐

der bank 2 (left-side).

– Unplug electrical connector from Hall sender 2 - G163- -1-.

– Push vacuum hoses to one side.

G247- .
WARNING

© satelettronica
– Unscrew union nut -1- (counterhold threaded connection).

– Remove bolts and nuts -arrows- and detach intake manifold
(bottom section) with fuel rail.
– Unplug electrical connector -2- at intake manifold flap poten‐
tiometer and pull off vacuum hose -3-.
Caution

♦ Block off the intake ports with clean cloths to prevent small
objects from dropping into the engine through the intake
ports in the cylinder heads.
Installing
Note
♦ If an injector has been pulled out of the cylinder head, the

teflon ring seal must be renewed.
♦ If threaded connection ⇒ Item 14 (page 298) has been loos‐
ened or removed, it must be renewed.

– Before installing intake manifold (bottom section), loosen bolt

-arrow- and move fuel rail -1- back and forth in direction of
-arrows-.
• If fuel rail -1- cannot be moved, remove and clean retainer for
fuel rail -2-.
– Re-assemble retainer for fuel rail -2- and fuel rail -1-, only
tightening bolt -arrow- hand-tight.
© satelettronica
Caution
Risk of damage to intake manifold flaps.

♦ To prevent the intake manifold flaps from catching on the
guide plates in the cylinder head, the flaps must be in the
power mode position -arrows- (intake passage fully open)
when the intake manifold (bottom section) is installed.
– Connect hand vacuum pump - VAS 6213- to vacuum unit for

actuating intake manifold flaps, as shown in illustration.
– Use vacuum pump to generate a vacuum.
• This will cause the intake manifold flaps to open.
to injectors.
– Tighten bolts and nuts for intake manifold (bottom section) in
diagonal sequence ⇒ page 299 .

– Disconnect hand vacuum pump from vacuum unit for actuat‐

ing intake manifold flaps.
© satelettronica
– Plug in electrical connector -4- at fuel pressure sender -
G247- .
– Tighten union nut -1- (counterhold threaded connection).
Tightening torques
♦ ⇒ Fig. ““Intake manifold (bottom section) - tightening torque”“ ,
page 299

module - J338-
Removing
– Move clear fuel line -1- and line -2- going to activated charcoal
filter at air pipe.


J338- with intermediate flange.
Caution

♦ Block off the intake port with a clean cloth to prevent small
items from dropping into the supercharger.
Installing
Note

© satelettronica
– Insert intermediate flange -2- with O-rings into supercharger

-1- -left arrows-.
– Fit throttle valve module - J338- -item 3- on intermediate flange
-right arrows-.
– Tighten bolts -4- for throttle valve module ⇒ page 299 .
If throttle valve module - J338- has been cleaned or renewed:
– Erase learnt values and adapt engine control unit - J623- to
throttle valve module - J338- ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ Fig. ““ Throttle valve module -J338- - tightening torque”“ ,
page 299
tem”, page 272
Note
Take care not to scratch the throttle valve housing when cleaning
it.

♦ Acetone (commercially available)
♦ Brush
Procedure

– Open throttle valve by hand and block it in the open position

with a suitable object (e.g. plastic or wooden wedge) -arrow-.
WARNING
Risk of injury caused by acetone. Acetone is highly flammable

and can cause irritation to the eyes and skin.
– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush.
– Wipe out throttle valve housing with a lint-free cloth.
– Allow acetone to evaporate completely and re-install throttle
valve module after cleaning.
© satelettronica
throttle valve module. Use ⇒ Vehicle diagnostic tester.
4.5 Removing and installing regulating flap

Removing
– Detach bypass elbow -1- with adapter (intermediate flange)
-2- and regulating flap control unit - J808- -4-.
Installing
Note
Fit new O-rings.
If a new regulating flap control unit - J808- has been installed:

regulating flap control unit - J808- . Use ⇒ Vehicle diagnostic
tester.
Tightening torques
♦ ⇒ Fig. ““ Regulating flap control unit -J808- - tightening torque

5 Injectors
⇒ “5.2 Cleaning injectors”, page 309

© satelettronica
Removing
– Remove corresponding intake manifold (bottom section) ⇒
page 300 .
Removing any injectors lodged in fuel rail
– Carefully pull injectors out of fuel rail.
Removing any injectors lodged in cylinder head
– Cover open inlet ports with a clean cloth.
– Unplug electrical connector at injector that is to be removed.
– Slide stop sleeve -T10133/18- over injector.


injector.
– Apply puller -T10133/2A- to groove on injector.
© satelettronica
– Attach removal tool -T10133/16- and pull out injector by turn‐
ing bolt -1-.
Dismantling injector
– Pull support ring -4-, O-ring -3- and spacer ring -2- off injector
-1-.
– Unclip sealing element -5-.
– Carefully remove old combustion chamber ring seal -6-. To do
so, cut open combustion chamber ring seal using knife or prise
open with small screwdriver and then pull off forwards.
Note

5. Injectors 307
Installing
Note
♦ Renew sealing element, combustion chamber ring seal and

O-ring.
♦ Renew spacer ring if damaged.

T10133/4- .
off groove for combustion chamber ring seal and injector stem
with a clean cloth.

© satelettronica
go.
Note


opposite direction.


opposite direction.

2 - Spacer ring - renew
3 - O-ring - renew (apply thin coating of clean engine oil prior to
installation)
4 - Support ring - renew (via this support ring, fuel rail exerts force
which secures injector in cylinder head)
5 - Retaining ring - renew (combined as a unit with intermediate
© satelettronica
ring -2-)
6 - Combustion chamber ring seal (teflon ring seal) - renew; when
fitting, do not grease ring or use any other lubricant
Note

ciently.
• Electrical connector of injector must engage in recess in cylin‐

der head.
Perform further installation in reverse order, paying attention to
the following:
5.2 Cleaning injectors

♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid - VAS 6418/2-
5. Injectors 309
Cleaning
– Remove injectors ⇒ page 306 .
– Fill ultrasonic unit with 2,120 ml of water which has been al‐
lowed to settle for a few minutes and cleaning fluid - VAS
6418/2- .
Mixture ratio for cleaning fluid
• 2,100 ml of tap water which has been allowed to settle for a
few minutes and 20 ml of cleaning fluid - VAS 6418/2-
– Place mounting plate for injection modules - VAS 6418/1- on

top of cleaning unit.
WARNING
© satelettronica
It is important to read the safety notes in the operating instruc‐
tions before switching on the ultrasonic cleaning unit - VAS
6418- .
The ideal fluid level is approx. 1-4 mm above the base of the
mounting plate. The ultrasonic cleaning unit - VAS 6418- can
be damaged if the fluid level is too low.
– Insert FSI injectors all the way into guides of mounting plate
for injection modules - VAS 6418/1- .

– Select a cleaning time of 30 minutes with rotary control -A-.
– Set rotary control -B- to a temperature of 50°C.
– Press ► button -D- to start cleaning procedure.
Note
♦ The temperature-controlled cleaning process is now started.

While the fluid is being heated, the ultrasound is activated at
intervals in order to circulate the cleaning solution. The ultra‐
sound is activated continuously when the preselected tem‐
perature is reached.
♦ The actual cleaning process commences when the tempera‐
ture reaches at least 50 ℃ and must last for at least 30
minutes.
– Install injectors with new combustion chamber seal ⇒ page

306 .


⇒ “6.1 Removing and installing intake air temperature sender
G42 / intake manifold pressure sender G71 ”, page 311

perature sender - G42- / intake manifold
pressure sender - G71-
Removing
– Unscrew bolts -arrows- and detach intake air temperature
Installing
Note
© satelettronica
Fit new O-rings.
Tightening torques
♦ ⇒ Fig. ““ Intake air temperature sender -G42- / intake manifold
pressure sender -G71- - tightening torque”“ , page 299

⇒ “7.2 Removing and installing high-pressure pump”, page
313

❑ 15 Nm
2 - Not fitted
3 - Bolt
sequence ⇒ Fig. ““High-
pressure pump - tight‐
© satelettronica
- N290-
pump”, page 313
❑ Connections must not
be damaged
❑ Always renew after re‐
moving
❑ 27 Nm
❑ Low-pressure section
pipe”, page 315
❑ Lubricate thread of union nut with fuel
❑ 27 Nm
8 - Gasket
❑ Renew
9 - Housing
11 - Bolt
❑ 9 Nm

12 - O-ring
❑ Renew
13 - Guard plate
14 - Nut
❑ 9 Nm
15 - Threaded pin
❑ 9 Nm
16 - Roller tappet
17 - O-ring
❑ Renew
© satelettronica
2. -arrows- Tighten in stages; final torque 20 Nm

pump

♦ Socket insert AF 14, flared ring spanner - V.A.G 1331/8-
Removing
Note

© satelettronica
♦ Always ensure that the high-pressure fuel pipes are free of
tension when tightening the connections.


WARNING

– Unscrew connections -2- and -5-.



Note
♦ Do not attempt to bend high-pressure pipe to a different shape.

Installing
Note
♦ Fit new O-ring.

aged.
© satelettronica
– Rotate crankshaft in direction of engine rotation by turning bolt
for vibration damper, and at the same time press roller tappet
into cylinder head until it reaches its lowest point.
onto stop.
– At the same time, tighten securing bolts by hand.
– Then tighten securing bolts alternately to 5 Nm (do not tilt high-
pressure pump).
– Now tighten securing bolts alternately to final torque.
Tightening torques
♦ ⇒ Fig. ““High-pressure pump - tightening torque and se‐

pipe

© satelettronica
Removing
– Remove bolts -arrows- and move intake manifold flap poten‐
tiometer - G336- (right-side) -item 1- with vacuum unit for
intake manifold flap clear to one side.
WARNING


– Unscrew bolts -arrows- and connection -1-.

– Unscrew union nuts -2- and -3- (counterhold threaded con‐
nection).
Note

♦ The threaded connection on the fuel rail must be renewed if it
has been loosened or removed at union nuts -2- and -3- ⇒ Item
14 (page 298) .
Installing
Note

aged.
© satelettronica
– First tighten union nut by hand until it makes contact, making
sure that high-pressure pipe is not under tension.
– Tighten union nut with torque wrench - V.A.G 1331- and open
end spanner insert AF 17 - V.A.G 1331/6- ; to do so, counter‐
hold at hexagon flats of threaded connection on fuel rail with
an open-end spanner.
– Do not tighten bolt for retainer until high-pressure pipe has
been tightened.
Tightening torques

8 Lambda probe
Note

♦ In the case of a used Lambda probe, coat only the thread with high-temperature paste; refer to ⇒ Electronic
parts catalogue for high-temperature paste.
♦ The assembly paste/high-temperature paste must not make contact with the slots on the Lambda probe
body.
1 - Lambda probe 2 after cat‐

alytic converter - G131-
© satelettronica
converter - Z30-
⇒ page 320
❑ 55 Nm
heater 2 - Z28-
⇒ page 320
❑ 55 Nm
heater - Z19-
⇒ page 319
❑ 55 Nm
converter - Z29-
⇒ page 319
❑ 55 Nm

⇒ “8.2.1 Removing and installing Lambda probe G39 / Lambda
probe after catalytic converter G130 ”, page 319

⇒ “8.2.2 Removing and installing Lambda probe 2 G108 / Lamb‐

da probe 2 after catalytic converter G131 ”, page 320

- G39- / Lambda probe after catalytic
converter - G130-
© satelettronica
Removing
clear at air pipe.

nition coils.
– Press electrical wiring harness up slightly.
Note
– Unplug relevant electrical connector and move electrical

wiring clear:
2- For Lambda probe - G39-
8. Lambda probe 319

– Unscrew relevant Lambda probes:

1- Lambda probe - G39- using ring spanner -3337/7-
2- Lambda probe after catalytic converter - G130- using ring
spanner -3337/2-
Note

the engine removed.
Installing
Note

♦ If re-installing the old Lambda probes, coat the threads with
high-temperature paste ⇒ Electronic parts catalogue .
© satelettronica
♦ The assembly paste/high-temperature paste must not get into
the slots on the Lambda probe body.
Tightening torques
tem”, page 272
8.2.2 Removing and installing Lambda

probe 2 - G108- / Lambda probe 2 after
catalytic converter - G131-

Removing
-arrows- attached.
– Unplug relevant electrical connector and move electrical

wiring clear:
© satelettronica
– Unscrew relevant Lambda probe using ring spanner -3337/7- :

Note

the engine removed.
Installing
Note

8. Lambda probe 321

Tightening torques
© satelettronica


page 324

© satelettronica
♦ Test box - V.A.G 1598/42-
Note
♦ The test box - V.A.G 1598/42- has 105 sockets. It can be con‐
nected to the engine control unit via 2 different adapter cables.
♦ The engine control unit is connected to the vehicle's wiring
harness via two connectors, one of which has 60 pins, the
other has 94 pins.
-A- on the test box. For components connected to 60-pin wiring
nectors -A- and -B- on the test box. For components connect‐
ed to 94-pin wiring harness connector ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.


and to the engine control unit itself at the same time. The ad‐
vantage of this is that the electronic engine control system
remains fully functional when the test box is connected (for
example, for measuring signals when the engine is running).
♦ Always use auxiliary measuring set - V.A.G 1527B- to connect
test equipment (e.g. voltage tester - V.A.G 1526E- , hand-held
multimeter - V.A.G 1594C- etc.).
The engine control unit has to be removed before connectors can

be unplugged from engine control unit ⇒ page 324 .
Caution

♦ Select the appropriate measuring range before connect‐
ing the test leads and observe test requirements.
© satelettronica
– Connect test box - V.A.G 1598/42- to wiring harness connec‐
tor. The earth clip on the test box must be connected to the
negative battery terminal. 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.
Note


Removing
chamber cover .

– Release catch -arrow- and detach engine control unit -

J623- -item 1-.
Note
Disregard -item 2-.
Installing
© satelettronica
chamber cover .
must be performed:
in “Guided Functions” mode, “Replace engine control unit”.

1 - Bolt
❑ 20 Nm
2 - Mounting
❑ Check preload ⇒
© satelettronica
“1.4 Stress-free align‐
tem”, page 331
3 - Centre silencer
be renewed separately
for repair purposes
prior to removal ⇒ Fig.
““Diagonal struts (Audi
A7)”“ , page 329
❑ Cutting point ⇒
“1.2 Separating exhaust
pipes/silencers”, page
329
it is free of stress ⇒
“1.4 Stress-free align‐
tem”, page 331
4 - Rear silencer
with centre silencer as
original equipment
❑ Centre silencer and rear
silencer can be renewed
separately
prior to removal ⇒ Fig. ““Diagonal struts (Audi A7)”“ , page 329
❑ Cutting point between centre silencer and rear silencer ⇒ “1.2 Separating exhaust pipes/silencers”, page
329
❑ Align exhaust system so it is free of stress ⇒ “1.4 Stress-free alignment of exhaust system”, page
331
5 - Gasket
❑ Renew

6 - Nut
❑ 23 Nm
❑ Renew
❑ Removing and installing:
♦ Vehicles with 7-speed dual clutch gearbox 0B5 (left-side) ⇒ “2.1.1 Removing and installing catalytic con‐
verter (left-side) - vehicles with dual clutch gearbox”, page 334
♦ Vehicles with 7-speed dual clutch gearbox 0B5 (right-side) ⇒ “2.1.2 Removing and installing catalytic con‐
verter (right-side) - vehicles with dual clutch gearbox”, page 337
♦ Vehicles with 8-speed automatic gearbox 0BK ⇒ “2.1.3 Removing catalytic converters - vehicles with auto‐
matic gearbox”, page 340
❑ Mounting components ⇒ Fig. ““Components of mountings for catalytic converter”“ , page 328
8 - Nut
❑ 23 Nm
❑ Renew
9 - Gasket
© satelettronica
❑ Renew
10 - Front silencer
❑ Removing and installing ⇒ “1.3 Removing and installing front silencer”, page 330
❑ Align exhaust system so it is free of stress ⇒ “1.4 Stress-free alignment of exhaust system”, page
331
11 - Clamp (front)
❑ Installation position ⇒ Fig. ““Installation position of front clamps”“ , page 328
❑ Push onto front silencer as far as stop
❑ Before tightening, align exhaust system so it is free of stress ⇒ “1.4 Stress-free alignment of exhaust
system”, page 331
12 - Nut
❑ 23 Nm
13 - Trim
❑ For tailpipe
14 - Mounting
15 - Nut
❑ Renew
❑ 20 Nm
16 - Clamp (rear)
❑ Before tightening, align exhaust system so it is free of stress ⇒ “1.4 Stress-free alignment of exhaust
system”, page 331
17 - Nut
❑ 23 Nm

18 - Bolt
❑ 23 Nm
19 - Mounting

bottom of clamp.
© satelettronica
bottom of clamp.
Components of mountings for catalytic converter

1- Nut, 23 Nm
2- Spacer sleeve
4- Washer
5- Bolt
6- Bolt, 23 Nm
7- Spacer sleeve
8- Buffer
9- Bracket
10 - Bolt, 23 Nm
11 - Bracket
Note



gr. 42 ; Subframe; Exploded view - subframe .
© satelettronica
Procedure
struts -1- and -2-.


© satelettronica
bottom of clamp.
331 .
Tightening torques

Removing
noise insulation .
WARNING
The exhaust system can become extremely hot. This can

cause injuries.
Danger of burns to hands and other parts of the body.
• Allow exhaust system to cool down.

© satelettronica
Caution

• Do not bend flexible joint more than 10°.
• Install flexible joint so that it is not under tension.
front silencer.
Installing
Note
Renew gaskets and self-locking nuts.

331 .
Tightening torques
1.4 Stress-free alignment of exhaust sys‐

tem
Procedure

Vehicles without clamps between centre silencer and rear si‐

lencers
6 ... 10 mm.
Note

© satelettronica
6 ... 10 mm.
– Push rear section of exhaust system towards front of

vehicle -arrow-, so that mountings (rear) for rear silencers are
preloaded by -a- = 11 ... 15 mm.
Aligning tailpipes
Tightening torques



any leaks.
© satelettronica



verter
vehicles with dual clutch gearbox”, page 334
⇒ “2.1.2 Removing and installing catalytic converter (right-side) -
vehicles with dual clutch gearbox”, page 337
⇒ “2.1.3 Removing catalytic converters - vehicles with automatic

verter (left-side) - vehicles with dual
clutch gearbox
© satelettronica
Removing
Note
– Remove Lambda probe 2 after catalytic converter - G131- ⇒

page 320 .
frame cross brace .

Caution

– Remove front silencer (left-side) ⇒ page 330 .

– Remove wheel housing liner (front left) ⇒ General body re‐
steering; Rep. gr. 48 ; Steering column; Removing and in‐
stalling intermediate steering shaft .
gearbox.
© satelettronica
-arrow-.
Note
Disregard -item 1-.


WARNING
Risk of accident.
© satelettronica
Installing
Note

– Install Lambda probe 2 after catalytic converter - G131- ⇒
page 320 .
Tightening torques
♦ Cover on gearbox ⇒ Rep. gr. 34 ; ATF circuit; Exploded view
- ATF circuit


verter (right-side) - vehicles with dual
clutch gearbox
© satelettronica
Removing
Note
– Remove front silencer (right-side) ⇒ page 330 .

frame cross brace .
Caution


pairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded view -
plenum chamber partition panel .
– Remove coolant pipe from right side of gearbox ⇒ page 235 .

– Remove Lambda probe after catalytic converter - G130- ⇒

page 319 .
– Detach electrical connectors -1 ... 4- from bracket.
– Unscrew bolts -arrows- and detach bracket.
© satelettronica
system.


secondary air system and press it to left side with secondary
air hose and vacuum hose -2- connected.
Note
Disregard -item 1-.
nel (top right).
© satelettronica
WARNING
Risk of accident.



Installing
© satelettronica
Note
– Install combination valve for secondary air (right-side) ⇒ page

351 .
– Install Lambda probe after catalytic converter - G130- ⇒ page
319 .
– Install coolant pipe (right-side) on gearbox ⇒ page 235 .
Tightening torques
♦ ⇒ Fig. ““Components of mountings for catalytic converter”“ ,
page 328
2.1.3 Removing catalytic converters - vehi‐


© satelettronica
Removing
Note

frame cross brace .
Caution

– Remove front silencer on relevant side ⇒ page 330 .

Catalytic converter (left-side):
– Remove intermediate steering shaft ⇒ Running gear, axles,


Note
– Remove nuts -arrows- and bolt -1-.
© satelettronica
Catalytic converter (right-side):
Note
Note
Disregard -item 1-.


WARNING
Risk of accident.
© satelettronica
– Detach catalytic converter on relevant side.
Installing
Note

– Install front silencers ⇒ page 330 .
Tightening torques


”, page 346
⇒ “3.3 Checking combination valve”, page 347
⇒ “3.4 Removing and installing combination valve”, page 348
⇒ “3.5 Removing and installing sender 1 for secondary air pres‐


- V101-
right of engine compart‐
member
© satelettronica
page 346
agnostic tester
2 - Bolt
❑ 9 Nm
❑ 3x
4 - Bracket
motor - V101-
5 - Nut
❑ 9 Nm
6 - Hose
❑ From air cleaner
7 - O-rings
❑ Renew
8 - Hose
❑ To combination valves
for secondary air inlet

1 - Hose
pump motor - V101-
2 - Gasket
❑ Renew
3 - Bolts
❑ 9 Nm
4 - Vacuum hose
check for leaks ⇒
“3.3 Checking combina‐
tion valve”, page 347
valve (right-side)”,
page 351
© satelettronica
6 - Bolt
❑ 9 Nm
7 - O-ring
❑ Renew
8 - Sender 1 for secondary air
pressure - G609-
❑ Fitted on some USA ve‐
hicles
stalling sender 1 for sec‐
ondary air pressure
G609 ”, page 353
9 - Bolt
❑ 9 Nm
10 - Combination valve for secondary air system (left-side)
❑ Check operation and check for leaks ⇒ “3.3 Checking combination valve”, page 347
❑ Removing and installing ⇒ “3.4.1 Removing and installing combination valve (left-side)”, page 348
11 - Vacuum hose
12 - Bolts
❑ 9 Nm
13 - Gasket
❑ Renew

Heat shield for combination valve for secondary air system - tight‐
ening torque
– Tighten bolts -arrows- for heat shield -1- to 9 Nm.
Note
The illustration shows the heat shield on the left side of the vehi‐
cle.

pump motor - V101-
Removing
Note
© satelettronica

V101- .
-2-.
Installing
Note
Fit new O-rings.

Tightening torques


(front)
3.3 Checking combination valve

Procedure
© satelettronica
Version with two secondary air inlet valves
– Detach vacuum hose -1- or -2- from combination valve to be
checked.
Version with one secondary air inlet valve

– Follow routing of vacuum hose -1- from secondary air inlet
valve downwards to T-piece -2-.
– Detach vacuum hose -arrow- from T-piece -2- for combination
valve to be checked.


– Release clip -2- and move secondary air hose clear.
bracket towards front.
– Blow lightly into secondary air hose with your mouth (do not
use compressed air).
Note

© satelettronica
not open: left-side ⇒ page 348 , right-side ⇒ page 351 .
Assembling
Note
Fit new O-ring.

valve
page 348
page 351

valve (left-side)
Removing
Note
– Remove front silencer (left-side) ⇒ page 330 .

body brace .


on subframe.
Caution


battery .

converter - G131- .
© satelettronica



trical wiring.
holder -3-.
© satelettronica
-arrow B-.
– Move clear wiring harness and press to one side.

– Remove bolts -3- for secondary air system hose.

– Detach vacuum hose -2- from combination valve for sec‐
ondary air system.
– Unscrew bolts -1- and detach combination valve for secondary
air system.
Installing
Note
Renew gasket.

– Install engine control unit - J623- ⇒ page 324 .
© satelettronica
– Install catalytic converter (left-side) ⇒ page 334 .
ing battery .
Tightening torques
♦ ⇒ Fig. ““Heat shield for combination valve for secondary air
system - tightening torque”“ , page 346
♦ ⇒ Electrical system; Rep. gr. 97 ; Relay carriers, fuse carriers,
electronics boxes; Overview of fitting locations - relay carriers,
fuse carriers, electronics boxes
strut, upper links

valve (right-side)
Removing
Note
– Remove front silencer (right-side) ⇒ page 330 .



-1- on subframe.

converter - G131- .
© satelettronica
release tabs).
Note
Disregard -item 1-.

– Detach vacuum hose -2- from combination valve for sec‐

ondary air system.
Installing
Note
Renew gasket.

– Install catalytic converter (right-side) ⇒ page 337 .
Tightening torques
© satelettronica
♦ ⇒ Fig. ““Heat shield for combination valve for secondary air
system - tightening torque”“ , page 346
3.5 Removing and installing sender 1 for

secondary air pressure - G609-
Removing
– Release catches -2 and 3- and detach sender 1 for secondary
air pressure - G609- .
Installing
Note
Fit new O-ring.

4 Exhaust manifolds
1 - Nut
❑ Renew
parts catalogue
left-side ⇒ page 355 ;
right-side ⇒ page 355
2 - Bracket for heat shield
© satelettronica
❑ Removing and in‐
stalling: left-side ⇒ page
355 , right-side ⇒
page 358
4 - Gasket
❑ Renew
5 - Bolt
❑ 9 Nm
6 - Heat shield
7 - Washer
8 - Bolt
❑ 9 Nm
9 - Lambda probe
❑ Before catalytic convert‐
er
⇒ page 320
10 - Nut
❑ Renew
❑ Coat thread with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts cata‐
logue
❑ 23 Nm
11 - Gasket
❑ Renew

Note
♦ Renew nuts.

2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm
Note
© satelettronica
♦ Renew nuts.

2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm

folds
page 355
page 358

fold (left-side)
Removing
Note

noise insulation .
page 73 .


on subframe.
(left-side).
© satelettronica
Caution

side).
Note
Disregard -item 2-.


Note
Disregard -items 1, 2, 3, 4- and -arrows-.

tudinal member.
© satelettronica


Installing
Note
© satelettronica
♦ Renew gasket and self-locking nuts.

tighten nuts ⇒ page 355 .
– Install catalytic converter (left-side) ⇒ page 334 .
Tightening torques

fold (right-side)
Removing
Note


– Also remove noise insulation (rear) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Removing and in‐
stalling noise insulation .
-1- on subframe.
© satelettronica
(right-side).
Caution

(right-side).

Note
Disregard -item 1-.

coolant pipe.
© satelettronica
Vehicles with auxiliary heater:
– Loosen nut -1- and remove bolt -2-.
coolant pipe.

Note

the engine removed.

Installing
Note
© satelettronica

tighten nuts ⇒ page 355 .
– Install catalytic converter (right-side) ⇒ page 337 .
Note

Tightening torques

1 Ignition system
⇒ “1.2 Test data - spark plugs”, page 363
page 363
367
1 - Bolt
❑ 9 Nm
© satelettronica
page 366
3 - O-ring
❑ Renew
4 - Knock sensor
G61-
G66-
page 365
5 - Bolt
❑ 20 Nm
6 - Spark plug
❑ Change interval ⇒
Maintenance tables
let 411
7 - Ignition coil
stalling ignition coils
with output stages”,
page 363
8 - Bolt
❑ 5 Nm


11 - Bolt
❑ 9 Nm
12 - O-ring
❑ Renew
14 - Bolt
❑ 9 Nm
1.2 Test data - spark plugs

3.0 ltr. TFSI engine
bilisation
© satelettronica
Tightening torque ⇒ Maintenance ; Booklet 411

with output stages
♦ Puller - T40039-


– Move fuel line -1- and line -2- from activated charcoal filter
clear at air cleaner housing and air pipe.

nition coils.
Note
© satelettronica
– Pull ignition coils out of spark plug holes using puller -
T40039- .

-arrows- attached.


nition coils.
Note

– Pull out ignition coils with puller - T40039- -arrow-.
© satelettronica
Installing
– Apply a thin bead of silicone paste all around end of sealing
hose of ignition coil with output stage -arrow-.
Silicone paste ⇒ Electronic parts catalogue (ETKA) .
– Fit all ignition coils loosely into spark plug holes.
onto coils simultaneously.
– Push ignition coils evenly onto spark plugs by hand (do NOT
quence.
Tightening torques

Removing
– Remove corresponding intake manifold (bottom section) ⇒
page 300 .

– Take electrical connector -3- (cylinder bank 1) out of bracket.

– Remove electrical connector -2- for knock sensor 1 - G61-
from bracket and unplug connector.
Note
Disregard -item 1-.
– Take electrical connector -2- (cylinder bank 2) for knock sen‐

sor 2 - G66- out of bracket and unplug connector.
Note
© satelettronica
– Remove bolt -1- for knock sensor 1 - G61- or bolt -2- for knock
sensor 2 - G66- and detach knock sensor.
Installing
– Re-install whichever knock sensor was removed.
Note
The tightening torque influences the function of the knock sensor.
– Install intake manifold bottom section (left and right) ⇒ page

300 .
Tightening torques

Removing


Installing
– Renew O-ring and lubricate with clean engine oil.
– Carefully press in Hall sender by hand.
– Secure Hall sender and plug back connector.
– The remaining installation steps are carried out in the reverse
sequence.
Tightening torques

sender - G28-
Removing
© satelettronica
noise insulation .

side.
Note
Disregard -item 1-.


Installing
– Install coolant pipe (right-side) on gearbox ⇒ page 235 .
Tightening torques
© satelettronica

Service
Workshop Manual
Audi A6 2011 ➤
6-cylinder TDI engine (3.0 ltr. 4-valve common rail -
generation II)
CLAB CLAA CDU
Engine ID
CGQ CKV CKV CDU CPN CTC
C B B C D B B
© satelettronica
CTC CVU CVU
C A B
Edition 09.2018

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
© satelettronica

Copyright © 2018 Audi AG, Ingolstadt D3E802E927D

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Adapting learnt values for SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
© satelettronica

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Removing and installing torque reaction support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Contents i
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

© satelettronica
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2.2 Exploded view - drive chain for oil pump and high-pressure pump . . . . . . . . . . . . . . . . . . 231
2.5 Removing and installing drive chain for oil pump and high-pressure pump . . . . . . . . . . . . 250
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
5.1 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
2.1 Exploded view - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
ii Contents

2.3 Removing and installing mounting plate for engine oil cooler/coolant shut-off valve . . . . . . 333
2.4 Removing and installing temperature regulator for engine oil cooler . . . . . . . . . . . . . . . . . . 333
3.1 Exploded view - oil filter housing/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3.2 Removing and installing oil pressure switch F22 / F378 . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3.6 Removing and installing oil temperature sender 2 G664 . . . . . . . . . . . . . . . . . . . . . . . . . . 340
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2.1 Exploded view - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
2.2 Exploded view - coolant valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
© satelettronica
2.5 Removing and installing map-controlled engine cooling system thermostat F265 . . . . . . 371
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
1 Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
1.1 Exploded view - turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
1.3 Removing and installing turbocharger 1 control unit J724 . . . . . . . . . . . . . . . . . . . . . . . . 434
1.4 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
1.5 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
2.4 Removing and installing charge pressure sender G31 / intake air temperature sender G42
........................................................................ 472

Contents iii

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
4.3 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 518
5.4 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
© satelettronica
5.5 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 527
5.7 Checking restrictor in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
6.1 Removing and installing control unit for structure-borne sound J869 and actuator for
structure-borne sound R214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
6.2 Removing and installing engine sound generator control unit J943 . . . . . . . . . . . . . . . . . . 547
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
8.3 Removing and installing NOx sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584

1.4 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
iv Contents

2.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
3 SCR (selective catalytic reduction) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
3.1 Exploded view - reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
3.2 Exploded view - reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
3.3 Exploded view - delivery unit for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
3.4 Exploded view - control unit for reducing agent metering system J880 . . . . . . . . . . . . . . 624
3.5 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
3.6 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
3.7 Removing and installing delivery unit for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . 628
3.8 Removing and installing injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 630
3.9 Removing and installing control unit for reducing agent metering system J880 . . . . . . . . 633
4.2 Removing and installing exhaust gas temperature sender . . . . . . . . . . . . . . . . . . . . . . . . 641
5.3 Removing and installing exhaust gas recirculation control motor V338 . . . . . . . . . . . . . . 662
© satelettronica
5.4 Removing and installing exhaust gas recirculation temperature sensor G98 . . . . . . . . . . 663
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
Contents v
© satelettronica
vi Contents
1 Identification
(ARL005994; Edition 09.2018)

Engine number
♦ The engine number (engine code and serial number) is loca‐
ted on the top of the cylinder block at the front -arrow-.
♦ There is also a sticker on the intake manifold showing the en‐
gine code and serial number.
© satelettronica
number.
Note

Engine data
Code letters CDUC CDUD CGQB CKVB

Capacity ltr. 2.967 2.967 2.967 2.967
Power output kW at rpm 180/4000 … 4400 180/4000 … 230/3900 … 4500 180/4000 …
4500 4400
Torque Nm at rpm 500/2100 580/1750 … 650/1450 … 2800 500/2100
2500
Bore ∅ mm 83.0 83.0 83.0 83.0
Stroke mm 91.4 91.4 91.4 91.4
Compression ra‐ 16.8 16.8 16.5 16.8
tio
Fuel According to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5
Exhaust gas recirculation yes yes yes yes
Turbocharging/supercharging Turbocharger (1x) Turbocharger Turbocharger (2x) Turbocharger
(1x) (1x)
Charge air cooling yes yes yes yes
Lambda control 1 Lambda probe 1 Lambda probe 1 Lambda probe 1 Lambda probe
Particulate filter yes yes yes yes
SCR system no no no yes
Valves per cylinder 4 4 4 4
1. Identification 1
Code letters CKVC CLAA CLAB CPNB

Capacity ltr. 2.967 2.967 2.967 2.967
Power output kW at rpm 180/4000 … 150/4000 … 150/4000 … 176/4000 …
4400 4250 4250 4500
Torque Nm at rpm 500/2100 450/1650 … 400/1650 … 580/1700 …
3200 3200 2750
Bore ∅ mm 83.0 83.0 83.0 83.0
Stroke mm 91.4 91.4 91.4 91.4
Compression 16.8 16.8 16.8 16.8
ratio
Firing order 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5
Turbocharging/supercharging Turbocharger Turbocharger Turbocharger Turbocharger
(1x) (1x) (1x) (1x)
© satelettronica
SCR system yes no no yes
Code letters CTCB CTCC CVUA CVUB

Capacity ltr. 2.967 2.967 2.967 2.967
Power output kW at rpm 155/4000 160/4000 235/4250 240/4250
Torque Nm at rpm 400/1250 … 400/1250 … 650/1450 … 650/1450 …
3500 3500 2800 2800
Bore ∅ mm 83.0 83.0 83.0 83.0
Stroke mm 91.4 91.4 91.4 91.4
Compression 16.8 16.8 16.8 16.8
ratio
CN at least 51 51 51 51
Firing order 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5
Turbocharging/supercharging Turbocharger Turbocharger Turbocharger Turbocharger
(1x) (1x) (2x) (2x)
SCR system yes yes yes yes

⇒ “2.1 Safety precautions when working on the fuel system”, page
3
page 5
page 6
⇒ “2.6 Safety precautions when working on the SCR system”,
page 6
page 7

fuel system
© satelettronica
When working on the fuel system note the following warnings:
WARNING
Fuel under pressure - risk of injuries!

♦ Put a clean cloth around the connection before opening
the fuel system. Then carefully loosen the connection to
relieve the pressure.
The fuel can become extremely hot. This can cause injuries.
♦ After switching off the engine, the temperature of fuel
pipes and the fuel itself can be up to 100 °C in extreme
cases. Let fuel cool off before opening any connections;
otherwise there is a danger of scalding!
Health risk: avoid skin contact with fuel.
♦ Avoid skin contact with fuel. Wear fuel-resistant gloves.
Danger due to escaping fuel.
♦ The power supply for the fuel system pressurisation pump
- G6- must be disconnected before opening the fuel sys‐
tem, since -G6- will be activated briefly when the driver's
door is opened with the battery still connected.
♦ Disconnect power supply by removing fuse for fuel pump
control unit - J538- /fuel delivery unit ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations, or
disconnect battery.
Caution

started for the first time ⇒ page 504 .
Observe the following points to prevent personal injuries and

damage to the injection and glow plug system:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as
injectors and gas-discharge headlights.
necting tester cables or electrical wiring for the injection or
glow plug system.
© satelettronica
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
♦ When installing, note colour coding of plug-in connectors.
♦ Plug-in connectors should engage audibly when connecting.
♦ Pull plug-in connectors to check that they are correctly engag‐
ed.
♦ Erase any entries in event memory resulting from testing or
installation ⇒ Vehicle diagnostic tester, Vehicle self-di-
agnosis , then Interrogate event memory .
Caution
When disconnecting the battery there is a risk of irreparable

damage to electronic components.


Please note the following when working on vehicles with start/stop
system:
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (indicated by
a message in the instrument cluster), the engine may start
automatically if it needs to.
♦ 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).

© satelettronica
road test
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.

subframe
Please note the following warnings when working on the sub‐
frame:
Caution


cooling system
When working on the cooling system note the following:
WARNING

hot.
radiator cowl.
Caution
© satelettronica
♦ Close filler cap on coolant expansion tank (make sure it
engages).

SCR system
When working on the SCR 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 SCR system,

note the following:
♦ When working on the SCR system, the reducing agent tank
must be empty. Refer to the corresponding work description
to find out when the reducing agent must be drained from the
tank. Drain tank if necessary; procedure ⇒ page 625 .
When removing and installing tank, note the following:
♦ The reducing agent tank must be empty. Drain tank if neces‐
sary; procedure ⇒ page 625 .

Automatic drawing back of reducing agent

• After the ignition is switched off, the reducing agent is auto‐
matically drawn back into the tank from the metering line
leading to the injector for reducing agent - N474- .
• Before performing work in this area, you must therefore wait
until the reducing agent has been drawn back; this can take
up to 10 minutes after the ignition has been switched off.
• It is also important to wait until the reducing agent has been
drawn back (i.e. 10 minutes after the ignition is switched off)
before disconnecting the battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
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 7 .
© satelettronica
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.
⇒ “3.2 General notes”, page 8
⇒ “3.3 General repair instructions”, page 9
⇒ “3.4 Adapting learnt values for SCR system”, page 10
11

© satelettronica
loosening.
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.2 General notes

Fuel supply/injection
♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash fuel shut-off system. This
system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel

pump is activated for 2 seconds in order to build up pressure

in the fuel system ⇒ page 3 .
Glow plug system
♦ The glow plug system is activated via the automatic glow pe‐
riod control unit - J179- . The control unit is self-diagnosis
compatible.
♦ Fitting location of automatic glow period control unit - J179-
⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
♦ A fault is stored in the engine control unit - J623- if a fault oc‐
curs in the glow plug system.
♦ The procedure for checking the glow plug system is described
in the “Guided Fault Finding”.
♦ For faster starting, the vehicle is equipped with electronically
controlled glow plugs and a separate glow period control unit.
♦ Each glow plug is activated and diagnosed separately.
Note
© satelettronica
♦ Wait for 60 seconds each time after performing final control
diagnosis of the glow period control unit. The ignition must re‐
main switched on.
♦ If you do not wait for 60 seconds (if ignition is switched off and
immediately switched on again), the glow plugs can be dam‐
aged (due to repeated pre-heating).
♦ The activation of the glow plugs is controlled according to
coolant temperature.
3.3 General repair instructions
Caution

started for the first time ⇒ page 504 .
♦ Clean tools and workbench etc. before working on the injection

system.
♦ Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
♦ If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
♦ Take care not to damage the injectors when removing the old
copper seals.
♦ Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
♦ Position high-pressure pipes so they are free of stress. Tighten

all unions lightly to start with before tightening to final torque.
♦ Never attempt to bend high-pressure fuel lines to shape.
♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely and sealed properly by
pulling them by hand from above.
♦ Do not dismantle individual common rail components. If there
is a fault, the complete components must be renewed.
♦ When the engine is running, do not perform any repairs to the
common rail system.
♦ Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
♦ All cable ties which are released or cut open when removing
© satelettronica
must be refitted in the same position when installing.
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.
3.4 Adapting learnt values for SCR system

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.
♦ Tank
♦ Pump for reducing agent
♦ Injector for reducing agent
♦ Reducing agent line
♦ Engine control unit
– Perform adaption ⇒ Vehicle diagnostic tester Guided Func-
tions .

to prevent further damage occurring later.
Note

⇒ page 420


fitted.
Please note:
ranty.

and wiring
© satelettronica

Even when the radiator, condenser and charge air cooler are cor‐
rectly installed, slight impressions may be visible on the fins of
these components. This does not mean that the components are
damaged. If the fins are only very slightly distorted, this does not
justify renewal of the radiator, charge air cooler or condenser.

page 144
1.1 Removing engine

⇒ “1.1.1 Removing engine - vehicles with manual gearbox”, page
12
⇒ “1.1.2 Removing engine - vehicles with multitronic gearbox”,
page 27
⇒ “1.1.3 Removing engine - vehicles with dual clutch gearbox
0B5”, page 42
© satelettronica
⇒ “1.1.4 Removing engine - vehicles with dual clutch gearbox
0CK”, page 56
⇒ “1.1.5 Removing engine - vehicles with 8-speed automatic
gearbox 0BK”, page 71
⇒ “1.1.6 Removing engine - vehicles with biturbo engine”,
page 85
1.1.1 Removing engine - vehicles with manual gearbox


equipment required
© satelettronica
♦ Removal lever - 80-200-
♦ Stepladder (commercially available) or -VAS 5085-
set for Audi - VAS 6131/10- and supplementary set -
VAS 6131/11- , -VAS 6131/13-

♦ Puller - T40160-
© satelettronica
Procedure
Note

WARNING

system ⇒ page 7 .
WARNING
moved.
must be empty.
cause injury.

Caution


battery .
R134a .
ments .
© satelettronica
WARNING

hot.

noise insulation .

gine.
tor.
– Release hose clip -arrow-, disconnect coolant hose from cool‐

ant pipe (bottom left) and drain off coolant.
chamber cover .
© satelettronica
Note
Disregard -item 1-.

– Unplug electrical connector -2- at air mass meter - G70- and

move clear.
© satelettronica
Caution

– Release hose clips and detach fuel hoses:

1- Fuel hose (blue)
2- Fuel hose (yellow)
3- Fuel hose (white)


– Release hose clip -arrow- and disconnect coolant hose from

coolant pipe (front).
Note
© satelettronica
– Remove bolts -1- and move refrigerant lines clear.
Caution

– Remove bolt -2-, disconnect refrigerant line from air condi‐

tioner compressor and move to one side.
Note


G31- / intake air temperature sender - G42- and move clear
electrical wiring.
Note
Disregard -item 1-.

body brace .
© satelettronica
– Remove bolts -arrows- and detach terminal 30 wiring junction
2 - TV22- from plenum chamber partition panel.



earth cables clear.
© satelettronica


trical wiring.
holder -3-.

-arrow B-.
© satelettronica
– Unplug electrical connector -1- and, if fitted, -2- for radiator fan
(push retainer to the rear -arrow- and press down release
catch).
– Release hose clip -arrow- and detach air hose from air pipe.

– Unplug electrical connector -arrow- at front wheel speed sen‐

sor on both sides ( -G45- and -G47- ).

Caution
© satelettronica

housing -arrows-.

Note

cross brace .
Caution



-1-.

catch).
- J500- .
© satelettronica
– Remove bolt -2- and tie up clutch slave cylinder at side of en‐
gine compartment.
Caution
Risk of damage to clutch slave cylinder.

♦ Do not press clutch pedal after removing slave cylinder.
– Remove nut -1- for selector rod.
– Apply puller -T40160- and pull off selector rod -1-.
Note
If separating the engine from the gearbox for subsequent work,

unscrew the bolted connection securing the drive plate to the fly‐
wheel/torque converter ⇒ page 106 .


VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /11-2
G6 /10-1 /10-2 /10-5 /11-2
A8+C8 /13-6 /13-2
F8+H8 /13-5 /13-2
B14 /10-1 /10-3 /10-5 /11-1
G14 /10-1 /10-4 /10-5 /11-1
F17 /10-1 /10-4 /10-5 /13-2
assembly platform.
© satelettronica
zontally.
WARNING



– Position support elements from -VAS 6131/10- and -

VAS 6131/11- (rear left and right) at front attachment points of
© satelettronica
subframe cross brace as shown.


shown.


6131/13- underneath front exhaust pipe, as shown in illustra‐
tion.

rear.
Caution
Risk of damage to flexible joint in front exhaust pipe.

♦ Do NOT bend flexible joint in front exhaust pipe more than
10°.
© satelettronica
Note
Disregard -item 1-.

Caution

♦ Carefully guide suspension struts past longitudinal mem‐
bers.

© satelettronica
– Remove bolts -1- and -3- for selector rod and push rod.
Note
Disregard -item 2-.

1.1.2 Removing engine - vehicles with multitronic gearbox


equipment required
© satelettronica
VAS 6131/11- , -VAS 6131/13-

Procedure
Note

© satelettronica
WARNING

system ⇒ page 7 .
WARNING
moved.
must be empty.
cause injury.
Caution


battery .


R134a .
ments .
WARNING

hot.
© satelettronica

noise insulation .
gine.
tor.


– Lift retaining clip -arrow-, disconnect coolant hose (rear right)

chamber cover .
© satelettronica
Note
Disregard -item 1-.


move clear.
© satelettronica
Caution


1- Fuel hose (blue)



Note
© satelettronica
Caution


Note


electrical wiring.
Note
Disregard -item 1-.

body brace .
© satelettronica



earth cables clear.
© satelettronica


trical wiring.
holder -3-.

-arrow B-.
© satelettronica
catch).



Caution
© satelettronica

housing -arrows-.

Note

cross brace .
Caution



-1-.
– Move clear selector lever cable.
Note
© satelettronica
♦ Disregard -arrow-.


catch).
- J500- .
Note



VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /11-2
G6 /10-1 /10-2 /10-5 /11-2
A8+C8 /13-6 /13-2
F8+H8 /13-5 /13-2
B14 /10-1 /10-3 /10-5 /11-1
G14 /10-1 /10-4 /10-5 /11-1
F17 /10-1 /10-4 /10-5 /13-2
assembly platform.
© satelettronica
zontally.
WARNING




© satelettronica


shown.


tion.
Caution

10°.
© satelettronica
rear.

Note
Disregard -item 1-.

Caution

bers.

1.1.3 Removing engine - vehicles with dual clutch gearbox 0B5
© satelettronica
equipment required


VAS 6131/11- , -VAS 6131/13-
© satelettronica
Procedure
Note

WARNING

system ⇒ page 7 .
WARNING
moved.
must be empty.
cause injury.

Note

ing removal.
Caution


battery .
© satelettronica
R134a .
ments .
WARNING

hot.

noise insulation .

gine.
tor.

© satelettronica
chamber cover .

Note
Disregard -item 1-.
© satelettronica
move clear.
Caution


1- Fuel hose (blue)



© satelettronica
– Remove bolts -2- and detach throttle valve module - J338- .


Caution


Note

electrical wiring.
© satelettronica
Note
Disregard -item 1-.

body brace .




earth cables clear.
© satelettronica



trical wiring.
holder -3-.
© satelettronica
-arrow B-.
catch).


© satelettronica
Caution


housing -arrows-.


Note

cross brace .
Caution

© satelettronica
-1-.

catch).
- J500- .
Vehicles with SCR system:

– Release retaining clip -3-, move clear injector for reducing
agent - N474- with electrical wire and tie up to underbody.
Note



VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /11-2
G6 /10-1 /10-2 /10-5 /11-2
A8+C8 /13-6 /13-2
F8+H8 /13-5 /13-2
B14 /10-1 /10-3 /10-5 /11-1
G14 /10-1 /10-4 /10-5 /11-1
F17 1) /10-1 /10-4 /10-5 /13-2
• 1)No support elements are required in this position for vehi‐
cles with SCR system.
© satelettronica
assembly platform.
zontally.
WARNING




© satelettronica


shown.

Vehicles without SCR system:

tion.

© satelettronica
Caution

bers.


from gearbox.
Note
© satelettronica
1.1.4 Removing engine - vehicles with dual clutch gearbox 0CK


equipment required
© satelettronica
VAS 6131/11- , -VAS 6131/13-

Procedure
Note

© satelettronica
WARNING

system ⇒ page 7 .
WARNING
moved.
must be empty.
cause injury.
Caution


battery .


R134a .
ments .
WARNING

hot.
© satelettronica

noise insulation .
gine.
tor.



chamber cover .
© satelettronica
Note
Disregard -item 1-.


move clear.
© satelettronica
Caution


1- Fuel hose (blue)



Note
© satelettronica
Caution


Note


electrical wiring.
Note
Disregard -item 1-.

body brace .
© satelettronica



earth cables clear.
© satelettronica


trical wiring.
holder -3-.

-arrow B-.
© satelettronica
catch).



Caution
© satelettronica

housing -arrows-.

Note


cross brace .
Caution


-1-.
© satelettronica
lever using removal lever - 80-200- .
– Move clear selector lever cable.
Note


catch).
- J500- .
– Remove underbody trim (centre, left-side) in direction of ex‐
haust system and press downwards slightly ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody trim; Removing and
installing underbody trim .

– Remove bolt and nuts -arrows- and detach cover -1- for re‐
ducing agent tank.
WARNING

♦ Observe safety measures when handling reducing agent
⇒ page 6 .
Note
Hold a clean cloth under the separating point to catch escaping

reducing agent.
– Unplug electrical connector -3- and move wiring harness clear.

– Press release tabs and disconnect SCR metering line -2-.
© satelettronica
– Move SCR metering line clear as far as subframe.
Note
Disregard -item 1-.

– Unscrew speed nut -2- for cable guide.
Note
Disregard -item 1-.

– Unscrew bolts -3- and tie control unit for NOx sender 2 - J881-
-2- with bracket to SCR catalytic converter.
Note
Disregard -arrows-.

WARNING

system ⇒ page 7 .
Note
Disregard -item 1-.

detach SCR catalytic converter.
Note
© satelettronica

VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /10-11
G6 /10-1 /10-2 /10-5 /10-11
A8+C8 /13-6 /13-2
F8+H8 /13-5 /13-2
B14 /10-1 /10-4 /10-5 /10-7
G14 /10-1 /10-4 /10-5 /11-1
assembly platform.
zontally.

WARNING


© satelettronica



shown.

© satelettronica
Note
Disregard -item 1-.
Caution

bers.

1.1.5 Removing engine - vehicles with 8-speed automatic gearbox 0BK


equipment required
© satelettronica
VAS 6131/11- , -VAS 6131/13-

Procedure
Note

© satelettronica
WARNING

system ⇒ page 7 .
WARNING
moved.
must be empty.
cause injury.
Note

ing removal.
Caution



battery .
R134a .
ments .
WARNING
© satelettronica
hot.

noise insulation .
gine.
tor.



chamber cover .
© satelettronica
Note
Disregard -item 1-.


move clear.
© satelettronica
Caution


1- Fuel hose (blue)



Note
© satelettronica
Caution


Note


electrical wiring.
Note
Disregard -item 1-.

body brace .
© satelettronica



earth cables clear.
© satelettronica


trical wiring.
holder -3-.

-arrow B-.
© satelettronica
catch).



Caution
© satelettronica

housing -arrows-.

Note

cross brace .
Caution



-1-.

catch).
- J500- .
© satelettronica
from gearbox.
Note

♦ If separating the engine from the gearbox for subsequent
work, unscrew the bolted connection securing the drive plate
to the flywheel/torque converter ⇒ page 134 .


VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /11-2
G6 /10-1 /10-2 /10-5 /11-2
A8+C8 /13-6 /13-2
F8+H8 /13-5 /13-2
B14 /10-1 /10-4 /10-5 /10-7
G14 /10-1 /10-4 /10-5 /11-1
F17 1) /10-1 /10-4 /10-5 /13-2
• 1)No support elements are required in this position for vehi‐
cles with SCR system.
© satelettronica
assembly platform.
zontally.
WARNING




© satelettronica

– Position support elements from -VAS 6131/10- at rear of cross

member on both sides, as shown in illustration.


tion.

© satelettronica
Caution

bers.

1.1.6 Removing engine - vehicles with biturbo engine


equipment required
© satelettronica
VAS 6131/11- , -VAS 6131/13-

Procedure
Note

© satelettronica
WARNING

system ⇒ page 7 .
WARNING
moved.
must be empty.
cause injury.
Caution


battery .


R134a .
ments .
WARNING

hot.
© satelettronica

– Remove wheel spoilers (front left and front right) ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Re‐
moving and installing wheel housing liner (front) .
noise insulation .
– Remove air intake grille (right-side) ⇒ General body repairs,
attachments .
– If fitted, release fasteners -arrows- and detach cover -1- (right-

side).

Note
Collect drained coolant in a clean container for re-use or disposal.
gine.
tor.

© satelettronica
chamber cover .

Note
Disregard -item 1-.
© satelettronica
move clear.
Caution


1- Fuel hose (blue)


– Release hose clip -2- and detach vacuum hose.

© satelettronica
Note
– Disconnect vacuum hose -arrow-.


Caution

© satelettronica
Note

electrical wiring.
Note
Disregard -item 1-.

– Unscrew NOx sender - G295- -arrow- and move clear to left
side.
body brace .


© satelettronica
– Unplug electrical connectors -arrows- from catalytic converter

heater control unit 1 - J1021- and move electrical wiring har‐
ness clear.



earth cables clear.
© satelettronica



trical wiring.
holder -3-.
© satelettronica
-arrow B-.
– Unplug electrical connectors -1, 2- for radiator fan (push re‐

tainer to the rear -arrow- and press down release catch).
Note
Disregard -item 3-.

– Unscrew nuts -arrows- on left and right of cross piece (leave

cross piece -1- in installation position).
© satelettronica
– Unscrew bolts -arrows- and press stop -1- for torque reaction
support towards engine.



Caution


housing -arrows-.
© satelettronica
Note


cross brace .
Caution



-1-.

catch).
- J500- .
© satelettronica
– If fitted, unscrew bolts -arrows- and detach heat shield.
from gearbox.
Note

Note
If engine is to be separated from gearbox, detach electrical con‐

nector from bracket.

– Release retaining clip -1-, move injector for reducing agent -
N474- with metering line -3- clear at tunnel cross member and
tie up to underbody.
Note
© satelettronica

VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /10-11
G6 /10-1 /10-2 /10-5 /10-11
A8+C8 /13-6 /13-2
F8+H8 /13-5 /13-2
B14 /10-1 /10-4 /10-5 /10-7
G14 /10-1 /10-4 /10-5 /11-1
assembly platform.
zontally.

WARNING


© satelettronica
shown.



shown.

© satelettronica
Caution

bers.



⇒ “1.2.1 Separating engine and gearbox - vehicles with manual
⇒ “1.2.2 Separating engine and gearbox - vehicles with multitronic
clutch gearbox 0B5”, page 115
clutch gearbox 0CK”, page 122
⇒ “1.2.5 Separating engine and gearbox - vehicles with automatic
⇒ “1.2.6 Separating engine and gearbox - vehicles with biturbo
engine ”, page 136

cles with manual gearbox
© satelettronica
VAS 6131/13-

♦ Bolt -3367/3- from viscous fan fitting tool - 3367-
♦ Bracket - T10014-
© satelettronica
♦ Wrench, 21 mm - T40263-

♦ Adapter -T40314-
Setting up support -VAS 6131/13-7- :

1- Bolt -3367/3- from viscous fan fitting tool - 3367-
2- Nut M10
3- Bracket - T10014-
4- Support -VAS 6131/13-7-
Procedure
© satelettronica
– Take electrical connectors -1, 3- out of bracket, unplug con‐

nectors and move electrical wiring clear.
– Unplug electrical connector -2-, unclip pressure differential
sender - G505- from bracket and move clear.
Note
Disregard -item 1-.

Note
– Remove nuts -arrows- for particulate filter and turbocharger.

– Detach particulate filter with front exhaust pipe.
© satelettronica
Note

– Loosen bolt -2- and move heat shield -B- clear to one side.
Note
Disregard -item A-.
– Move electrical wiring for engine speed sender - G28- clear on
gearbox.

– Assemble tools as shown in illustration.

1- Socket (21 mm) for 1/2" drive
© satelettronica
– Counterhold crankshaft to slacken bolts for dual-mass fly‐
wheel.
Note
– Remove 6 bolts -arrow- for clutch module, turning crankshaft

60° in normal direction of rotation each time.


Note

VAS 6131/14-
H2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5
– Secure support -VAS 6131/13-7- at front of engine (right-side)

with M10 nut -arrow-, as illustrated.
© satelettronica
Note
– Secure support to scissor-type assembly platform - VAS 6131

B- and tighten to 20 Nm.



Note
Disregard -item A-.

© satelettronica
cles with multitronic gearbox

VAS 6131/13-

© satelettronica
♦ Wrench, 21 mm - T40263-


2- Nut M10
4- Support -VAS 6131/13-7-
© satelettronica
Procedure
Note
Disregard -item 1-.


Note
– Unscrew nuts -arrows- and detach particulate filter with front

exhaust pipe.
© satelettronica

Caution

hand.
with your hands.

Note
© satelettronica
Note
– Remove bolt -arrow- and detach ATF lines from gearbox.


– Remove bolts -3- and move gear oil cooling valve - N509- to
one side.

Note

– Remove bolts -arrows- and detach ATF cooler.
© satelettronica

wheel.
Note

– Remove 6 bolts -arrow- for dual-mass flywheel. Turn crank‐

shaft 60° in direction of engine rotation each time.

Note
© satelettronica
VAS 6131/14-
F2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5


Caution
Risk of leaks at ATF sump.

♦ Do not apply gearbox support - VAS 6131/14- at ATF oil
pan.


© satelettronica
Note
Disregard -item A-.

gether with gearbox slightly towards rear.

cles with dual clutch gearbox 0B5


VAS 6131/13-

© satelettronica

♦ Wrench, 21 mm - T40263-
© satelettronica
2- Nut M10
4- Support -VAS 6131/13-7-
Procedure
Exhaust temperature sender - version 1:


plug.
Note

Note
Disregard -item 2-.
© satelettronica
Note

exhaust pipe.

Caution

© satelettronica
hand.
with your hands.

– Remove bolts -arrows- and push ATF cooler to one side.
Note



wheel.
Note
© satelettronica

one side.
Note
Disregard -item 1-.


support set for Audi - VAS 6131/10- , supplementary set -
VAS 6131/11- and support -VAS 6131/13-7- as follows:
Note

VAS 6131/13-7-
F2 /13-7
B10 /10-1 /10-3 /10-5 /11-4
G10 /10-1 /10-3 /10-5 /11-4

© satelettronica
Caution

pan.

VAS 6131/11- at front of gearbox, as shown in illustration.


Note
Disregard -item A-.

© satelettronica
cles with dual clutch gearbox 0CK

VAS 6131/13-

© satelettronica
♦ Wrench, 21 mm - T40263-


2- Nut M10
4- Support -VAS 6131/13-7-
Procedure
© satelettronica
– Take electrical connector -1- for exhaust gas temperature

sender 3 - G495- -item 2- out of bracket and unplug.
Note
Disregard -item 3-.


sender 2 - G448- -item 1- from bracket, unplug connector and
– Take electrical connector -2- for Lambda probe - G39-

-item 1- out of bracket, unplug and move wiring clear.
© satelettronica
– Release retaining clip -1-, detach injector for reducing agent -
N474- and push to one side with coolant hoses -2- attached.
– Unplug electrical connectors for catalytic converter heater 1 -

Z119- / catalytic converter heater 2 - Z120- using puller -
T40317- and move to one side if necessary.

– Take electrical connector -3- out of bracket, unplug it and

Note
Disregard -item 1-.
Note
© satelettronica
– Remove nuts -arrows- and detach heat shield -1-.

– Detach particulate filter with front exhaust pipe.

– Unplug electrical connector -2- at gear oil pump -1-.
Note
Disregard -arrows-.
Caution

© satelettronica
hand.
with your hands.
– Unplug electrical connector -1- by pressing catch -arrow B-

and pulling fastener -2- in direction of -arrow A-.



wheel.
Note
© satelettronica

Note

VAS 6131/14-
F2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5


© satelettronica
Caution

pan.


Note
Disregard -item A-.



© satelettronica
VAS 6131/13-


© satelettronica
♦ Wrench, 21 mm - T40263-


2- Nut M10
4- Support -VAS 6131/13-7-
Procedure
© satelettronica

plug.
Note
Note


exhaust pipe.
© satelettronica
Caution

hand.
with your hands.

Note
Place a cloth under the connection to catch escaping coolant.

Note
Disregard -item 2-.

Note
© satelettronica

wheel.
Note



– Remove bolts -arrows- and move gear oil cooling valve -
N509- to one side.
Note
Disregard -item 1-.
© satelettronica
Note

VAS 6131/14-
F2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5


Caution

pan.


© satelettronica
Note
Disregard -item A-.


cles with biturbo engine


VAS 6131/13-

© satelettronica

♦ Wrench, 21 mm - T40263-
© satelettronica
♦ Puller -T40317-
2- Nut M10
4- Support -VAS 6131/13-7-
Procedure
– Detach electrical connector -1- and, if fitted, -4- from bracket
and unplug connectors.
Note

– Detach electrical connector -2- from bracket, unplug and move

clear.
Note

– Remove bolt -3- and detach bracket with pressure differential
sender - G505- from gearbox.
Note
© satelettronica
Note
Disregard -item 2-.
Caution

hand.
with your hands.


Note
Disregard -item 1-.

– Remove nuts -1, 2-.
Z119- and catalytic converter heater 2 - Z120- using puller -
T40317- .
© satelettronica
– Detach catalytic converter with front exhaust pipe.
– Remove bolts -1- on both sides and bolt -3- on strut -2- for
turbocharger.

Note
Place a cloth under the connection to catch escaping coolant.

Note
Disregard -item 2-.
Note
© satelettronica


– Counterhold crankshaft to slacken bolts for torque converter.
Note
– Remove 6 bolts -arrows- for torque converter. Turn crankshaft

60° in direction of engine rotation each time.
© satelettronica
-2- with stop -1-.

Note

VAS 6131/14-
F2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5


© satelettronica
Caution

pan.


Note
Disregard -item A-.



equipment required
© satelettronica

♦ Lift arm extension/workshop hoist - VAS 6101-

♦ Bracket for V6 TDI engine - VAS 6095/1-11-
Procedure
type assembly platform - VAS 6131- (with engine detached
from gearbox)
– Attach lift arm extension - VAS 6101- to workshop hoist -
VAS 6100- .
© satelettronica
– Attach lifting tackle - 3033- to engine lifting eyes and workshop
hoist as shown in illustration.
Routing of wires - version 1:

mounting solenoid valves -N144- / -N145- out of brackets and
unplug (both sides).
subframe.
Note
The illustration shows the installation position with the engine in‐
stalled.

Routing of wires - version 2:

– Unscrew bolt -1- and detach bracket with electrical wiring from
subframe.
Note
stalled.

Note
Disregard -item 1-.
© satelettronica
– Unscrew bolts -arrows- and remove engine support (left-side).


side).
Note
Disregard -item 1-.
– Using universal mounting - VAS 6095/1- and bracket for V6

TDI engine - VAS 6095/1-11- , secure engine to engine and
gearbox support - VAS 6095- (40 Nm) as shown in illustration.
© satelettronica

© satelettronica
Tightening torques
Note

♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
gearbox; Tightening torques for gearbox or ⇒ Rep. gr. 37 ;
box

Procedure
Note

and O-rings.

© satelettronica
– If fitted, place torque reaction support with stop into installation
position and tighten bolts.
and gearbox:
– Insert assembly aid - T40169- into gearbox housing and dual-
mass flywheel/torque converter from below, as illustrated.
Note

dual-mass flywheel/torque converter accordingly.


– Fit starter and end seal -1- (where present) in correct installa‐
tion position.
© satelettronica
Vehicles with manual gearbox or multitronic gearbox:
sleeves.
-3 … 11-.


sleeves.
-3 … 10-.

sleeves.
© satelettronica
-3 … 9-.
Vehicles with 8-speed automatic gearbox 0BK

sleeves.
-3 … 11-.

• End seal -1- must be correctly fitted -arrows- before installing
starter.
Note
Apply a small amount of lubricant to the end seal if the starter

cannot be installed easily.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Ex‐

ploded view - starter .

Note

wheel/torque converter is straight and that it makes even contact
with the drive plate.
– Use assembly lever -1- to press dual-mass flywheel/torque

converter -2- slightly against drive plate -3- in direction of
-arrow-.
– Bolt dual-mass flywheel/torque converter onto drive plate as

follows:
Note
© satelettronica

Caution
Irreparable damage can be caused if the camshaft timing chain

slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– Turn crankshaft by 180° in direction of engine rotation.

⇒ Rep. gr. 30 ; Clutch; Exploded view - flywheel and dual
clutch or ⇒ Rep. gr. 32 ; Torque converter; Exploded view -
torque converter .
flywheel and dual clutch or ⇒ Rep. gr. 32 ; Torque converter;
Exploded view - torque converter .
subframe.
© satelettronica
– Secure drive shafts (left and right) to gearbox flange shafts ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Ex‐
ploded view - drive shaft .
– Install ATF lines ⇒ Rep. gr. 34 ; ATF circuit; Removing and
installing ATF lines or ⇒ Rep. gr. 37 ; ATF circuit; Removing
and installing ATF lines .
– Install particulate filter:
♦ Front-wheel drive vehicles ⇒ page 612 .
♦ Four-wheel drive vehicles ⇒ page 616 .
– Vehicles with biturbo engine: install catalytic converter with
front exhaust pipe ⇒ page 605 .
– Secure electrical wiring to catalytic converter heater 1 - Z119- /
catalytic converter heater 2 - Z120- ⇒ Item 5 (page 568) .
– Align subframe and tunnel cross member on longitudinal
members according to markings made before removal.
WARNING


mountings; Exploded view - assembly mountings ; or ⇒ Rep.
gr. 37 ; Assembly mountings; Exploded view - assembly
mountings .
note the following:


– Install selector lever cable ⇒ Rep. gr. 34 ; Selector mecha‐
nism; Removing and installing selector lever cable or ⇒ Rep.
lever cable .
frame .
carrier .
© satelettronica
ing battery .
Caution

sive voltage.

ments .
chamber cover .

411 .
Note

R134a .
Wheels, tyres .
© satelettronica
WARNING

– Depending on gearbox version, fill up with ATF ⇒ Rep. gr.

34 ; ATF; Checking ATF level or ⇒ Rep. gr. 37 ; ATF; Check‐
ing ATF level .
insulation .
Bleeding fuel system and checking 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 the affected component if leakage occurs.

⇒ “2.4 Removing and installing torque reaction support”,
page 166

Engine mounting
1 - Bolt
❑ 20 Nm
2 - Bracket
© satelettronica
fective
necessary
3 - Bolt
❑ 40 Nm
4 - Engine support
5 - Bolt
❑ 10 Nm
6 - Heat shield
7 - Bolt
❑ Renew
❑ 90 Nm +90°
8 - Engine mounting
trohydraulic engine
- N144-
- N145-
⇒ page 163
9 - Subframe
❑ Different versions available; for allocation refer to ⇒ Electronic parts catalogue
10 - Bolt
❑ 55 Nm
Torque reaction support

1 - Lock carrier
2 - Cross piece
3 - Nut
❑ 40 Nm
4 - Stop plate
❑ For torque reaction sup‐
port
5 - Bolt
❑ 30 Nm
6 - Buffer
❑ For torque reaction sup‐
port
7 - Torque reaction support
⇒ page 166
8 - Bolt
❑ Renew
© satelettronica
❑ 20 Nm +90°
Gearbox mounting for manual gearbox

1 - Nut
mountings; Exploded
ings
2 - Bolt
mountings; Exploded
ings
3 - Bolt
mountings; Exploded
ings
4 - Nut
© satelettronica
mountings; Exploded
ings
5 - Gearbox support
⇒ page 168
7 - Stop (bottom)
8 - Bolt
Gearbox mounting for multitronic gearbox

1 - Nut
mountings; Exploded
ings
2 - Bolt
mountings; Exploded
ings
3 - Bolt
mountings; Exploded
ings
4 - Nut
© satelettronica
mountings; Exploded
ings
5 - Gearbox support
⇒ page 168
7 - Stop (bottom)
8 - Bolt

1 - Bolt
mountings; Exploded
ings
ded view - assembly
mountings
3 - Stop plate
⇒ page 169
5 - Bolt
© satelettronica
mountings; Exploded
ings
6 - Nut
mountings; Exploded
ings
7 - Bolt
Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
8 - Gearbox support
9 - Bolt
10 - Nut
Gearbox mounting for dual clutch gearbox 0CK


ded view - assembly
mountings
2 - Bolt
mountings; Exploded
ings
3 - Nut
mountings; Exploded
ings
© satelettronica
4 - Gearbox support
5 - Bolt
mountings; Exploded
ings
⇒ page 169
7 - Stop plate
8 - Bolt
9 - Nut
Gearbox mounting for automatic gearbox 0BK

1 - Bolt
mountings; Exploded
ings
ded view - assembly
mountings
3 - Stop plate
⇒ page 171
5 - Bolt
© satelettronica
mountings; Exploded
ings
6 - Nut
mountings; Exploded
ings
7 - Bolt
Rep. gr. 37 ; Assembly mountings; Exploded view - assembly mountings
8 - Gearbox support
9 - Bolt
10 - Nut

tion

Procedure
© satelettronica
Caution
Risk of damage to turbocharger unit on biturbo engine.

• Support bracket spindles must only be engaged on engine
lifting eyes, as described here, and never on turbocharger
unit lifting eyes.
– Engage spindles -10 - 222 A /11- at engine lifting eyes (left

and right).

ings
Note

♦ On some vehicle versions, the engine mounting on the other
side of the vehicle has to be renewed as well; for allocation
refer to ⇒ Electronic parts catalogue .
Removing


noise insulation .
– If fitted, remove nuts -arrows- and move bracket -1- to one
side.
Caution
© satelettronica

– If fitted, remove bracket -1-.
– Detach air conditioner compressor from bracket and tie up.
– If fitted, unscrew nuts -arrows- on left and right of cross piece

(leave cross piece -1- in installation position).
– If fitted, unscrew bolts -arrows- and press stop -1- for torque
reaction support towards engine.

Note
side remain fitted.
Routing of wires (right-side) - version 1:

Routing of wires (both sides) - version 1:
– Detach bracket with electrical connector -2- for electrohydraul‐
ic engine mounting solenoid valves -N144- / -N145- from
subframe (both sides).
– Unplug electrical connectors and move wiring clear.
© satelettronica
Routing of wires (right-side) - version 2:
Routing of wires (both sides) - version 2:

– Remove bolts (left and right) -1- and -arrows- and place re‐
taining plate to one side.
Note
Disregard -item 2-.


Installing
Note

Tightening torques
© satelettronica
(front)

support
Removing
– Also remove noise insulation ⇒ General body repairs, exterior;
insulation .
-2- with stop -1-.
Installing
Note

Tightening torques


mounting
mounting - vehicles with manual gearbox”, page 167
mounting - vehicles with dual clutch gearbox 0B5”, page 169
with dual clutch gearbox 0B5”, page 169
mounting - vehicles with dual clutch gearbox 0CK”, page 170
with dual clutch gearbox 0CK”, page 170
mounting - vehicles with automatic gearbox”, page 171
© satelettronica
with automatic gearbox”, page 171

with manual gearbox
Removing
Installing
Tightening torques
sembly mountings


mounting - vehicles with manual gear‐
box
Removing
⇒ page 169 .
mounting.
box support -3-.
Installing
© satelettronica
Tightening torques
sembly mountings

mounting - vehicles with multitronic
gearbox
Removing
mounting.
box support -3-.
Installing
Tightening torques
sembly mountings


with dual clutch gearbox 0B5
Removing
Installing
Tightening torques
sembly mountings

gearbox 0B5
© satelettronica
Removing
⇒ page 169 .
Installing
Tightening torques
sembly mountings


with dual clutch gearbox 0CK
Removing
Installing
Tightening torques
sembly mountings

gearbox 0CK
© satelettronica
Removing
⇒ page 169 .
Installing
Tightening torques
sembly mountings


with automatic gearbox
Removing
Installing
Tightening torques
sembly mountings

mounting - vehicles with automatic gear‐
box
© satelettronica
Removing
⇒ page 171 .
Installing
Tightening torques
sembly mountings



panel
Removing
Installing
filler neck.
– First press engine cover panel onto rear retaining pins and
then onto front retaining pins with both hands.
© satelettronica

page 182
page 187
189
© satelettronica
1 - Poly V-belt
❑ Check for wear
⇒ page 180
❑ Do not kink
on pulleys
❑ Removing and instal‐
ling:
♦ Vehicles without torque re‐
action support
⇒ page 182
♦ Vehicles with torque reac‐
tion support ⇒ page 183
3 - Washer
❑ Renew
4 - Bolt
❑ Renew
❑ 20 Nm +90°
5 - Idler roller
❑ For poly V-belt
6 - Bolt
❑ 30 Nm
7 - Cover

8 - Cover
9 - Bolt
❑ 23 Nm
10 - Idler roller
❑ For poly V-belt
11 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
12 - Alternator
13 - Bracket
❑ For alternator
14 - Bolt
❑ Tighten in two stages:
♦ 5 Nm in diagonal sequence
© satelettronica
15 - Bolt
17 - Coolant pump
18 - Bolt
❑ Renew
❑ 50 Nm +90°
19 - Tensioner
❑ For poly V-belt
❑ Different versions (with or without washer for tensioner) ⇒ page 175
20 - Seal
❑ Renew
21 - Bracket
❑ For air conditioner compressor
22 - Bolt
❑ Tighten in two stages:
23 - Dowel sleeve
❑ 2x
24 - Bolt


Allocation of washer for tensioner

1- Sealing flange WITH support for tensioner
– Install tensioner WITHOUT washer.
2 - Sealing flange WITHOUT support for tensioner
– Install tensioner WITH washer.
© satelettronica
Tensioner with washer for sealing flange without support
1 - Bolt - tightening torque ⇒ Item 18 (page 174)
2 - Tensioner
3 - Washer - only for sealing flange without support
4 - Sealing flange - without support

1.2 Exploded view - sealing flange (pulley end)
1 - Bolt
❑ Renew
❑ Steel bolts: tightening
torque and sequence
⇒ page 177
❑ Aluminium bolts: tight‐
quence ⇒ page 179
2 - Oil seal
end)
3 - Temperature regulator
❑ For engine oil cooler
⇒ page 333
© satelettronica
4 - Bolt
5 - Cover
❑ For temperature regula‐
tor for engine oil cooler
stalling temperature
regulator for engine oil
cooler”, page 333
6 - O-ring
❑ Renew
7 - Sealing flange
❑ Pulley end
Caution
Different versions possi‐
ble; see ⇒ Electronic
parts catalogue
The
♦ sealing flange ver‐
sion is matched to the
gasket version (with or
without metal carrier).
Different
♦ versions (with or
without washer for ten‐
sioner) ⇒ page 175

8 - O-ring
❑ Renew
9 - Oil temperature sender 2 - G664-
10 - Bolt
❑ 9 Nm

11 - Retainer
❑ For oil temperature sender 2 - G664-
12 - O-ring
❑ Renew
13 - Cover
❑ For sealing flange (pulley end)
14 - Bolt
❑ 9 Nm
15 - Gasket
❑ Renew
16 - Dowel pins
❑ 2x
17 - Gasket
❑ Renew
Caution
© satelettronica
Different versions possi‐
ble; see ⇒ Electronic
parts catalogue
The
♦ sealing flange ver‐
sion is matched to the
gasket version (with or
without metal carrier).
Steel bolts: sealing flange (pulley end) - tightening torque and se‐
quence
– Tighten bolts in 7 stages in the sequence shown.
Stages 1 ... 3:
1. Fit sealing flange with gasket on cyl‐
inder block
2. -1- Tighten for idler roller
3. -2, 3, 4- 9 Nm

Stages 4 ... 6:
4. Insert temperature regulator for en‐
gine oil cooler with cover
5. -10- Screw in by hand until contact is made
6. -1 … 19- 9 Nm
Stage 7:
© satelettronica
7. -2, 3, 4- 9 Nm

Aluminium bolts: sealing flange (pulley end) - tightening torque

and sequence
Caution
Risk of damage to aluminium bolts when installing sealing

flange (pulley end).
♦ Do not use aluminium bolts to pull sealing flange (pulley
end) onto cylinder block.
♦ Use three steel bolts M6x20 to secure sealing flange (pul‐
ley end); refer to the following description.

Stages 1 ... 3:
1. Fit sealing flange with gasket on cyl‐
inder block
2. -1- Tighten for idler roller
© satelettronica
3. -2, 3, 4- Tighten steel bolts M6x20 to 9 Nm
Stages 4 ... 8:
4. Insert temperature regulator for en‐
gine oil cooler with cover
5. -10- Screw in by hand until contact is made
6. -1 … 19- 3 Nm
7. -1 … 19- 3 Nm; this step is performed to allow
for settling of sealing flange (pulley
end)
8. -1 … 19- Turn 90° further

Stages 9 ... 11:

9. -2, 3, 4- Unscrew steel bolts M6x20
10. -2, 3, 4- Insert aluminium bolts and tighten to
3 Nm
11. -2, 3, 4- Turn aluminium bolts 90° further
© satelettronica
♦ Socket Torx T60 - T40087-

Removing
Caution

– Slacken poly V-belt by turning tensioner in clockwise direction

-arrow- using socket Torx T 60 - T40087- .
A- .
Installing
– Fit poly V-belt onto poly V-belt pulleys.
1- Alternator
© satelettronica
2- Idler roller
3- Idler roller
4- Coolant pump
7- Vibration damper
Note

pulleys.


poly V-belt
Removing
– Detach poly V-belt from tensioner
Installing
Note
Depending on version, install tensioner with or without washer

⇒ page 175 .

Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”,
© satelettronica
page 173

er
⇒ “1.5.1 Removing and installing vibration damper - vehicles with‐
out torque reaction support”, page 182
⇒ “1.5.2 Removing and installing vibration damper - vehicles with
torque reaction support”, page 183
1.5.1 Removing and installing vibration damp‐

er - vehicles without torque reaction sup‐
port
Removing
noise insulation .

– Remove bolts -1- and detach shim -2- and vibration damper
-3-.
Installing
Note

♦ Renew the shim.

Tightening torques
page 173
1.5.2 Removing and installing vibration damp‐
© satelettronica
er - vehicles with torque reaction support
Removing
noise insulation .
– Unscrew nuts -arrows- on left and right of cross piece (leave
cross piece -1- in installation position).

– Unscrew bolts -arrows- and press stop -1- for torque reaction
support towards engine.

– Unplug electrical connector -2- and move electrical wiring har‐
ness clear.
Note
Disregard -item 3-.
© satelettronica
ments .
Note
Disregard -item 1-.


© satelettronica
– Set up support bracket - 10 - 222 A- top edges of body flanges
Caution
Risk of damage to turbocharger unit on biturbo engine.

• Support bracket spindles must only be engaged on engine
lifting eyes, as described here, and never on turbocharger
unit lifting eyes.

and right).
– Using spindles -1- on both sides, raise engine through dis‐

tance -a-.

– Remove bolts -1- and detach shim -2- and vibration damper
-3-.
Installing
Note

♦ Renew the shim.

ments .
Tightening torques
page 173
© satelettronica
♦ ⇒ “2.1 Exploded view - coolant pump”, page 367


cillaries
Removing
– Unscrew bolts -arrows- and detach bracket for air conditioner
compressor.
Note
Installing
© satelettronica
Note
♦ Renew seal.

Tightening torques
page 173

end)
♦ Oil seal extractor - T40019-

♦ Assembly appliance - T40048 A- with -T40048/7-
♦ Bolts M8x55 mm (2x)

Procedure
– Remove vibration damper:
♦ Vehicles without torque reaction support ⇒ page 182
♦ Vehicles with torque reaction support ⇒ page 183
– Adjust inner part of oil seal extractor -T40019- so it is flush with
© satelettronica
the outer part and lock in position with knurled screw.
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
oil seal.

and slide oil seal -1- onto assembly sleeve.
– Fit assembly sleeve -T40048/2- on crankshaft and slide oil

seal -1- into sealing flange (pulley end).
Note
Leave assembly sleeve -T40048/2- in position on crankshaft

when pressing in seal.

– Apply press sleeve -T40048/7- to crankshaft using M8×55 mm

bolts -arrows-.
– Screw in bolts hand-tight at first.
– Tighten bolts alternately, 1/2 turn at a time, to press in oil seal
onto stop.
note the following:
– Installing vibration damper:

(pulley end)
⇒ “1.8.1 Removing and installing sealing flange (pulley end)”,
page 189
⇒ “1.8.2 Removing and installing cover for sealing flange (pulley
end)”, page 193
© satelettronica
1.8.1 Removing and installing sealing flange
(pulley end)
♦ Steel bolt M6x20 (3x)

Removing
Vehicles without torque reaction support:
– Unplug electrical connector -1- and unclip change-over valve
from bracket.
Vehicles with torque reaction support:
– Remove poly V-belt tensioner ⇒ page 182 .
© satelettronica
– Remove bolt -1- and pull out guide tube for oil dipstick.
Note



– Unplug electrical connector -1- at oil temperature sender 2 -
G664- .
Note
Disregard -item 2-.

© satelettronica
– Unclip cover -1-.
– Unscrew bolt -2- and remove idler roller.

– Slacken and remove bolts in the sequence: -23 ... 1-.

– Detach temperature regulator for engine oil cooler
⇒ page 333 .
– Disconnect coolant hose (top) -arrow- from sealing flange
(pulley end) and detach.
– Drive crankshaft oil seal out of sealing flange after removing
sealing flange.
Installing
Note
♦ Renew gasket, O-ring for temperature regulator and crank‐

shaft oil seal.

– Tighten sealing flange bolts (pulley end) ⇒ page 179 .
© satelettronica
note the following:
– Install crankshaft oil seal (pulley end) ⇒ page 187 .
– Install idler roller for poly V-belt ⇒ page 173 .
– Install oil filter element ⇒ Maintenance ; Booklet 411 .
– Install poly V-belt tensioner ⇒ page 182 .
– Installing vibration damper:
Note

Tightening torques
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”,
page 176
♦ ⇒ Fig. ““Aluminium bolts: sealing flange (pulley end) - tighten‐
ing torque and sequence”“ , page 179
page 335

1.8.2 Removing and installing cover for seal‐

ing flange (pulley end)
Removing
– Unscrew bolts -arrows- and detach cover -1-.
Installing
Note
Renew seal.

Tightening torques
page 176
© satelettronica


Note
1 - Bolt
❑ Renew
❑ 60 Nm +90°
© satelettronica
2 - Drive plate
❑ Check holes for fly‐
wheel/torque converter
for cracks and scoring
⇒ page 195
3 - Dowel pin
4 - Crankshaft
5 - Oil seal
end)
6 - Sender wheel
er - G28-
Caution
causing irreparable
damage to sender
wheel.
The
loudspeaker).
stallation ⇒ page 197 .

❑ Checking sender wheel ⇒ page 197


Removing
© satelettronica
Caution

wheel.
– Insert counterhold tool - 10 - 201- to slacken bolts.
Caution

drive plate.
– Unscrew bolts for drive plate in diagonal sequence and re‐

move.
– Detach drive plate and sender wheel.
Installing
Note

angle.

Threads in crankshaft must be cleaned before any further as‐

sembly work is performed.
– Clean crankshaft flange until all residual adhesive has been
removed completely.
• Ensure you do not damage oil seal when cleaning flange.
• Use a vacuum cleaner to hoover up residual adhesive; do NOT
use compressed air.
– Remove residual adhesive from one of the old bolts -2- for
drive plate using wire brush and remove oil residue using
brake cleaner.
– Screw cleaned bolt into a thread on crankshaft -1- and out
again; repeat this action until no further residual adhesive ap‐
pears.
• Do not screw bolt in too far; otherwise, the camshaft timing
chain located behind it may be damaged.
– When no further residual adhesive appears, repeat the pro‐
cedure for the other crankshaft threads.
• Finally, use a vacuum cleaner to hoover up residual adhesive;
do NOT use compressed air.
© satelettronica
– Clean crankshaft flange with a cloth.
• Thread in crankshaft must be free of oil and grease.
– Install drive plate with sender wheel (pay attention to dowel
pin).
– Fit counterhold tool - 10 - 201- the other way round to tighten
bolts for drive plate.
Tightening torques
page 194

Removing
Installing

Caution

wheel.

© satelettronica
Procedure


A - Sender wheel OK

end)
© satelettronica

♦ Extractor tool - T20143/2-

Procedure

© satelettronica
ing bolts -arrows-.
Caution


hand.
– Press in oil seal uniformly until flush all round using press
sleeve -T10122/5- .
oil seal.

3 Crankshaft
Note
1 - Crankshaft
ance ⇒ page 202
ance ⇒ page 203
© satelettronica
⇒ page 202
2 - Dowel sleeve
❑ 4x
❑ Insert in cylinder block
3 - Retaining frame
4 - Bolt
❑ Renew
ance
5 - Thrust washer
❑ Only fitted on 3rd crank‐
shaft bearing
❑ Installation position: oil
grooves face outwards
❑ Note location
6 - Bearing shell
❑ For retaining frame
(without oil groove)
shells
❑ Install new bearing
shells for retaining
frame with correct col‐
oured markings ⇒ page 202
7 - Dowel pin
❑ Check that pin is firmly seated in crankshaft
8 - Thrust washer
❑ Installation position: oil grooves face outwards

9 - Bearing shell
❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ page 201
Retaining frame - tightening torque and sequence
Note
– Insert two dowel sleeves in cylinder block.

1. -1 … 16- 30 Nm
2. -1 … 16- 50 Nm
3. -1 … 16- Turn 180° further
© satelettronica
Allocation of crankshaft bearing shells for cylinder block
Bearing shells of the correct thickness are matched to the bear‐
ings in the cylinder block at the factory. Coloured dots on the
bearing shells are used to identify the bearing shell thickness.
• -Arrow-: Pulley end.
The allocation of the bearing shells to the cylinder block is iden‐
tified by a code letter next to the relevant bearing.
Letter on cylinder block Colour coding of bearing
R = Red
G= Yellow
B = Blue
3. Crankshaft 201
Allocation of crankshaft bearing shells for retaining frame

Bearing shells of the correct thickness are matched to the bear‐
ings in the retaining frame at the factory. Coloured dots on the
side of the bearing shells are used to identify the bearing shell
thickness.
The allocation of the bearing shells to the bearing positions in the
retaining frame is indicated by a sequence of letters on the fly‐
wheel flange on the crankshaft. The first letter in the sequence
stands for bearing “1”, the second letter for bearing “2”, etc.
R = Red
G= Yellow
B= Blue
Position of dowel sleeves
© satelettronica
• -Arrow-: Pulley end.

Honing di‐ Main bearing journal Conrod journal ∅
mension ∅ mm
mm
Basic dimen‐ 65.000 – 0.022 60.000 – 0.022
sion – 0.042 – 0.042


Procedure
“0”.
© satelettronica
Axial clearance:
• New: 0.09 ... 0.25 mm.

shaft
♦ Plastigauge
Procedure
ing shell
– Fit retaining frame and secure with old bolts ⇒ page 201 with‐
out rotating crankshaft.
Radial clearance:
• New: 0.02 ... 0.05 mm.
3. Crankshaft 203
4 Balance shaft
1 - Bolt
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
❑ 9 Nm
2 - Bearing plate
3 - Bolt
❑ 23 Nm
4 - Nut
❑ Counterhold with diesel
© satelettronica
injection pump locking
pin - 3359- when loos‐
ening and tightening
❑ Balance shaft must be
renewed if nut has been
loosened
❑ 30 Nm +90°
6 - Balance weight
❑ Gearbox end
7 - Roller bearing
8 - Balance shaft
⇒ page 204
❑ Balance shaft must be
renewed if nut -item 4-
has been loosened
9 - Bolt
❑ Counterhold with diesel
injection pump locking pin - 3359- when loosening and tightening
❑ 60 Nm
10 - Balance weight
❑ Pulley end
11 - Roller bearing


Removing
• Gearbox removed
– Remove camshaft timing chain ⇒ page 240 .
– Lock balance shaft at rear of engine with diesel injection pump
© satelettronica
locking pin - 3359- .
– Remove bolts -arrows- at rear of engine and detach drive
chain sprocket from balance weight.
– Loosen bolt -arrow- at front of engine.

– Remove bolt and detach balance weight from balance shaft.
– Remove nut -arrow- at rear of engine and detach balance

weight from balance shaft.
4. Balance shaft 205

– Remove bolts -arrows- and detach bearing plate for balance

shaft.
Installing
3242- .
Note
© satelettronica
Renew balance shaft.
– Install camshaft timing chain ⇒ page 240 .

Tightening torques


⇒ “5.3 Measuring piston projection at TDC”, page 210
page 214
Note

♦ Oil spray jet for piston cooling ⇒ page 208 .
1 - Bolts
© satelettronica
❑ Renew
ance
contact surface
❑ 35 Nm +90°
❑ 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
in colour -B-
⇒ page 209
❑ Note when fitting: the
wide contact shoulder
-A- must point towards
same side on conrod
and conrod bearing cap
3 - Bearing shells
tion
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-resistant material; refer to ⇒ Electronic parts catalogue
❑ Ensure that retaining lugs are securely seated.

4 - Conrod
❑ With industrially cracked conrod bearing cap
❑ Mark cylinder allocation in colour -B- ⇒ page 209
❑ Note when fitting: the wide contact shoulder -A- must point towards same side on conrod and conrod
bearing cap
5 - Circlip
❑ Renew
6 - Piston pin
7 - Piston
❑ Measuring piston projection at “TDC” ⇒ page 210
❑ Mark installation position and cylinder number ⇒ page 209
© satelettronica
❑ Checking pistons and cylinder bores ⇒ page 213
8 - Circlip
❑ Renew
9 - Piston rings

1- Bolt, 9 Nm
2- Oil spray jet with spray nozzle valve for piston cooling
Caution

♦ Check that oil spray jets have adequate clearance after
re-installing pistons.

Caution
Risk of damage to piston crown.

a scratch, notch or similar.
• Installation position: Arrow -item 1- on piston crown points to

pulley end.
Marking conrods
– Before removing, mark mating positions of conrods and con‐
rod bearing caps with coloured pen -arrow-.
Note
© satelettronica
♦ Only renew conrods as a complete set.
♦ Do not interchange conrod bearings.

The larger contact shoulder on the conrod -arrows- faces towards
the adjacent crankshaft bearing.
Note
Illustration shows first conrod pair.

♦ Pin - VW 222 A-

Removing
⇒ page 144
– Remove sump (top section) ⇒ page 324 .
to cylinder and to conrods for re-installation ⇒ page 209 .
Note

Installing
© satelettronica
Note

– Install pistons using commercially available piston ring clamp.
• Pistons ⇒ page 209
• Conrods ⇒ page 209
– Install sump (upper section) ⇒ page 324 .
Tightening torques
5.3 Measuring piston projection at TDC
Note
Piston projection at “TDC” must be measured when installing new

pistons or a short engine.

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

VW 385-
© satelettronica

Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
– Measure projection at each piston at both locations marked
with -arrows- (seen in longitudinal direction of engine: at front
and rear of piston).
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.
♦ The cylinder head gasket size must be determined separately
for each cylinder bank.
– 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)
© satelettronica
0.82…0.92 mm 1
0.92…0.97 mm 2
0.97…1.08 mm 3

1- Part number
2- Holes
Note
The gaskets for the left and right cylinder heads have different
shapes and cannot be interchanged.


Checking piston
There are different piston sizes specifically matched to the differ‐
ent dimensions of the cylinder block.
Piston ∅ mm
Nominal dimension 82.924 … 82.936 1)
Repair oversize 82.964 … 82.976 1)
• 1) Dimensions not including coating (thickness 0.02 mm). The
coating will wear down partly in service.

© satelettronica
-B-.
Nominal dimension 83.006 … 83.014 1)
Repair oversize 83.046 … 83.054 1)

of cylinder.
mm mm


mm mm

bearings
♦ Plastigauge
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
© satelettronica
journal.
Radial clearance:
• New: 0.02 ... 0.07 mm.


1 - Bolt
❑ Renew
2 - Sender wheel
er - G28-
3 - Oil seal
© satelettronica
end)
⇒ page 198
⇒ page 225
5 - Dowel sleeve
6 - Gasket
❑ Renew
7 - Bolt
❑ Renew
8 - Timing chain cover (left-
side)
⇒ page 220
9 - Bolt
❑ Renew
10 - Gasket
❑ Renew
11 - Bolt
❑ Renew
13 - Bolt
❑ Renew

14 - Dowel sleeve
15 - Sealing element
❑ 2x
17 - Bolt
Timing chain cover (top left) - tightening torque and tightening

sequence
Note

© satelettronica
1. -1, 2, 3- Screw in by hand until contact is made
3. -1 … 7- 8 Nm
4. -1 … 7- 8 Nm (this step is performed to allow
for settling of timing chain cover)
Timing chain cover (top right) - tightening torque and tightening

sequence
Note

3. -1 … 7- 8 Nm
for settling of timing chain cover)

Timing chain cover (bottom) - tightening torque and tightening

sequence: vehicles with aluminium sump (top section)
Caution
♦ For vehicles with magnesium sump (top section) (identifi‐

cation: letter combination “MRI” -arrow- on top section of
sump), proceed as follows ⇒ page 218 .
Stages 1 and 2:
1. Fit timing chain cover (bottom) on cyl‐
inder block with sealant and sealing
elements.
2. -1, 2, 3, 4- 9 Nm
© satelettronica
Stages 3 ... 6:
3. -1 … 20- 3 Nm
4. -1 … 6- 8 Nm
6. -7 … 20- 9 Nm

Stage 7:
7. -1, 2, 3, 4- 9 Nm

sequence: vehicles with magnesium sump (top section)
© satelettronica
Identification: magnesium sump (top section)
Note
Caution
Risk of damage to aluminium bolts when installing timing chain

cover (bottom).
♦ Do not use aluminium bolts to pull timing chain cover (bot‐
tom) onto cylinder block.
♦ Therefore use four steel bolts M6x20 to install the timing
chain cover (bottom); see the following description.

Stages 1 and 2:
1. Fit timing chain cover (bottom) on cyl‐
inder block with sealant and sealing
elements.
2. -1, 2, 3, 4- Tighten steel bolts M6x20 to 9 Nm
Stages 3 ... 6:
© satelettronica
3. -1 … 20- 3 Nm
for settling of bottom timing chain cov‐
er)
5. -1 … 6- 8 Nm
6. -1 … 20- Turn 90° further
Stages 7 ... 9:
7. -1, 2, 3, 4- Unscrew steel bolts M6x20
8. -1, 2, 3, 4- Insert aluminium bolts and tighten to
3 Nm
9. -1, 2, 3, 4- Turn aluminium bolts 90° further


cover
⇒ “1.2.1 Removing and installing timing chain cover (top left)”,
page 220
⇒ “1.2.2 Removing and installing timing chain cover (top right)”,
page 222
page 225

cover (top left)
♦ Safety goggles
Removing
© satelettronica
– Remove cylinder head cover (left-side).
♦ ⇒ “3.4.1 Removing and installing cylinder head cover (left-
side) - vehicles with one turbocharger”, page 267
♦ ⇒ “3.4.3 Removing and installing cylinder head cover (left-
side) - vehicles with two turbochargers”, page 272
⇒ page 267
Vehicles with one turbocharger:
– Remove particulate filter ⇒ page 612 .
– If fitted, unscrew bolts -2- and detach heat shield.
Note
Disregard -item 1-.


– Carefully release timing chain cover (top left) from bonded joint
and remove cover.
Installing
– Remove old sealant from sealing surfaces on timing chain
cover.
Caution

WARNING
Risk of eye injury.
© satelettronica
– Remove remaining sealant on timing chain cover -1- and cyl‐

inder head using rotating plastic brush or similar.
Note

mm).
– Fit gasket -1-.

– Apply sealant at joints between cylinder head and timing chain
cover (bottom) -arrow-, as shown in illustration.
Caution


sealing surface.

– Apply sealant beads -1 and 2- onto clean sealing surface of

timing chain cover (left-side), as illustrated.
Note

– Fit timing chain cover and tighten bolts ⇒ page 216 .

note the following:
– Install cylinder head cover (left-side) ⇒ page 267 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (top left) - tightening torque and
tightening sequence”“ , page 216
© satelettronica
cover (top right)
♦ Safety goggles
Removing
– Remove cylinder head cover (right-side).
♦ ⇒ “3.4.2 Removing and installing cylinder head cover (right-
side) - vehicles with one turbocharger”, page 269
♦ ⇒ “3.4.4 Removing and installing cylinder head cover (right-
side) - vehicles with two turbochargers”, page 275
– Press air pipe to rear.

Vehicles with two turbochargers:

– Remove bolt -1- on intermediate pipe.
Note
Disregard -item 2-.
– Release clip -3- and detach air hose.

– Pull air pipe off bypass valve at right and guide intermediate
pipe -1- out of turbocharger at same time.
– Press air pipe to the side.
© satelettronica
– Unscrew bolts -arrows- and detach bracket -1-.
– Open clip -1- and detach bypass valve -2-.


– Carefully release timing chain cover (top) from bonded joint
and remove cover.
Installing
– Remove old sealant from sealing surfaces on timing chain
cover.
Caution

WARNING
Risk of eye injury.

© satelettronica
Note

mm).
– Fit gasket -1-.

– Apply sealant at joints between cylinder head and timing chain
cover (bottom) -arrow-, as shown in illustration.
Caution


sealing surface.

– Apply sealant beads -1 and 2- onto clean sealing surface of

timing chain cover (right-side), as illustrated.
Note

– Move cover (top right) into installation position, check sealant

bead and correct if necessary.
– Fit timing chain cover and tighten bolts ⇒ page 216 .
note the following:
– Install air pipe ⇒ page 463 .
– Install exhaust gas temperature sender 4 - G648-
⇒ page 650 .
– Install cylinder head cover (right-side) ⇒ page 269 .
© satelettronica
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (top right) - tightening torque and
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead;
Exploded view - plenum chamber partition panel

cover (bottom)
♦ Safety goggles
♦ Steel bolt M6x20 (4x)
Removing
• Vehicles with one turbocharger: Gearbox removed ⇒ Rep. gr.
34 ; Removing and installing gearbox; Removing gearbox or
⇒ Rep. gr. 37 ; Removing and installing gearbox; Removing
gearbox
• Vehicles with two turbochargers: engine separated from gear‐
box ⇒ page 136
– Remove turbocharger:
♦ Vehicles with one turbocharger ⇒ page 420
♦ Vehicles with two turbochargers ⇒ page 424
– Remove timing chain covers (top) ⇒ page 220 .
– Remove exhaust manifold (left and right) ⇒ page 666 .


– Unscrew bolts -arrows- and detach bracket -1- for turbocharg‐
er.

– Release clamp -1- and detach exhaust gas recirculation pipe.
Note
Disregard -item 2-.
© satelettronica
– Unscrew bolts -arrows- and swivel bracket -1- for turbocharger
to side.
– Remove bolt -2- and detach oil return pipe.
Note
Disregard -item 1-.


cover (bottom).
Installing
– Remove old sealant from grooves on timing chain cover and
Caution

© satelettronica
WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover (bottom)

-1- and on cylinder block using rotating plastic brush or similar.
Note

mm).

– Fit sealing elements -arrows- (without sealant).
Caution

– Apply beads of sealant onto clean sealing surface of timing

chain cover (bottom) as illustrated.
• The beads of sealant -1, 2, 4- must be 1.5 ... 2.0 mm thick.
• The beads of sealant around drillings -3- and -5- must be
1.5 … 2.0 mm thick.
Note

– Check whether the two dowel sleeves are fitted in the cylinder
© satelettronica
block; install if necessary.
– Install timing chain cover (bottom) and tighten bolts
⇒ page 217 .
note the following:
– Install crankshaft oil seal (gearbox end) ⇒ page 198 .
– Install timing chain covers (top) ⇒ page 220 .
– Install exhaust manifold (left-side) ⇒ page 666 .
– Install exhaust manifold (right-side) ⇒ page 670 .
– Install bracket for turbocharger:
– Install turbocharger:
Tightening torques
♦ ⇒ page 217
♦ ⇒ “1.1.1 Exploded view - turbocharger, vehicles with one tur‐
bocharger”, page 412
♦ ⇒ “1.1.2 Exploded view - turbochargers, vehicles with two tur‐
bochargers”, page 414

2 Chain drive
⇒ “2.2 Exploded view - drive chain for oil pump and high-pressure
pump”, page 231
page 232
page 240
⇒ “2.5 Removing and installing drive chain for oil pump and high-
pressure pump”, page 250
1 - Bolt
❑ 9 Nm
2 - Chain slip preventer
3 - Crankshaft
© satelettronica
❑ With sprocket for cam‐
shaft timing chain
4 - Guide rail
tion
5 - Bolt
6 - Guide pin
❑ For guide rail
❑ Renew
❑ 5 Nm +90°
7 - Guide rail
tion
8 - Bolt
❑ 23 Nm
Side with lettering legi‐
ble from rear
10 - Guide pin
❑ For guide rail
❑ Renew
❑ 5 Nm +90°
11 - Chain sprocket
12 - Guide rail
2. Chain drive 229

13 - Guide pin
❑ For guide rail
❑ 23 Nm
❑ Installation position: Side with lettering legible from rear
15 - Bolt
❑ 23 Nm
16 - Guide pin
❑ For guide rail
❑ Renew
❑ 5 Nm +90°
17 - Guide pin
❑ For tensioning rail
❑ 23 Nm
18 - Tensioning rail
© satelettronica
❑ For camshaft timing chain
20 - Bolt
❑ Renew
❑ 5 Nm +90°
21 - Camshaft timing chain
❑ Removing from camshafts ⇒ page 232
❑ Before removing, mark running direction with paint

2.2 Exploded view - drive chain for oil pump and high-pressure pump
1 - Drive chain for oil pump and

high-pressure pump
⇒ page 250
2 - Bolt
❑ Renew
❑ 30 Nm +45°
❑ For oil pump
5 - Crankshaft
❑ With drive chain sprock‐
et for oil pump and high-
pressure pump
© satelettronica
❑ For high-pressure pump
7 - Guide rail
8 - Guide pin
❑ For guide rail
❑ Renew
❑ 5 Nm +90°
9 - Chain tensioner
❑ With guide rail
10 - Bolt
❑ Renew
❑ 5 Nm +90°
2. Chain drive 231


equipment required
© satelettronica
♦ Locking pin - 3242-
♦ Adjustment pin - T40060- (2x)

♦ Wrench, 21 mm - T40263-
© satelettronica
♦ Bolt, M6x20 (2x)
♦ Bolt, M6x40 (2x)
Removing
• Engine and gearbox in vehicle
Note
When working on the bank 1 cylinder head (right-side) only, it is

not necessary to remove the timing chain cover on the bank 2
cylinder head (left-side).
– Remove timing chain covers (top) ⇒ page 220 .

2. Chain drive 233

Caution

slips.
-arrow-.
– Turn crankshaft until vibration damper is at “TDC” position.

• Mark (stuck on) -arrow- must be vertical.
© satelettronica
Note
♦ The adjustment pin - T40060- has a flat -2- which makes it

easier to insert when the locating bores in the camshaft and
cylinder head are not exactly in line.
♦ The adjustment pin is inserted initially so that the side pin -1-
is perpendicular to the imaginary line between the adjustment
pin and the centre of the camshaft.
♦ To obtain the correct “TDC” position, the side pin -1- must then
be turned 90° -arrow- so it is in line with the imaginary line
between the adjustment pin and the centre of the camshaft.
– Check that camshafts on both cylinder heads are positioned

at “TDC”.
• It should be possible to lock the camshafts with the adjustment
pins - T40060- .
• The side pin -arrow- on the adjustment pin - T40060- must be
in line with the imaginary line between the adjustment pin and
the centre of the camshaft on cylinder bank 1 (right-side).


the centre of the camshaft on cylinder bank 2 (left-side).
Note
Place a cloth beneath the sump (top section) to catch escaping

oil.
– Unscrew plug -arrow- from sump (top section).
© satelettronica
– Screw locking pin - 3242- into hole (20 Nm); if necessary, turn
crankshaft -1- backwards and forwards slightly to fully cen‐
tralise locking pin.
– Secure bracket - T40246- as shown in illustration.

1. -1- M6x40 Screw in by hand until contact is made
2. -2- M6x20 Screw in by hand until contact is made
3. -2- M6x40 8 Nm
4. -1- M6x20 8 Nm
Caution

engine.
– Remove adjustment pin - T40060- from both camshafts.
2. Chain drive 235


– Detach camshaft chain sprockets.
© satelettronica
Installing
3242- .
Note

♦ Renew the seal on the screw plug for the “TDC” mark.

at “TDC”.
pins - T40060- .


Caution

the camshafts are to be turned.
© satelettronica
Note
If the pins cannot be inserted in the camshafts, the camshafts can

be turned slightly using adapter - T40061- . To do so, screw se‐
curing bolts for camshaft sprocket into camshaft.
– Fit camshaft sprocket (left-side) with camshaft timing chain.

• The elongated holes in the camshaft chain sprocket must be
aligned centrally over the threaded holes in the camshaft.
– First screw in two bolts -1- loosely for camshaft chain sprocket.
– Use adjustment pin - T40060- to lock camshaft (left-side).
the centre of the camshaft.
– Fit camshaft sprocket (right-side) with camshaft timing chain.

– Use adjustment pin - T40060- to lock camshaft (right-side).
2. Chain drive 237

– Remove bracket - T40246- .
– With the help of a second mechanic, apply a torque of 20 Nm

to camshaft chain sprocket (right-side) in clockwise direction
-arrow- using a torque wrench and adapter - T40062- and
maintain this torque.
– Tighten bolts -1- and -2- for camshaft chain sprocket (right-
side).
© satelettronica
– Tighten bolts -1- for camshaft chain sprocket (left-side); while
doing so, second mechanic must keep maintaining torque.
– Remove adapter - T40062- and adjustment pins -T40060- .
– Tighten remaining bolts for camshaft chain sprockets (both
sides).
– Remove locking pin - 3242- .

Checking valve timing
Caution

slips.
-arrow-.
– Turn crankshaft two rotations until it is again positioned just

before “TDC”.
– While turning in this direction, lock crankshaft -1- with locking

pin - 3242- . Tighten locking pin to 20 Nm.
Caution
The crankshaft must be exactly in “TDC” position to ensure

accurate valve timing adjustment.
♦ If crankshaft has been turned past “TDC” position, turn
© satelettronica
crankshaft two further rotations until it is again positioned
just before “TDC”. Then turn further in the same direction
and lock crankshaft with locking pin - 3242- .

at “TDC”.
pins - T40060- .

2. Chain drive 239

Adjusting valve timing

– If the pin cannot be inserted in one of the camshafts, loosen
all bolts -arrows- of relevant camshaft chain sprocket approx.
1 turn.
– Apply adapter - T40061- to the heads of the loosened bolts.

– Turn camshaft slightly backwards and forwards with adapter -
T40061- until adjustment pin - T40060- can be inserted.
© satelettronica
– With adapter - T40061- and adjustment pin - T40060- still in
position, tighten bolts on camshaft sprocket to approx. 5 Nm.
– Remove adjustment pin - T40060- and adapter - T40061- .
– Tighten bolts for camshaft chain sprocket to final torque.
– Repeat procedure on other cylinder bank if necessary.
note the following:
– Install timing chain covers (top) ⇒ page 220 .
Tightening torques
♦ Plug for “TDC” marking ⇒ Item 17 (page 321)
2.4 Removing and installing camshaft timing chain


equipment required
© satelettronica
♦ Locking pin - 3242-
♦ Key - T40049-
♦ Adjustment pin - T40060- (2x)
♦ Locking pin - T40316- (not illustrated)
2. Chain drive 241

♦ Nuts M12 (2x)

Removing
Caution

♦ The crankshaft and camshafts must only be turned with
the chain drive mechanism fully installed.
Caution

fied length.
© satelettronica
not exceed 22 mm.
– Secure special wrench - T40049- onto rear of crankshaft

-arrows-.
Caution

slips.
Note
♦ The adjustment pin - T40060- has a flat -2- which makes it

easier to insert when the locating bores in the camshaft and
cylinder head are not exactly in line.
♦ The adjustment pin is inserted initially so that the side pin -1-
is perpendicular to the imaginary line between the adjustment
pin and the centre of the camshaft.
♦ To obtain the correct “TDC” position, the side pin -1- must then
be turned 90° -arrow- so it is in line with the imaginary line
between the adjustment pin and the centre of the camshaft.

– Rotate crankshaft to “TDC”:

pins - T40060- .

© satelettronica
– Unscrew plug -arrow- from sump (top section).
– Screw locking pin - 3242- into hole (20 Nm); if necessary, turn
crankshaft -1- backwards and forwards slightly to fully cen‐
tralise locking pin.
2. Chain drive 243

– Press tensioning rail of camshaft timing chain tensioner in di‐

rection of -arrow- and lock chain tensioner by inserting locking
pin - T40316- -item 1-.
– Remove guide pin -2- and detach tensioning rail.
Caution

♦ Mark running direction of timing chain with coloured ar‐
rows for re-installation.
– Remove bolt -arrow- for chain slip preventer.
© satelettronica

– Remove camshaft sprockets and camshaft timing chain.

Installing
3242- .
Note
♦ Renew the seal on the screw plug for the “TDC” mark.

at “TDC”.
pins - T40060- .
© satelettronica
Caution

the camshafts are to be turned.
Note
If the pins cannot be inserted in the camshafts, the camshafts can

be turned slightly using adapter - T40061- . To do so, screw se‐
curing bolts for camshaft sprocket into camshaft.
2. Chain drive 245

– Fit camshaft sprocket (left-side) with camshaft timing chain.

– Use adjustment pin - T40060- to lock camshaft (left-side).
– Fit camshaft sprocket (right-side) with camshaft timing chain.

– Use adjustment pin - T40060- to lock camshaft (right-side).
© satelettronica
– Secure tensioning rail with guide pin -2-.

– Pull locking pin -T40316- -1- out of locating hole; this releases
chain tensioner.
– Screw in bolt -arrow- for chain slip preventer.

– Loosen bolts -2-.

– Lock balance shaft -3- with diesel injection pump locking pin -
3359- , as shown in illustration.
Note
If necessary, remove bolts and bring balance shaft into position.
– Loosely screw in bolts -2-.

• It should just be possible to turn the sprocket -1- on the balance
– With the help of a second mechanic, apply a torque of 20 Nm

to camshaft chain sprocket (right-side) in clockwise direction
-arrow- using a torque wrench and adapter - T40062- and
maintain this torque.
– Tighten bolts -1- and -2- for camshaft chain sprocket (right-
side).
© satelettronica
– Tighten bolts -1- for camshaft chain sprocket (left-side); while
doing so, second mechanic must keep maintaining torque.
– Tighten bolts -2- at chain sprocket -1- for balance shaft -3-.
– Remove diesel injection pump locking pin - 3359- , adapter -
T40062- and adjustment pins -T40060- .
– Tighten remaining bolts for camshaft chain sprockets (both
sides).
2. Chain drive 247

Checking valve timing
Caution

slips.
© satelettronica
– Turn crankshaft two rotations until it is again positioned just
before “TDC”.
– While turning in this direction, lock crankshaft -1- with locking

pin - 3242- . Tighten locking pin to 20 Nm.
Caution
The crankshaft must be exactly in “TDC” position to ensure

accurate valve timing adjustment.
♦ If crankshaft has been turned past “TDC” position, turn
crankshaft two further rotations until it is again positioned
just before “TDC”. Then turn further in the same direction
and lock crankshaft with locking pin - 3242- .

at “TDC”.
pins - T40060- .


Adjusting valve timing

– If the pin cannot be inserted in one of the camshafts, loosen
all bolts -arrows- of relevant camshaft chain sprocket approx.
1 turn.
© satelettronica
– Apply adapter - T40061- to the heads of the loosened bolts.
– Turn camshaft slightly backwards and forwards with adapter -
T40061- until adjustment pin - T40060- can be inserted.

– With adapter - T40061- and adjustment pin - T40060- still in
position, tighten bolts on camshaft sprocket to approx. 5 Nm.
– Remove adjustment pin - T40060- and adapter - T40061- .
– Tighten bolts for camshaft chain sprocket to final torque.
– Repeat procedure on other cylinder bank if necessary.
note the following:
Tightening torques
♦ Plug for “TDC” marking ⇒ Item 17 (page 321)
2. Chain drive 249


oil pump and high-pressure pump
♦ Locking pin -T40316-

Removing
© satelettronica
– Remove camshaft timing chain ⇒ page 240 .
– Remove both guide rails (top) for camshaft timing chain.
– Press tensioning rail of chain tensioner in direction of -arrow-
and lock chain tensioner by inserting locking pin -T40316-
-item 2-.
– Unscrew bolt -1- and remove tensioning rail.

– Remove bolts -1, 2, 3- and take off chain tensioner for drive
chain for oil pump and high-pressure pump.
– Detach drive chain for oil pump and high-pressure pump.
Installing
© satelettronica
3242- .
– Lock chain sprocket for high-pressure pump in position using

Note
The illustration shows the chain sprocket with the timing chain
cover (bottom) installed.
– Install camshaft timing chain ⇒ page 240 .

– Remove locking pin - T40245- for chain sprocket for high-
pressure pump.
Tightening torques
♦ ⇒ “2.2 Exploded view - drive chain for oil pump and high-pres‐
sure pump”, page 231
2. Chain drive 251

3 Cylinder head
Note

❑ Renewing:
© satelettronica
♦ Vehicles with one turbo‐
charger ⇒ page 257
♦ Vehicles with two turbo‐
chargers ⇒ page 259
❑ Identification
⇒ page 254
cylinder head
2 - Cylinder head
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal.
❑ Removing:
♦ Vehicles with one turbo‐
charger ⇒ page 257
♦ Vehicles with two turbo‐
chargers ⇒ page 259
⇒ page 253
❑ Cylinder heads must not
be reworked on TDI en‐
gines
3 - Bolt
❑ 23 Nm

4 - Bracket
6 - Bolt
❑ 23 Nm
7 - Seals
❑ Renew
8 - Banjo bolt
9 - Coolant lines
10 - Bolt
11 - Banjo bolt
12 - Seals
❑ Renew
13 - Bolt
© satelettronica
❑ 23 Nm
15 - Bolt
❑ Renew

• Max. permissible distortion: 0.1 mm.
Note
Cylinder heads must not be reworked on TDI engines.


1- Part number
2- Holes
Note
♦ Cylinder head gaskets of different thicknesses are fitted de‐

pending on the amount of piston projection ⇒ page 210 . When
renewing only the cylinder head gasket, the new gasket should
have the same identification as the old one.
♦ The gaskets for the left and right cylinder heads have different
© satelettronica
Identification based on lettering on bolt head
A - Bolt head with lettering
B - Bolt head without lettering
Note
Tightening torque/angle specification for bolts -A-:

2. -1 … 8- 35 Nm
3. -1 … 8- 50 Nm

Tightening torque/angle specification for bolts -B-:

2. -1 … 8- 35 Nm
3. -1 … 8- 60 Nm
Note
The illustration shows the cylinder head cover for cylinder bank 2 (left-side).
© satelettronica
1 - Gasket
leaking
⇒ page 257
3 - Grommet
leaking
4 - Seal
❑ For injector
5 - Grommet
6 - Seal
❑ For sealing cap
leaking
7 - Filler cap
8 - Hose
9 - O-ring
10 - Clamping piece
stalling injectors”,
page 533
11 - Sealing bush
❑ For fuel rail
12 - Fuel rail
❑ Do not attempt to bend high-pressure pipes to a different shape

❑ Installing high-pressure pipes ⇒ page 539

13 - Bolt
14 - Bolt
16 - O-ring
❑ Renew
17 - Injector
18 - O-ring
❑ Renew
19 - Copper seal
❑ Renew
© satelettronica
20 - Bolt
❑ 9 Nm
21 - Heat shield
❑ Not installed on all versions
22 - Bolt
❑ With seal
❑ Renew
❑ Tightening torque and tightening sequence: left-side ⇒ page 256 ; right-side ⇒ page 257
Note

2. -1 … 7- 8 Nm

Note

2. -1 … 7- 8 Nm

⇒ “3.3.1 Removing cylinder head - vehicles with one turbocharg‐
er”, page 257
⇒ “3.3.2 Removing cylinder head - vehicles with two turbocharg‐
ers”, page 259
© satelettronica
⇒ “3.3.3 Installing cylinder head, all engines”, page 264

one turbocharger
Removing
– Remove corresponding camshafts ⇒ page 285 .


Note
Disregard -item 2-.
Note
Disregard -item 2-.
© satelettronica
– Unscrew union nut -left arrow- and detach high-pressure pipe
-1-.
Note
Disregard -arrow- on right-side of illustration.

hoses.
Note
Disregard -arrows-.

– Unscrew union nut -right arrow- and detach high-pressure

pipe -1-.
Note
Ignore -arrow on left side of illustration-.
– Remove banjo bolt -arrow-.
© satelettronica
– Remove guide pin -1- for guide rail and -2- for tensioning rail.
Note
Ignore -T40246- .

– Remove bolts and carefully take off cylinder head.
Caution

head.

two turbochargers

Removing
– Remove corresponding camshafts ⇒ page 285 .
© satelettronica
– Remove cover (left-side) -1- for drive shaft in wheel housing.
– Unscrew union nut -left arrow- and detach high-pressure pipe

-1-.
Note
Disregard -arrow- on right-side of illustration.

Note
Disregard -item 2-.
– Remove bolts -3, 4- and union nut -2-.

– Disconnect coolant line from cylinder block and push slightly
towards front.
Note
Disregard -item 1-.
© satelettronica
– Open clip -arrow- and detach.

– Unscrew union nut -right arrow- and detach high-pressure
pipe -1-.
Note
Ignore -arrow on left side of illustration-.

– Unscrew bolt -2- and detach intermediate pipe from air pipe
(right-side).
Note
Disregard -item 1-.
© satelettronica
– Remove nut -1- and detach bracket -2- for air pipe (right-side).
– Detach air pipe (right-side) towards rear.
– Remove banjo bolt -arrow-.

– Remove guide pin -1- for guide rail and -2- for tensioning rail.
Note
Ignore -T40246- .

– Remove bolts and carefully take off cylinder head.
Caution
© satelettronica
head.

3.3.3 Installing cylinder head, all engines

Procedure
Caution

cylinder block.
surfaces.
Risk of leaks at cylinder head gasket.
terial.
© satelettronica
gasket.
valve gear.
erated.
Note

♦ Cylinder heads must not be reworked on TDI engines.
faces between roller rocker fingers and cams must be oiled
before installing the cylinder head cover.
change the engine oil and the coolant in the entire cooling
system.

– Note cylinder head gasket identification:

1- Part number
2- Holes
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 210 .
♦ The gaskets for the left and right cylinder heads have different
© satelettronica


inder head.
– Tighten cylinder head bolts ⇒ page 254 .
Note

after repair work.

note the following:
– Install high-pressure pipes ⇒ page 539 .
© satelettronica
– Install camshafts:
♦ ⇒ “4.4.1 Removing camshafts and re-installing used cam‐
shafts - cylinder bank 1 (right-side)”, page 285
shafts - cylinder bank 2 (left-side)”, page 298
– Install intake manifold ⇒ page 513 .
Tightening torques
♦ Cylinder head - tightening torque and sequence ⇒ page 254
♦ ⇒ “2.1.2 Exploded view - charge air system, vehicles with two
turbochargers”, page 465
tem”, page 466
page 657


cover
⇒ “3.4.1 Removing and installing cylinder head cover (left-side) -
vehicles with one turbocharger”, page 267
⇒ “3.4.2 Removing and installing cylinder head cover (right-side)
- vehicles with one turbocharger”, page 269
⇒ “3.4.3 Removing and installing cylinder head cover (left-side) -
vehicles with two turbochargers”, page 272
⇒ “3.4.4 Removing and installing cylinder head cover (right-side)
- vehicles with two turbochargers”, page 275

cover (left-side) - vehicles with one tur‐
bocharger
© satelettronica
Removing
– Remove injectors (left-side) ⇒ page 533 .
– Remove fuel rail (left-side) ⇒ page 541 .
– Remove refrigerant line with internal heat exchanger ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Remov‐
ing and installing refrigerant lines with internal heat exchang‐
er .
– Remove intake manifold flap motor - V157- ⇒ page 518 .
– If fitted, detach electrical connector -1- for exhaust gas tem‐
perature sender 3 - G495- -item 2- from bracket and unplug
connector.
Note
Disregard -item 3-.

– Remove bolts -1- and detach bracket for intake manifold.
Note
Disregard -item 2-.
– If fitted, unscrew bolt -1- for heat shield.
Note
Disregard -item 2-.
– Using removal lever - 80 - 200- , move clear electrical wiring

harness at cylinder head cover.
© satelettronica
Caution
Depending on the vehicle version and country version, a crank‐

case breather hose may be fitted which cannot be detached
from the cylinder head cover without being damaged irrepara‐
bly. For these versions, the hose on the cylinder head cover
will be damaged irreparably and must then be renewed.
– Remove crankcase breather hose -arrow-; to do so, press re‐

lease tabs (if present) or break hose connection at cylinder
head cover as necessary.
– Remove bolts and take off cylinder head cover.
Installing
Note

♦ Renew crankcase breather hose if it was damaged irreparably
during removal.

Note

2 mm).
– Apply sealant bead -arrows- at each joint between cylinder

head and timing chain cover (top).
• Width of sealant beads: approx. 2 mm.
– Install intake manifold flap motor - V157- ⇒ page 518 .
© satelettronica
Tightening torques

cover (right-side) - vehicles with one tur‐
bocharger

Removing
– Remove injectors (right-side) ⇒ page 533 .
– Remove fuel rail (right-side) ⇒ page 541 .

– Unplug electrical connector -3- at Hall sender - G40- -item 2-

and move clear wiring harness at cylinder head cover using
removal lever - 80 - 200- .
Note
Disregard -item 1-.
– Take electrical connector -3- and pressure differential sender

- G505- -item 2- out of bracket.
Note
Disregard -item 1-.
© satelettronica
Caution

bly. For these versions, only detach the crankcase breather
hose at the connection piece for the air intake hose.
– Press release tabs and remove crankcase breather hose -1-.
Note
If the crankcase breather hose cannot be detached from the cyl‐

inder head cover without being damaged irreparably, detach it
from the connection for the turbocharger only.
– Unscrew bolts -arrows- and detach connection from turbo‐

charger.

Caution


Installing
Note
© satelettronica
♦ Renew crankcase breather hose if it was damaged irreparably
during removal.
Note

2 mm).

– Install fuel rail (right-side) ⇒ page 541 .
Tightening torques


cover (left-side) - vehicles with two tur‐
bochargers

Removing
© satelettronica
– Remove injectors (left-side) ⇒ page 533 .
– Remove refrigerant line with internal heat exchanger ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Remov‐
ing and installing refrigerant lines with internal heat exchang‐
er .
Note
Disregard -item 2-.
– Remove exhaust gas temperature sender 3 - G495- -item 1-

and pressure pipe -3- for pressure differential sender - G505- .
Note
Disregard -item 2-.


– If fitted, unscrew and detach exhaust gas temperature sender
2 - G448- -item 3-.
Note
Disregard -item 2-.
– Unscrew nuts -arrows- and press catalytic converter towards

rear.
© satelettronica
– Remove bolts -arrows- and push vacuum line to the side.
Note
Disregard -item 1-.

Note
Disregard -item 2-.
– Remove bolts -1- and detach bracket for intake manifold.
Note
Disregard -item 2-.
– Using removal lever - 80 - 200- , move clear electrical wiring

harness at cylinder head cover.
© satelettronica
Note
Disregard -item 2-.
– Unplug electrical connector -1- and move wiring harness clear.

– Remove bolts -2- and move turbine changeover valve - N529-
clear to one side.

– Press release tabs and disconnect crankcase breather hose

-arrow-.
Installing
Note

Note
© satelettronica
2 mm).

Tightening torques

cover (right-side) - vehicles with two tur‐
bochargers


Removing
– Remove injectors (right-side) ⇒ page 533 .
– Remove fuel rail (right-side) ⇒ page 541 .
– Unplug electrical connector -3- at Hall sender - G40- -item 2-
© satelettronica
and move clear wiring harness at cylinder head cover using
removal lever - 80 - 200- .
Note
Disregard -item 1-.
Caution

bly. For these versions, only detach the crankcase breather
hose at the connection piece for the air intake hose.
– Move vacuum lines clear.

– Remove bolts -arrows- and detach connection for turbocharg‐
er.


-arrow-.
Installing
Note

Note
© satelettronica

2 mm).

– Install fuel rail (right-side) ⇒ page 541 .
Tightening torques

tors

♦ Socket, 24 mm - T10361 A-
© satelettronica
♦ Oil seal extractor - T40195-
Procedure
– Remove corresponding injector ⇒ page 533 .
– 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-.

♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/8-
© satelettronica
Procedure
– Unplug electrical connectors on all glow plugs.
valve - N276- on fuel rail (cylinder bank 1, right-side).
– Briefly start engine to relieve fuel pressure in fuel rail.

– Screw in adapter - V.A.G 1763/8- in place of the glow plugs

and connect compression tester - V.A.G 1763- .
Note
– Have a second mechanic operate starter until tester shows no

further pressure increase.
Compression pressure Vehicles with 1 turbo‐ Vehicles with 2 turbo‐

charger chargers
bar
When new 28 … 33 26 … 31
Wear limit 21 20
Maximum difference between cylinders 5 5
© satelettronica
Attaching
– Entries 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.

4 Valve gear
Note
1 - Valve
❑ Do not machine, only
grinding-in is permitted
© satelettronica
⇒ page 317
⇒ page 315
2 - Cylinder head
⇒ page 315
❑ Machining valve seats
⇒ page 315
4 - Valve spring
6 - Valve cotters
ement
finger -item 9-
❑ Lubricate contact surfa‐
ces before installing
8 - Securing clip
❑ Check for firm attach‐
ment
4. Valve gear 281

10 - Inlet camshaft
♦ Cylinder bank 1 (right-side) ⇒ page 285 , ⇒ page 291
♦ Cylinder bank 2 (left-side) ⇒ page 298 , ⇒ page 303
11 - Bearing cap
♦ Cylinder bank 1 (right-side) ⇒ page 285
♦ Cylinder bank 2 (left-side) ⇒ page 298
12 - Support bracket
❑ For clamping piece
© satelettronica
13 - Bolt
❑ Tightening torque and tightening sequence: cylinder bank 1 (right-side) ⇒ page 282 , cylinder bank 2
(left-side) ⇒ page 283
♦ Cylinder bank 1 (right-side) ⇒ page 285 , ⇒ page 291
♦ Cylinder bank 2 (left-side) ⇒ page 298 , ⇒ page 303
15 - Bearing pedestal
♦ Cylinder bank 1 (right-side) ⇒ page 285
♦ Cylinder bank 2 (left-side) ⇒ page 298
16 - Spring pins
❑ Only for bearing pedestal (rear) with camshaft axial bearing
Bearing cap, cylinder bank 1 (right-side) - tightening torque and

sequence
2. -1 … 12- 9 Nm

Bearing cap, cylinder bank 2 (left-side) - tightening torque and

sequence
2. -1 … 12- 9 Nm

© satelettronica
Procedure
clean surface.
– Re-install camshafts with outer bearings ⇒ page 283 .
bracket - VW 387- to cylinder head as shown in illustrations.
4. Valve gear 283

Axial clearance (inlet camshaft)

Axial clearance (exhaust camshaft)

© satelettronica
♦ Plastigauge
Procedure
clean surface.
ing.
– Re-insert camshafts with bearing caps and secure with old
bolts without rotating camshafts.
♦ Bearing cap, cylinder bank 1 (right-side) - tightening torque
and sequence ⇒ page 282
♦ Bearing cap, cylinder bank 2 (left-side) - tightening torque and
– Remove camshafts with bearing caps again.
Radial clearance:
• New: 0.037 ... 0.063 mm.


⇒ “4.4.1 Removing camshafts and re-installing used camshafts -
cylinder bank 1 (right-side)”, page 285
⇒ “4.4.2 Removing and renewing camshafts or camshaft bearings
- cylinder bank 1 (right-side)”, page 291
⇒ “4.4.3 Removing camshafts and re-installing used camshafts -
cylinder bank 2 (left-side)”, page 298
⇒ “4.4.4 Removing and renewing camshafts or camshaft bearings
- cylinder bank 2 (left-side)”, page 303
4.4.1 Removing camshafts and re-installing

used camshafts - cylinder bank 1 (right-
side)
♦ Counterhold tool - T10172A- with adapters -T10172/5-
© satelettronica
♦ Adjustment pin - T40060-
4. Valve gear 285

♦ Setting tool - T40311-
Removing
– Remove timing chain from inlet camshaft ⇒ page 232 .
3242- .
© satelettronica
– Check “TDC” position of camshafts:
• It should be possible to lock the inlet camshaft -1- with the
adjustment pin - T40060- .
• Exhaust camshaft -2- must be set so that groove -arrow B- is
parallel above joint -arrow A- between bearing pedestal and
bearing cap.
– Place camshaft fitting tool - T40096- on teeth of inlet camshaft

so that the two arms of the tool engage on the two halves of
the gear (one in each half, as shown in illustration).

– Wrap one cable tie -arrows- on each side around bearing ped‐
estal and bearing cap and secure.
Note
With the cable ties it is possible to detach the camshafts together

with the camshaft bearings. This prevents components from be‐
ing interchanged.
– Pull off adjustment pin - T40060- .
© satelettronica
– Screw two bolts for camshaft chain sprocket five turns into
threaded holes in camshaft, as shown in illustration.
– Fit counterhold tool - T10172A- with adapters -T10172/5- on

both bolts and turn camshafts approx. 30° in anti-clockwise
direction -arrow- until groove -arrow A- in camshaft points ver‐
tically to sealing surface -arrows B- of cylinder head.
Caution
Risk of damage to valves.

♦ Do not turn camshafts any further than specified.
4. Valve gear 287

– Loosen bearing cap bolts in the sequence -12 ... 1-.
Note
Make sure you do not damage the roller rocker fingers and hy‐
draulic compensation elements when removing the camshafts.
– Carefully detach bearing caps together with camshafts.
Caution
Do NOT interchange components!

♦ Do not release cable ties until after re-installation.
Installing
• Crankshaft locked in “TDC” position with locking pin - 3242- .
© satelettronica
– Fit camshafts and camshaft bearings (secured with cable ties

-arrows-) on cylinder head.
Note
The cable ties help to keep the camshafts and camshaft bearings
straight when they are tightened.


• Exhaust camshaft -2- must be set so that groove -arrow A- is
parallel above joint -arrow B- between bearing pedestal and
bearing cap.

© satelettronica
Caution

– Check installation position of dowel sleeves:

• Both dowel sleeves -arrows- must be inserted in holes in bear‐
ing pedestal “IV”.
• Dowel sleeves must engage in holes in cylinder head.
4. Valve gear 289

– Fit bolts -1 … 12- in bearing caps.
– Fit setting tool - T40311- onto support brackets -arrows- for

clamping pieces, as shown in illustration.
© satelettronica
– Tighten bearing cap bolts ⇒ page 283 .
– Detach setting tool - T40311- .

both bolts and turn camshafts approx. 30° in clockwise direc‐
tion -arrow- until groove -arrow A- in camshaft is aligned with
hole -arrow B- for adjustment pin - T40060- .


bearing cap.
note the following:
– Remove camshaft fitting tool - T40096- .
Caution

valve gear.
© satelettronica
erated.
Tightening torques
4.4.2 Removing and renewing camshafts or

camshaft bearings - cylinder bank 1
(right-side)
♦ Counterhold tool - T10172A- with adapters -T10172/5-
4. Valve gear 291

© satelettronica
Removing
3242- .


bearing cap.

© satelettronica

Caution

4. Valve gear 293

Note
– Carefully detach bearing caps and camshafts.
Installing
© satelettronica
To prevent installation at the wrong locations, the camshaft bear‐

ing pedestals and bearing caps for cylinder bank 1 are marked at
the factory on the exhaust side:
Cylinder bank 1 (right-side)
R1/R1 Front
R2/R2 Front centre
R3/R3 Rear centre
R4/R4 Rear
– Fit camshaft bearing pedestals “I, II and III” on cylinder head.

• The oil drillings -arrow 1- in the cylinder head must be in line
with the oil passages -arrow 2- in the bearing pedestals.

– Fit camshaft bearing pedestal “IV” on cylinder head.

ing pedestal.
– Check that bearing pedestals are positioned correctly:

• The round side -arrow 2- faces the inlet side.
• The square side -arrow 1- faces the exhaust side.
© satelettronica
– Insert camshafts in bearing pedestals in “TDC” position.
bearing cap.
– Fit matching bearing caps on bearing pedestals.
Note
4. Valve gear 295



Caution
© satelettronica



– Detach setting tool - T40311- .

both bolts and turn camshafts approx. 30° in clockwise direc‐
tion -arrow- until groove -arrow A- in camshaft is aligned with
hole -arrow B- for adjustment pin - T40060- .
© satelettronica
4. Valve gear 297


bearing cap.
note the following:
Caution

valve gear.
© satelettronica
erated.
Tightening torques
4.4.3 Removing camshafts and re-installing

used camshafts - cylinder bank 2 (left-
side)

© satelettronica
Removing
3242- .

bearing cap.
4. Valve gear 299


Note
With the cable ties it is possible to detach the camshafts together

with the camshaft bearings. This prevents components from be‐
ing interchanged.
© satelettronica
Note
– Carefully detach bearing caps together with camshafts.
Caution
Do NOT interchange components!

♦ Do not release cable ties until after re-installation.

Installing
– Fit camshafts and camshaft bearings (secured with cable ties

-arrows-) on cylinder head.
Note
© satelettronica
bearing cap.
– Check installation position of dowel sleeves:

ing pedestal “IV”.
4. Valve gear 301

– Screw locating pin -T40311/1- into threaded hole -1- in line

with cylinder 5, as shown in illustration.
– Fit setting tool - T40311- onto support brackets for clamping
pieces -arrows-, as shown in illustration.
© satelettronica
– Detach setting tool - T40311- and unscrew locating pin -
T40311/1- .


bearing cap.
note the following:
Caution

valve gear.
© satelettronica
erated.
Tightening torques
4.4.4 Removing and renewing camshafts or

camshaft bearings - cylinder bank 2
(left-side)
4. Valve gear 303

© satelettronica
Removing
3242- .

bearing cap.


Note
– Carefully detach bearing caps and camshafts.
© satelettronica
Installing
To prevent installation at the wrong locations, the camshaft bear‐

ing pedestals and bearing caps for cylinder bank 2 are marked at
the factory on the exhaust side:
Cylinder bank 2 (left-side)
L1/L1 Front
L2/L2 Front centre
L3/L3 Rear centre
L4/L4 Rear
4. Valve gear 305

– Fit camshaft bearing pedestals “I, II and III” on cylinder head.

• The oil drillings -arrow 1- in the cylinder head must be in line
with the oil passages -arrow 2- in the bearing pedestals.
– Fit camshaft bearing pedestal “IV” on cylinder head.

ing pedestal.
© satelettronica
– Check that bearing pedestals are positioned correctly:
• The round side -arrow 2- faces the inlet side.
• The square side -arrow 1- faces the exhaust side.
– Insert camshafts in bearing pedestals in “TDC” position.

bearing cap.
– Fit matching bearing caps on bearing pedestals.

Note
© satelettronica
– Screw locating pin -T40311/1- into threaded hole -1- in line
with cylinder 5, as shown in illustration.
4. Valve gear 307


– Detach setting tool - T40311- and unscrew locating pin -
T40311/1- .

© satelettronica
bearing cap.
note the following:
Caution

valve gear.
erated.
Tightening torques

seals
4.5.1 Removing and installing valve stem oil

seals (cylinder head installed)

© satelettronica
A- with drift -VAS 5161/3 A- , assembly cartridge -VAS 5161/8
A- , guide plate -VAS 5161/29- and sealing pin -VAS
5161/29-1-
Procedure
– Remove camshafts:
4. Valve gear 309

– Fit guide plate -VAS 5161/29- onto cylinder head.

– Insert drift -VAS 5161/3 A- into guide plate and use plastic-
– Screw sealing pin -VAS 5161/29-1- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into corresponding
glow plug thread.
© satelettronica
– Insert assembly cartridge -VAS 5161/8 A- in hole above valve
spring that is to be removed.

If the puller cannot be used on some of the valve stem oil seals
due to the confined space, proceed as follows:

lustration.
-arrow-.
© satelettronica
Caution
ling.


4. Valve gear 311

– Insert assembly cartridge in guide plate -VAS 5161/29- again.

cotters.
tion.
Attaching
– Install camshafts:
© satelettronica
equipment required


A- with drift -VAS 5161/3 A- , assembly cartridge -VAS 5161/8
A- and guide plate -VAS 5161/29-
Procedure
• Exhaust manifold removed ⇒ page 666 .
supply.
© satelettronica
with valve heads.
– Mark fitting location of roller rocker fingers for re-installation
and remove.
– Fit guide plate -VAS 5161/29- onto cylinder head.

– Insert drift -VAS 5161/3 A- into guide plate and use plastic-

– Insert assembly cartridge -VAS 5161/8 A- in hole above valve
spring that is to be removed.
4. Valve gear 313

Caution
ling.
© satelettronica

– Insert assembly cartridge in guide plate -VAS 5161/29- again.

cotters.
tion.
Attaching
Assemble in reverse order.


⇒ “5.1 Machining valve seats”, page 315
5.1 Machining valve seats
Note
Valve seats may not be machined due to the very small toleran‐
ces.

© satelettronica

Procedure
Note


new valves.
Note
© satelettronica
5.3 Checking valves

faces.

Note

is permitted.

∅a mm 28.5 … 28.7 25.9 … 26.1
∅b mm 5.968 … 5.982 5.958 … 5.972
c mm 97.2 … 97.4 99.0 … 99.2
α ∠° 45° 10' 45° 10'
WARNING
Care must be taken when disposing of old sodium-cooled ex‐

haust valves - risk of injury.
© satelettronica
valves must not come into contact with water.
♦ Then throw a maximum of ten valves into a bucket of water
and step away immediately.
♦ A sudden chemical reaction will occur upon contact with
water in which the sodium filling burns.

17 – Lubrication
1 Sump/oil pump
page 322
er G266 ”, page 330
Note
© satelettronica
♦ If large quantities of metal shavings or particles are found in the engine oil when repairing the engine, the
oil passages must be cleaned carefully, and the engine oil cooler must be renewed in order to prevent further
damage occurring later.
♦ The oil level must not be above max. mark on dipstick – danger of damage to catalytic converter.
♦ Oil spray jet for piston cooling ⇒ page 208 .
Sump/oil pump


sender - G266-
⇒ page 330
2 - Seal
❑ Renew
3 - Bolt
❑ Renew
⇒ page 322
5 - Bolt
❑ Renew
❑ 3 Nm +90°
6 - Baffle plate
7 - Bolt
© satelettronica
❑ Aluminium or steel
bolts, depending on ver‐
sion
❑ Renew aluminium bolts
❑ Aluminium bolts: 3 Nm +
90°
❑ Steel bolts: 9 Nm
8 - Suction pipe
9 - Bolt
❑ 9 Nm
10 - O-ring
❑ Renew
11 - Bolt
❑ Renew
12 - Oil pump
❑ With vacuum pump for brake servo
13 - O-ring
❑ Renew
14 - Dowel sleeves
❑ 2x
15 - Drive shaft
❑ For oil pump
17 - Coupling
18 - Chain sprocket
❑ For oil pump
❑ Installation position: Side with lettering faces engine

19 - Bolt
❑ To loosen, use pin wrench - 3212- to counterhold chain sprocket
❑ Renew
❑ 30 Nm +45°
❑ If bolt cannot be tightened to torque, remove sump (bottom section) with baffle plate and counterhold oil
pump drive shaft using an open-end spanner.
20 - Bolt
❑ Aluminium or steel bolts, depending on version
❑ Aluminium bolts: 3 Nm + 90°
21 - Oil return pipe
22 - Seal
❑ Renew
23 - Oil drain plug
❑ 30 Nm
24 - Bolt
© satelettronica
❑ 9 Nm
Note

1. -1 … 15- 2 Nm
2. -1 … 15- 3 Nm
3. -1 … 15- Turn 45° further
Oil pump with vacuum pump - tightening torque and sequence
Note

2. -1 … 3- 8 Nm
Sump (top section)

1 - Bolt
❑ 9 Nm
trol - N428-
⇒ page 339
3 - O-ring
❑ Renew
⇒ page 324
5 - Seal
❑ Renew
6 - Dowel sleeve
7 - Guide tube
8 - Bolts
© satelettronica
❑ 9 Nm
9 - O-rings
❑ Renew
10 - Sealing plug
11 - Seal
❑ Renew
12 - Oil return valve
13 - Seal
❑ Renew
14 - Dowel sleeve
15 - Bolt
16 - Seal
❑ Renew
17 - Plug
❑ For “TDC” marking
❑ 25 Nm
18 - Vacuum line
❑ From vacuum pump
19 - Bolt
❑ Renew
❑ 3 Nm +45°
20 - O-ring
❑ Renew
21 - Bolt
❑ 9 Nm

Note

1. -1 … 12- 2 Nm
2. -1 … 12- 5 Nm
3. -1 … 12- Turn 90° further
1.2 Engine oil
© satelettronica
nance tables .
Caution

dipstick.

section)
♦ Safety goggles

Removing
– Unplug electrical connector -arrow- at oil level and oil temper‐
ature sender - G266- .
Caution

♦ There will still be some oil in the sump (bottom section).

– Carefully release sump (bottom section) from bonded joint and
detach.
Installing
Caution
© satelettronica
tion.
WARNING
Risk of eye injury.

– Remove remaining sealant on bottom and top sections of

sump with a rotating plastic brush or similar.
Note
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 3

mm).

Caution

– Apply sealant bead -arrow- onto clean sealing surface of sump

(bottom section) as shown in illustration.
Note

– Fit sump (bottom section) and tighten bolts ⇒ page 320 .

411 .
© satelettronica
Tightening torques

tion)
♦ Key - T40049-

♦ Counterhold tool - T10172A-
© satelettronica
♦ Safety goggles
Removing
• Engine removed and secured to engine and gearbox support
⇒ page 144
– Remove oil pump ⇒ page 329 .
– Unplug electrical connector -1- at valve for oil pressure control
- N428- .
Note
Disregard -item 2-.

– Remove bolt -item 2- and disconnect vacuum hose -item 1-.
Caution

fied length.
© satelettronica
not exceed 22 mm.
– Secure special wrench - T40049- onto rear of crankshaft

-arrows-.
Caution

slips.
– Turn crankshaft in direction of engine rotation until high-pres‐

sure pump sprocket can be locked in position with locking pin
- T40245- , as shown in illustration.

– Press tensioning rail of chain tensioner in direction of -arrow-

and lock chain tensioner by inserting locking pin -T40316-
-item 2-.
– Using counterhold tool - T10172A- , release and remove bolt

-1-.
© satelettronica
– Pull off drive chain with chain sprocket (leave in installation
position).

– Carefully release sump (top section) from bonded joint, pry
sump off dowel sleeves and detach.
Installing
Note
Renew gaskets, seals and O-rings.
Caution


WARNING
Risk of eye injury.

– Remove remaining sealant from sump (top section) and cyl‐

inder block using rotating plastic brush or similar.
Note

mm).
© satelettronica
– Fit seals -1 and 2- in sump (top section).
Caution

– Apply beads of sealant -arrows- onto clean sealing surface of

with sealant.
• The beads of sealant must project 3.5 mm above the sealing
surface.
Note

– Fit sump (top section) and tighten bolts ⇒ page 322 .

note the following:
– Install oil pump ⇒ page 329 .

Note
The oil pump is removed and installed together with the vacuum
pump.
Removing
– Remove sump (bottom section) ⇒ page 322 .
– Remove bolts -arrows- and detach baffle plate.
© satelettronica
– Remove bolts -arrows- and detach oil return pipe -1-.


– Press oil pump drive shaft back against spring pressure and
detach oil pump.
Note
Oil pump drive shaft remains in position.
Installing
– Check that the two dowel sleeves are fitted in the oil pump.
Install missing dowel sleeves.
– Install sump (bottom section) ⇒ page 322 .
411 .
Tightening torques
© satelettronica
Removing
– Remove bolts -1- and detach oil level and oil temperature
Installing
Note
Renew seal -2-.
411 .
Tightening torques

2 Engine oil cooler

⇒ “2.1 Exploded view - engine oil cooler”, page 331
⇒ “2.3 Removing and installing mounting plate for engine oil cool‐
er/coolant shut-off valve”, page 333
⇒ “2.4 Removing and installing temperature regulator for engine
oil cooler”, page 333
2.1 Exploded view - engine oil cooler

Engine oil cooler, coolant shut-off valve
1 - Gaskets
❑ For mounting plate
2 - Mounting plate
3 - Bolt
© satelettronica
❑ 9 Nm
4 - Gasket
❑ Renew
5 - Bolt
❑ 9 Nm
⇒ page 332
⇒ page 375
8 - Bolt
9 - Gasket
❑ For shut-off valve
❑ Renew
Temperature regulator for engine oil cooler

1 - Cover
❑ For temperature regula‐
tor for engine oil cooler
installing sealing flange
2 - Bolt
❑ Renew
3 - O-ring
❑ Renew
4 - Temperature regulator for
engine oil cooler
⇒ page 333
5 - Sealing flange
❑ Pulley end
© satelettronica
⇒ page 189

er

Removing
– Open hose clip -1- and disconnect coolant hose from engine
oil cooler.
– Detach engine oil cooler.
Installing
Note
♦ Renew seal.

– Check engine oil level.
© satelettronica
Tightening torques
♦ ⇒ “2.1 Exploded view - engine oil cooler”, page 331
2.3 Removing and installing mounting plate

for engine oil cooler/coolant shut-off
valve
Removing
– Remove engine oil cooler ⇒ page 332 .
– Move coolant shut-off valve -1- to one side and detach mount‐
ing plate for engine oil cooler and shut-off valve.
Installing
Note
Renew seals and/or gaskets.

Tightening torques

regulator for engine oil cooler

♦ M6 bolt
Removing
– Remove bolts for coolant pump pulley -arrows- (counterhold
© satelettronica
Note
– Remove bolt -arrow- for cover -1-.
– To remove cover -2-, screw M6 bolt -item 1- into thread in

cover and pull out cover by lifting bolt.
– Pull out temperature regulator -4- for engine oil cooler.
Installing
Note
Fit new O-ring -3-.
– Install poly V-belt pulley for coolant pump ⇒ page 367 .

Tightening torques


⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”, page
335
⇒ “3.2 Removing and installing oil pressure switch F22 / F378 ”,
page 336
”, page 339
⇒ “3.6 Removing and installing oil temperature sender 2 G664 ”,
page 340
3.1 Exploded view - oil filter housing/oil pressure switch
1 - Bolt
❑ 9 Nm
© satelettronica
❑ With map-controlled en‐
gine cooling system
thermostat - F265-
⇒ page 338
3 - Seal
❑ Permanently attached
to oil pressure switch;
not available as a re‐
placement part
sure 2.0 ... 2.5 bar
❑ Green insulation
agnostic tester
⇒ page 336
❑ 20 Nm
5 - Seal
placement part
sure 0.75 ... 1.05 bar
❑ Grey insulation
❑ Check in Guided Fault Finding ⇒ Vehicle diagnostic tester
❑ 20 Nm

7 - Sealing cap
❑ With oil filter bypass valve
❑ 35 Nm
8 - O-ring
❑ Renew

switch -F22- / -F378-
© satelettronica
Removing
Oil pressure switch - F22- :
ments .

Note
Disregard -item 1-.
Continuation for both oil pressure switches:

1- For oil pressure switch - F22-
2- For oil pressure switch for reduced oil pressure - F378-
Note
© satelettronica
– Use articulated wrench, 24 mm - T40175- to remove relevant

oil pressure switch.
Installing
ments .
Tightening torques
page 335

♦ Oil pressure tester - V.A.G 1342- with adapter -V.A.G 1342/14-

Procedure
• Oil level OK
– Connect oil pressure tester - V.A.G 1342- with adapter -V.A.G
1342/14- , as shown in illustration.
– Screw oil pressure switch - F22- into hole in -V.A.G 1342- to
seal hole.
– Start engine.
• Oil pressure when starting and then at idling speed: at least
0.8 bar.
If specification is not obtained, switch off engine immediately and
check oil pump drive; renew oil pump if necessary
If specification is obtained, let engine warm up.
• Oil pressure specification at operating temperature and 2000
rpm: at least 1.5 bar.
Attaching
© satelettronica
– Unscrew adapter -V.A.G 1342/14- and install oil pressure
switch - F22- ⇒ page 336 .
Note
The seals on the oil filter housing can only be used once and
cannot be supplied as replacement parts. After removing the oil
filter housing, it must always be renewed.

Removing
– Remove oil pressure switch - F22- and oil pressure switch for
reduced oil pressure - F378- ⇒ page 336 .

– Open hose clips -1 and 2- and disconnect coolant hoses from

oil filter housing.
– Detach oil filter housing and unplug electrical connector -3-.
Installing
Note
♦ Renew oil filter housing.

– Install oil pressure switch - F22- and oil pressure switch for
reduced oil pressure - F378- ⇒ page 336 .
© satelettronica
Tightening torques
page 335

Removing
– Vehicles with two turbochargers: Remove poly V-belt
⇒ page 180 .
noise insulation .

Note
– Unscrew bolt -2- and remove valve for oil pressure control -
N428- .
Installing
Note
Fit new O-ring.

– Vehicles with two turbochargers: Install poly V-belt
⇒ page 180 .
© satelettronica
Tightening torques
3.6 Removing and installing oil temperature

sender 2 - G664-
Removing
ments .

Note
Disregard -item 1-.
Caution
Oil will escape through mounting hole for oil temperature send‐
er.
♦ Lay a cloth under the mounting hole to catch escaping
engine oil or close the mounting hole using a clean plug
© satelettronica
from the engine bung set - VAS 6122- .
– Unscrew bolt -2- and remove oil temperature sender 2 -

G664- .
Installing
Note
Fit new O-ring.

ments .
Tightening torques
page 176

19 – Cooling

⇒ “1.1.1 Connection diagram - coolant hoses, vehicles with one
turbocharger and without auxiliary heater”, page 342
turbocharger and with auxiliary heater”, page 345
turbocharger and water-cooled SCR valve and without auxiliary
heater”, page 347
turbocharger and water-cooled SCR valve and with auxiliary heat‐
© satelettronica
er”, page 349
⇒ “1.1.5 Connection diagram - coolant hoses, vehicles with two
turbochargers, without SCR system and without auxiliary heater”,
page 351
turbochargers, without SCR system and with auxiliary heater”,
page 353
turbochargers, with SCR system and without auxiliary heater”,
page 354
turbochargers, with SCR system and with auxiliary heater”, page
356
1.1.1 Connection diagram - coolant hoses, vehicles with one turbocharger and
Note

♦ Orange = Coolant circuit for cylinder block.

1 - Radiator
3 - Map-controlled engine cool‐
ing system thermostat - F265-
4 - Cylinder block
side)
⇒ page 377
6 - Cylinder head
side)
er - G62-
N82-
© satelettronica
❑ In RHD vehicles: In sup‐
ply line for heat ex‐
changer for heater
Coolant circuit; Remov‐
ing and installing cool‐
ant shut-off valve - N82-
9 - Bleeder screw
unit; Removing and installing heat exchanger
12 - ATF cooler
❑ Removing and installing ⇒ Rep. gr. 34 ; ATF circuit; Removing and installing ATF cooler or ⇒ Rep. gr.
15 - Exhaust gas recirculation cooler
16 - Cylinder head
17 - Filler cap

20 - Cylinder block
24 - Coolant pump
❑ Optional equipment
© satelettronica

with auxiliary heater
Note

1 - Radiator
© satelettronica
4 - Cylinder block
side)
V55-
ry heater; Removing
⇒ page 377
7 - Cylinder head
side)
er - G62-
valve - N279-
view of fitting locations -
coolant circuit
10 - Bleeder screw

13 - ATF cooler
17 - Cylinder head
18 - Filler cap
21 - Cylinder block
© satelettronica
25 - Coolant pump

water-cooled SCR valve and without auxiliary heater
Note

1 - Radiator
© satelettronica
4 - Cylinder block
side)
⇒ page 377
6 - Cylinder head
side)
er - G62-
N82-
changer for heater
11 - Bleeder screw
14 - Injector for reducing agent - N474-
❑ Water-cooled

15 - Thermostat
❑ For ATF coolant circuit
16 - ATF cooler
19 - Cylinder head
20 - Filler cap
23 - Cylinder block
© satelettronica
27 - Coolant pump

water-cooled SCR valve and with auxiliary heater
Note

1 - Radiator
© satelettronica
4 - Cylinder block
side)
V55-
ry heater; Removing
⇒ page 377
7 - Cylinder head
side)
er - G62-
valve - N279-
tioning; Rep. gr. 87 ; Coolant circuit; Overview of fitting locations - coolant circuit
12 - Bleeder screw
❑ Water-cooled

15 - Thermostat
❑ For ATF coolant circuit
16 - ATF cooler
19 - Cylinder head
20 - Filler cap
23 - Cylinder block
© satelettronica
27 - Coolant pump

1.1.5 Connection diagram - coolant hoses, vehicles with two turbochargers, with‐
out SCR system and without auxiliary heater
Note

1 - Radiator
© satelettronica
4 - Cylinder block
side)
⇒ page 377
6 - Cylinder head
side)
er - G62-
N82-
changer for heater
10 - Bleeder screw
tioning; Rep. gr. 87 ; Front air conditioning unit; Removing and installing heat exchanger
13 - Thermostat
❑ For ATF cooler

14 - Turbocharger unit
15 - ATF cooler
❑ Removing and installing ⇒ Rep. gr. 37 ; ATF circuit; Removing and installing ATF cooler
19 - Cylinder head
20 - Filler cap
23 - Cylinder block
© satelettronica
27 - Coolant pump

1.1.6 Connection diagram - coolant hoses, vehicles with two turbochargers, with‐
out SCR system and with auxiliary heater
Note

1 - Radiator
© satelettronica
4 - Cylinder block
side)
V55-
ry heater; Removing
⇒ page 377
7 - Cylinder head
side)
er - G62-
valve - N279-
view of fitting locations - coolant circuit
11 - Bleeder screw


14 - Thermostat
❑ For ATF cooler
16 - ATF cooler
20 - Cylinder head
21 - Filler cap
© satelettronica
24 - Cylinder block
28 - Coolant pump
1.1.7 Connection diagram - coolant hoses,

vehicles with two turbochargers, with
SCR system and without auxiliary heat‐
er
Note


1 - Radiator
4 - Cylinder block
side)
⇒ page 377
6 - Cylinder head
side)
er - G62-
© satelettronica
N82-
changer for heater
10 - Bleeder screw
tioning; Rep. gr. 87 ; Front air conditioning unit; Removing and installing heat exchanger
13 - ATF cooler
19 - Cylinder head
20 - Filler cap

23 - Cylinder block
27 - Coolant pump
1.1.8 Connection diagram - coolant hoses,

vehicles with two turbochargers, with
SCR system and with auxiliary heater
Note
© satelettronica

1 - Radiator
4 - Cylinder block
side)
V55-
ry heater; Removing
© satelettronica
⇒ page 377
7 - Cylinder head
side)
er - G62-
valve - N279-
view of fitting locations - coolant circuit
11 - Bleeder screw
14 - ATF cooler
20 - Cylinder head

21 - Filler cap
24 - Cylinder block
28 - Coolant pump
© satelettronica

equipment required


Procedure
WARNING

© satelettronica
nutes.
inate fault.
Note

engine is cold.

1.4 ... 1.6 bar.
scribed.


equipment required
© satelettronica
Draining
WARNING


WARNING

hot.

noise insulation .
gine.
tor.
© satelettronica
ant pipe (front left) and drain off coolant.
Vehicles with automatic/dual clutch gearbox:

Filling
Caution


Note

© satelettronica
ical climates.
ses.


Procedure
– Connect coolant hose (rear right) with plug-in connector
-arrow- ⇒ page 394 .

– Connect coolant hose to radiator with plug-in connector -2-
⇒ page 394 .
© satelettronica
– Connect coolant hose to coolant pipe (front left) with hose clip
-arrow-.


– Fill reservoir of cooling system charge unit -VAS 6096- with at
least 12 litres of premixed coolant (according to recommended
ratio):
V.A.G 1274/8- .
Note

rection of flow).
© satelettronica
zone.
in the green zone.
sequent filling.
Note
ess.
tained.

– Open valve -A-.
is then filled.


cedure.
chamber cover .
© satelettronica
– Open bleeder screw -arrow- at exhaust gas recirculation cool‐
er until coolant flows out.

hose.
clip.

it engages).
– Start engine.


not lit
speed (= 0)
Until both large coolant Idling • Air conditioning system “OFF”

come warm • Heating at “HI”
2 minutes 2000 rpm • Air conditioning system “OFF”

• Heating at “HI”

insulation .
© satelettronica
• The coolant level must be at the -MAX- marking when the en‐
gine is cold.
• The coolant level can be above the -MAX- marking when the
engine is warm.


⇒ “2.1 Exploded view - coolant pump”, page 367
⇒ “2.2 Exploded view - coolant valve”, page 368
page 369
⇒ “2.5 Removing and installing map-controlled engine cooling
system thermostat F265 ”, page 371
”, page 371
2.1 Exploded view - coolant pump
© satelettronica
1 - Bolt
❑ Aluminium or steel
bolts, depending on ver‐
sion
❑ Tighten in stages and in
diagonal sequence
❑ Aluminium bolts: 3 Nm +
90°
2 - Poly V-belt pulley for cool‐
ant pump
marking “vorne” (front)
faces in direction of trav‐
el
3 - Bolt
❑ 23 Nm
4 - Coolant pump
able; for allocation refer
to ⇒ Electronic parts
catalogue
⇒ page 370
❑ Renew coolant pump if
seal is damaged

2.2 Exploded view - coolant valve
1 - Mounting plate
and coolant shut-off
valve
2 - Gasket
❑ Renew
3 - Bolt
❑ 9 Nm
4 - Coolant hose
⇒ page 375
6 - O-ring
❑ Renew
7 - Bolt
© satelettronica
❑ 9 Nm
8 - Coolant connection
9 - Gasket
❑ Renew


⇒ page 372
2 - Retaining clip
❑ Check that it is securely
seated
3 - O-ring
❑ Renew
4 - O-rings
❑ Renew
er - G62-
⇒ page 371
6 - Bolt
© satelettronica
❑ 9 Nm
7 - O-rings
❑ Renew
8 - Temperature sender for en‐
gine temperature regulation -
G694-
⇒ page 373
9 - Bolt
❑ 9 Nm
Gearbox oil cooling valve - N509- on vehicles with dual clutch

gearbox 0B5 or 8-speed automatic gearbox 0BK - tightening tor‐
que
– Tighten bolts -3- to 20 Nm.

Gearbox oil cooling valve - N509- on vehicles with multitronic

gearbox - tightening torque

© satelettronica
Removing
– Remove bolts for coolant pump pulley -arrows- (counterhold

gine.
– Remove bolts -arrows- and detach coolant pump.
Installing
– Clean sealing surface.
Note

Tightening torques
2.5 Removing and installing map-controlled
© satelettronica
engine cooling system thermostat -
F265-
Note
♦ The map-controlled engine cooling system thermostat - F265-

is integrated in the oil filter housing and cannot be renewed
separately.
♦ The seals on the oil filter housing can only be used once and
cannot be supplied as replacement parts. After removing the
oil filter housing, it must always be renewed.
– Oil filter housing must be removed and installed ⇒ page 338 .

ature sender - G62-
Removing
• Engine cold.


– Unscrew bolt -1- and pull off coolant temperature sender -
G62- .
Installing
Note

♦ To avoid loss of coolant, insert new coolant temperature send‐
er - G62- immediately.

Tightening torques
♦ ⇒ “2.3 Exploded view - coolant temperature senders”,
page 369
© satelettronica
Removing
• Engine cold.
noise insulation .

Note
– Pull off retaining clip -2- and detach radiator outlet coolant
Installing
Note

♦ To avoid loss of coolant, insert new radiator outlet coolant
temperature sender - G83- immediately.
© satelettronica
Tightening torques

tion - G694-
Removing
• Engine cold.

Note
– Unscrew bolt -2- and detach temperature sender for engine

temperature regulation - G694- .
Installing
Note

♦ To avoid loss of coolant, insert new temperature sender for
engine temperature regulation - G694- immediately.
© satelettronica
Tightening torques
page 369


⇒ “2.9.1 Removing and installing coolant shut-off valve”,
page 375
⇒ “2.9.2 Removing and installing gearbox oil cooling valve N509
”, page 375
⇒ “2.9.3 Removing and installing non-return valve - cylinder bank
1 (right-side)”, page 377
⇒ “2.9.4 Removing and installing non-return valve - cylinder bank
2 (left-side)”, page 378
2.9.1 Removing and installing coolant shut-off

valve
Removing
– Unscrew bolts -arrows- and detach shut-off valve with coolant
connection -3-.
© satelettronica
– Release hose clip -1- and detach coolant connection.
Installing
Note
♦ Renew gaskets and O-ring.


Tightening torques
♦ ⇒ “2.2 Exploded view - coolant valve”, page 368
2.9.2 Removing and installing gearbox oil

cooling valve - N509-

© satelettronica
Removing
noise insulation .
one side.

Vehicles with dual clutch gearbox 0B5 or 8-speed automatic gear‐

box 0BK:
– Unscrew bolts -arrows- and remove gearbox oil cooling valve
- N509- .
Installing
Note
♦ To avoid loss of coolant, insert new gearbox oil cooling valve

- N509- immediately.
© satelettronica
Tightening torques
♦ ⇒ Fig. ““ Gearbox oil cooling valve -N509- on vehicles with dual
clutch gearbox 0B5 or 8-speed automatic gearbox 0BK - tight‐
ening torque”“ , page 369
♦ ⇒ Fig. ““ Gearbox oil cooling valve -N509- on vehicles with
multitronic gearbox - tightening torque”“ , page 370
2.9.3 Removing and installing non-return

valve - cylinder bank 1 (right-side)
Note
The removal and installation procedures are described for the

version without a connection for a coolant hose.
Removing
– Remove engine mounting (right-side) ⇒ page 163 .
– If fitted: Remove nut -1- and move earth wire clear at engine
support (right-side).
side).
Note
Illustration shows engine support without heat shield.


– Detach non-return valve -1-.
Installing
– Install engine support and engine mounting ⇒ page 156 .
Note

Tightening torques
2.9.4 Removing and installing non-return

valve - cylinder bank 2 (left-side)
© satelettronica
Note
The removal and installation procedures are described for the

version with a connection for a coolant hose.

Removing



Installing
© satelettronica
Note
Note

Tightening torques

3 Coolant pipes
Note
The arrow markings on coolant pipes and on ends of hoses must

align.
1 - Bolt
❑ 9 Nm
ling:
© satelettronica
♦ Cylinder bank 1
⇒ page 377
♦ Cylinder bank 2
⇒ page 378
3 - O-ring
❑ Renew
4 - Bolt
❑ 9 Nm
⇒ page 384
6 - Bolt
❑ 9 Nm
7 - O-ring
❑ Renew
8 - O-ring
❑ Renew
⇒ page 382
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 9 Nm
12 - Seals
❑ Renew
13 - Banjo bolt
❑ 12 Nm
14 - Coolant lines
❑ For cylinder head, bank 2 (left-side)

15 - Bolt
❑ 9 Nm
16 - Banjo bolt
❑ 12 Nm
17 - Seals
❑ Renew
18 - Coolant pipe (rear left)
❑ Only fitted on vehicles with automatic/dual clutch gearbox
19 - Bolt
❑ 9 Nm
20 - Bolt
❑ 9 Nm
21 - Coolant hose
© satelettronica
22 - Bolt
❑ 9 Nm
23 - Coolant pipe (front left)
24 - Bolt
❑ 20 Nm
25 - O-ring
❑ Renew
Coolant pipes on dual clutch gearbox 0CK

1 - Bolt
❑ 9 Nm
2 - Coolant pipe (bottom) on
gearbox
⇒ page 390
gearbox
⇒ page 388
4 - Bolt
❑ 9 Nm
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 9 Nm
© satelettronica
page 384
⇒ “3.2.3 Removing and installing coolant pipe (front left)”,
page 386
⇒ “3.2.4 Removing and installing coolant pipe (rear left)”,
page 386
⇒ “3.2.5 Removing and installing coolant pipe on gearbox (left-
side) - vehicles with dual clutch gearbox 0CK”, page 388
⇒ “3.2.6 Removing and installing coolant pipe on gearbox (bot‐
tom) - vehicles with dual clutch gearbox 0CK”, page 390

(top)

Removing
© satelettronica
hoses.
– Remove bolts -arrows- and detach coolant pipe (top) from cyl‐
inder head.

– Remove air hose and air mass meter - G70- . To do so, release
hose clip -2- and clamps -arrows-.
Caution



– Move clear vacuum hose.

charger.
hoses.
– Remove bolts -arrows- and detach coolant pipe (top) from cyl‐
inder head.
Installing
© satelettronica
Note
♦ Fit new O-ring.


– Vehicles with one turbocharger: Install turbocharger
⇒ page 420 .
Note

Tightening torques

(front)

Removing
– Remove bolts -arrows- and detach coolant pipe (front) from oil
© satelettronica
filter housing.
Installing
Note
♦ Fit new O-ring.


Note

Tightening torques


(front left)
Removing
– Remove bracket for air conditioner compressor ⇒ page 187 .
– Remove bolts -1 and 2- and detach coolant pipe (front left).
Note
Disregard -arrows-.
Installing
Note
♦ Fit new O-ring.

© satelettronica
note the following:
– Install bracket for air conditioner compressor ⇒ page 187 .
Tightening torques

(rear left)
♦ Hose clip pliers - VAS 6340- for vehicles with two turbocharg‐
ers.

Removing
© satelettronica
– Release hose clips -arrows- and detach coolant hoses from
coolant pipe.
– Detach coolant pipe (rear left).


– Release hose clips -arrows- and detach coolant hoses from
coolant pipe.
– Detach coolant pipe (rear left).
Installing
Note
Note
© satelettronica
Tightening torques

gearbox (left-side) - vehicles with dual
clutch gearbox 0CK

Removing
WARNING

© satelettronica
hot.

noise insulation .
tion.
– Clamp off coolant hose with hose clamp -3094- .

tion.
Installing
Note

Tightening torques
© satelettronica

gearbox (bottom) - vehicles with dual
clutch gearbox 0CK

Removing
WARNING

© satelettronica
hot.

noise insulation .
– Clamp off coolant hose -arrow- with hose clamp -3094- .

tion.
Installing
Note

Tightening torques
© satelettronica


Radiator and condenser
1 - Retaining clip
⇒ page 372
© satelettronica
3 - Air duct
4 - Coolant hose
tach
❑ Connecting
⇒ page 394
5 - O-ring
❑ Renew
6 - Radiator
⇒ page 397
7 - Coolant hose
tach
❑ Connecting
⇒ page 394
8 - O-ring
❑ Renew
9 - Coolant pipe
tank
tach
❑ Connecting
⇒ page 394
10 - O-ring
❑ Renew
11 - Rubber bush
❑ For radiator

12 - Retaining pin
13 - Air duct
14 - Condenser
15 - Air duct
16 - Rubber bush
❑ For radiator
18 - Bolt
❑ 5 Nm
19 - Washer
20 - Bolt
❑ 4.5 Nm
21 - O-ring
© satelettronica
❑ Renew
22 - Coolant hose
❑ Connecting to radiator ⇒ page 394
23 - O-ring
❑ Renew
Note

ant hose.
bly.
Radiator cowl and radiator fans - version 1


⇒ page 409
2 - Bolt
❑ 3.5 Nm
3 - Bolt
❑ 5 Nm
4 - Radiator cowl
able; for allocation refer
to ⇒ Electronic parts
catalogue
⇒ page 405
© satelettronica
⇒ page 408
⇒ page 408
7 - Bolt
❑ 5 Nm
Radiator cowl and radiator fans - version 2


unit 2 - J671-
⇒ page 408
unit - J293-
⇒ page 408
3 - Radiator cowl
⇒ page 405
4 - Bolt
❑ 3.5 Nm
5 - Fan wheel
6 - Bolt
© satelettronica
❑ 5 Nm
7 - Fan wheel
8 - Bolt
❑ 5 Nm
9 - Bolt
❑ 3.5 Nm

1 - Front air duct

❑ Clipped onto rear air
duct
❑ Move to side to unclip
and remove
2 - Clip
⇒ page 410
4 - Clip
5 - Coolant hoses
6 - Bolt
❑ 20 Nm
© satelettronica
7 - Nut
❑ 8 Nm
8 - Bracket
9 - Rubber bush
❑ For radiator
10 - Rubber bush
❑ For radiator
11 - Washer
12 - Bolt
❑ 3.5 Nm
Note
gether as one unit.

© satelettronica
Removing
noise insulation .
impact absorber .
gine.
– Pull out retaining clip -2- and disconnect coolant hose from
radiator.

– Lift retaining clip -arrow- and detach connection (bottom left)

from radiator.
WARNING

radiator cowl.

catch).
© satelettronica
– Remove bolt -3- securing bracket.


Note
Disregard -item 1-.
diator.
© satelettronica
upwards -arrows-.
– Release catches -arrows A- and detach air duct (left-side)

-1- slightly -arrow B-.

Condenser with angled connection for refrigerant line:

-arrows B-.
Caution

hoses.

Condenser with straight connection for refrigerant line:
© satelettronica

Installing
Note

Note
© satelettronica
Tightening torques
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
Exploded view - condenser

page 402
page 405

Audi A6
Removing


Note
Disregard -item 2-.

© satelettronica
noise insulation .


catch).



gine.
tor.
© satelettronica
upwards -arrows-.

from below.
Installing
Note

Tightening torques
© satelettronica

Audi A7
Removing
WARNING

radiator cowl.

catch).


ments .
© satelettronica
Note
Disregard -item 2-.


radiator.
upwards -arrows-.
© satelettronica
Installing
– Install closure plate and lock carrier cover ⇒ General body
repairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view
- bumper cover .
Tightening torques


V7-
⇒ “4.5.1 Removing and installing radiator fans V7 / V177 - version
1”, page 408
⇒ “4.5.2 Removing and installing radiator fans V7 / V177 - version
2”, page 409
⇒ “4.5.3 Removing and installing radiator fan control unit J293 /
J671 ”, page 409

V7- / -V177- - version 1
Removing
Note
© satelettronica

side).
Installing
Tightening torques


V7- / -V177- - version 2
Removing
Note

Installing
– Note installation position of fan wheel:

© satelettronica
Tightening torques

Removing
noise insulation .
trol unit.

– Unplug electrical connectors -2- and -3- (if fitted).

Installing
Tightening torques

tor
© satelettronica

Removing
noise insulation .
bumper cover .
– Unclip air duct -1- in direction of -arrow- and remove.
© satelettronica
– Lift radiator -1- off bracket.
Installing
Note
♦ The coolant in the entire system must be changed if the radi‐
ator is renewed.

cover .
Tightening torques

1 Turbochargers
⇒ “1.1 Exploded view - turbochargers”, page 412
⇒ “1.3 Removing and installing turbocharger 1 control unit J724
”, page 434
⇒ “1.4 Adjusting vacuum unit for turbocharger”, page 455
⇒ “1.5 Renewing vacuum unit for turbocharger”, page 461
1.1 Exploded view - turbochargers

⇒ “1.1.1 Exploded view - turbocharger, vehicles with one turbo‐
⇒ “1.1.2 Exploded view - turbochargers, vehicles with two turbo‐
chargers”, page 414
1.1.1 Exploded view - turbocharger, vehicles with one turbocharger
© satelettronica
1 - Gasket
❑ Renew
2 - Bracket
3 - Bolt
❑ Tighten in stages and in
diagonal sequence; fi‐
nal torque 23 Nm.
4 - Studs
❑ Must always be re‐
newed if nuts are loos‐
ened
❑ 10 Nm
5 - Gasket
❑ Renew
6 - Turbocharger
❑ With turbocharger 1
turbocharger
⇒ page 420
turbocharger 1 control
unit - J724-
⇒ page 434
7 - Bracket
❑ For electrical connector
and engine cover panel
8 - Bolt
❑ 9 Nm
9 - Connection
❑ For air hose

❑ From air mass meter - G70- to turbocharger

❑ Must be free of oil and grease when installing
10 - O-ring
❑ Renew
11 - Hose
12 - Bolt
❑ 9 Nm
13 - Nut
❑ Renew
15 - Gasket
❑ Renew
16 - Bolt
© satelettronica
❑ Renew
17 - Pipe
❑ To exhaust gas recirculation cooler
18 - Gasket
❑ Renew
19 - Nut
❑ Renew
❑ Tightening torque - vehicles without SCR system ⇒ Item 6 (page 585)
❑ Tightening torque - vehicles with SCR system ⇒ Item 7 (page 588)
20 - Exhaust pipe
21 - Gasket
❑ Renew
22 - Bolt
❑ Renew
❑ Removing and installing: left-side ⇒ page 666 , right-side ⇒ page 670
24 - Bolt
25 - Bolt
26 - Bracket
1. Turbochargers 413
Turbocharger - tightening torque and sequence
Note
Renew studs and nuts.
– Tighten bolts and nuts in 7 stages in the sequence shown:

Stage Bolts/nuts Torque for tightening/tightening fur‐
ther
1. Studs for nuts 10 Nm
-1, 2-
3. -1, 2- 9 Nm
4. -1, 2- Turn 90° further
6. -3, 4- 9 Nm
7. -5- 23 Nm
© satelettronica
1.1.2 Exploded view - turbochargers, vehicles with two turbochargers
Part 1


pipe
❑ To exhaust gas recircu‐
lation cooler
❑ If screw-type clip has
been unfastened, pipe
for exhaust gas recircu‐
lation and screw-type
clip must always be re‐
newed
2 - Gasket
❑ Renew
3 - Union nut
❑ 25 Nm
Note
Counterhold adapter connection

when slackening; check that adapt‐
© satelettronica
er connection is firmly seated before
installing.
4 - Oil return pipe

5 - Bolt
❑ 9 Nm
6 - O-ring
❑ Renew
7 - Bolt
❑ 9 Nm
8 - Gasket
❑ Renew
9 - Gasket
10 - Bolt
❑ 9 Nm
11 - Connection
12 - Bypass valve
13 - Clamp
❑ 6 Nm
14 - O-ring
❑ Renew
15 - Seals
❑ Renew
16 - Banjo bolt
❑ 15 Nm
Note

installing.
17 - Oil supply line

18 - Seals
❑ Renew
19 - Banjo bolt
❑ 15 Nm
20 - O-ring
❑ Renew
21 - Intermediate pipe
22 - O-ring
❑ Renew
23 - Connecting pipe
© satelettronica
24 - Seal
❑ Renew
25 - Charge pressure sender 2 - G447-
❑ 25 Nm
26 - Bolt
❑ 7 Nm
27 - O-ring
❑ Renew
28 - Banjo bolt
❑ 35 Nm
Note

installing.
29 - Banjo bolt
❑ 35 Nm
Note

installing.
30 - Seals
❑ Renew
31 - Seals
❑ Renew

32 - Coolant return line

33 - Bolt
❑ 9 Nm
34 - Union nut
❑ 25 Nm
Note

installing.
❑ With:
♦ High-pressure turbocharger
♦ Low-pressure turbocharger
❑ Must not be disconnected
© satelettronica
36 - Bolt
❑ 9 Nm
37 - Coolant supply line
38 - Bolt
❑ 9 Nm
39 - O-ring
❑ Renew
40 - Bolt
Installation position of bypass valve and clamp

• Bypass valve -3- and clamp -2- must be aligned with edge
-1- of turbocharger unit.
• Tolerance for installation of clamp ± 10°.
Part 2
❑ With:
♦ High-pressure turbocharg‐
er
♦ Low-pressure turbocharger
⇒ page 424
❑ Must not be disconnec‐
ted
2 - Vacuum unit
❑ For low-pressure turbo‐
charger
⇒ page 461
❑ Adjusting ⇒ page 461
operating rod locking
nut: 7 Nm.
3 - Nut
© satelettronica
❑ 7 Nm
4 - Securing clip
❑ Renew
5 - Bolt
❑ 7 Nm
6 - Bracket
❑ For turbocharger 1 con‐
trol unit - J724-
7 - Control unit for turbocharg‐
er 1 - J724-
❑ For high-pressure tur‐
bocharger
8 - Bolt
❑ 7 Nm
9 - Securing clip
❑ Renew
10 - Operating rod
11 - Bolt
❑ 23.5 Nm
12 - Securing clip
❑ Renew
13 - Vacuum unit
❑ For turbine changeover between high and low pressure
❑ With regulating flap potentiometer - G584-
❑ Adjusting ⇒ page 458
❑ Tightening torque for operating rod locking nut: 11 Nm.
14 - Bolt
❑ 23.5 Nm

15 - Securing clip
❑ Renew
Part 3
1 - Gasket
❑ Renew
2 - Bracket
3 - Bolt
4 - O-ring
❑ Renew
5 - Bolt
❑ 9 Nm
© satelettronica
6 - Oil return connection
7 - Gasket
❑ Renew
8 - Bolt
❑ 23 Nm
9 - Low-pressure turbocharger
❑ Combined as a unit with
-item 13-
❑ Must not be disconnec‐
ted
⇒ page 424
10 - Nut
❑ Not available as re‐
placement part
11 - Bolt
❑ 60 Nm
12 - Gasket
❑ Not available as replacement part
13 - High-pressure turbocharger
❑ Combined as a unit with -item 9-
❑ Must not be disconnected
14 - Bolt
❑ 23 Nm
15 - Support
16 - Bolt
❑ 23 Nm
17 - Bolt
❑ Not available as replacement part
18 - Gasket
❑ Renew
19 - Bolt
❑ 23.5 Nm
❑ Attached to exhaust manifolds with clamp ⇒ Item 5 (page 665)
21 - Bolt
Bracket for turbocharger - tightening torque and tightening se‐

quence
1. -1, 2- 3 Nm
2. -3 … 8- 15 Nm
3. -3 … 8- 28 Nm
© satelettronica
4. -1, 2- 28 Nm
Actuator for structure-borne sound - R214- - tightening torque

– Tighten nut -arrow- to 5 Nm.

⇒ “1.2.1 Removing and installing turbocharger - vehicles with one
turbocharger”, page 420
⇒ “1.2.2 Removing and installing turbochargers - vehicles with
two turbochargers”, page 424
1.2.1 Removing and installing turbocharger -

vehicles with one turbocharger

Removing
WARNING

system ⇒ page 7 .
© satelettronica
Caution

♦ Mechanical faults on the turbocharger can be caused by
foreign matter from the exhaust manifold.
if necessary.
Note

ments .
Note
Disregard -item 2-.
© satelettronica

Caution


© satelettronica
– Release screw-type clip -1- and detach exhaust gas recircu‐
lation pipe.

– Move clear electrical wiring.
Note
Disregard -item 1-.
– Loosen bolt -5-.

– Remove nuts -1, 2- and bolts -3, 4-.
– Remove turbocharger.
Installing
Note

♦ 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
© satelettronica
– Install exhaust gas recirculation pipe ⇒ page 660 .
ments .
Tightening torques
♦ ⇒ Fig. ““Turbocharger - tightening torque and sequence”“ ,
page 414
tem”, page 466
1.2.2 Removing and installing turbochargers -

vehicles with two turbochargers

© satelettronica
Removing
WARNING

system ⇒ page 7 .
Caution

♦ Mechanical faults on the turbocharger can be caused by
foreign matter from the exhaust manifold.
if necessary.
Note

pairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and instal‐
ling plenum chamber partition panel .
Caution


battery .
© satelettronica
Note
Disregard -arrows-.

Note
Disregard -arrows-.

Note
– Release hose clips -2 and 3- and disconnect coolant hoses

-1 and 4- from heat exchanger.
Note
Ignore -3094- .
– Unplug electrical connectors -1 ... 4- and move wiring harness

clear.
© satelettronica
Caution
Risk of damage to turbocharger shaft.

♦ The shaft of the compressor blades projects beyond the
contour of the turbocharger housing.
♦ Take care not to damage compressor blades when con‐
necting pipe is removed.
– Remove bolts -arrows- and detach connecting pipe -1-.


Note
Disregard -item 2-.

– If fitted, unscrew and detach exhaust gas temperature sender
2 - G448- -item 3-.
Note
Disregard -item 2-.

side.
© satelettronica
– Unscrew nuts -arrows- and push catalytic converter towards
rear; on vehicles with SCR system, pay attention to electrical
wiring of catalytic converter heater when doing so.


– Detach vacuum hose -1- and press vacuum line to one side.
– Remove banjo bolts -arrows- and disconnect oil supply line

-1-.
© satelettronica
Remove bolts -3, 4- and union nuts -1, 2- for coolant supply line.
Note
– Disconnect vacuum hose -2- and move clear vacuum hose

and vacuum line -1- at connection.
© satelettronica
Note
Disregard -item 2-.

– Disconnect air pipe (right-side) -2- together with intermediate
pipe -1- from turbocharger unit and move clear to one side.
Note
Disregard -item 3-.

– Open clamp -1- and detach bypass valve -2-.
– Unscrew bolts -1- and swivel lug to one side.
© satelettronica
– Remove bolts -1- on both sides.
– Loosen bolts (left and right) -3- on bracket -2- for turbocharger.
– Open clamp -arrow- on both sides and slide onto exhaust

manifold.
Caution
Risk of damage to oil return pipe.

♦ Do not bend oil return pipe.
– Remove bolts -1- for oil return pipe.
Note
Disregard -item 2-.
Note
Disregard -item 1-.
© satelettronica

WARNING

Caution
Risk of damage to turbocharger shaft.

♦ The turbocharger shaft projects beyond the contour of the
turbocharger housing.
– Engage lifting tackle - 2024 A- on turbocharger unit and work‐

shop hoist - VAS 6100- .
– Take care when detaching turbocharger unit.
© satelettronica
Note
The turbocharger unit must not be disconnected.
Installing
Note

♦ Fill turbochargers with engine oil at connections for oil supply
line.
♦ After installing the turbocharger unit, allow the engine to idle
for approx. 1 minute without pressing the accelerator to ensure

Note

Tightening torques
♦ ⇒ Fig. ““Exhaust gas recirculation pipe to turbocharger - tight‐
ening torque and sequence”“ , page 660

tem”, page 466
1.3 Removing and installing turbocharger 1

⇒ “1.3.1 Removing and installing turbocharger 1 control unit J724
- vehicles with one turbocharger”, page 434
⇒ “1.3.2 Removing and installing turbocharger 1 control unit J724
- vehicles with two turbochargers, manual mode”, page 444
1.3.1 Removing and installing turbocharger 1

control unit - J724- - vehicles with one
turbocharger
♦ Tester for E-positioner - VAS 6395- or -VAS 6395A-
♦ Bracket - VAS 6395 /6-
© satelettronica
Removing
Note

– Release cover -3- and swivel to side -arrow-.
– Connect tester - VAS 6395 A/1- to positive terminal -2- and
earth -1- with connection lead - VAS 6395/2- .

Procedure for tester for E-positioner - VAS 6395 A/1- :

– Select software version with buttons ↑ -item 5- and ↓
-item 6-.
– To confirm software version, press v button -item 4-.
Procedure for tester for E-positioner - VAS 6395 /1- :
© satelettronica
Checking software version of tester - VAS 6395 /1- :
Caution
Risk of damage to turbocharger 1 control unit - J724- .

♦ Before continuing, check whether the correct software
version is loaded in the tester - VAS 6395 /1- . To do so,
proceed as follows:
Display on -VAS 6395 /1- (2 seconds after connecting to power

supply) if correct software version is loaded:
1- > 1. START
2- 2. NEXT [>]
Note
♦ If the following appears on the display, an incorrect software

version has been loaded:
♦ 1. >TEST
♦ 2. LEARN
♦ German market: If this is the case, download the correct soft‐
ware version from the “Audi Partner Portal (under Service)” in
the section “Workshop Equipment”.
♦ Rest of the world: If this is the case, download the correct soft‐
ware version from your Importer's information platform.
Continuation for both testers:

– Unplug electrical connector for turbocharger 1 control unit -
J724- .
– Connect connection lead - VAS 6395/2- to turbocharger 1
control unit - J724- and to tester - VAS 6395 A/1- .
Display on -VAS 6395 A/1- :

1- > 1. START
2- 2. NEXT [>]
– To continue, press v button -item 4-.
• The tester - VAS 6395 A/1- runs through the adjustment range
of the turbocharger 1 control unit - J724- and checks that the
end positions are reached; display indicates “CHECK”.
© satelettronica
1-
2- [OK]
Note
♦ If the display indicates “[OK]”, the adjustment range of the tur‐

bocharger 1 control unit - J724- is OK.
♦ If the display shows “FAULT [OK]”, tap gently several times on
the housing of turbocharger 1 control unit - J724- with the
handle of a screwdriver and repeat the check by pressing v
button -item 4-.

Note
Do NOT unscrew any of the other bolts visible in the illustration.
– Fit bracket - VAS 6395 /6- on centring hole of bracket for tur‐
bocharger 1 control unit - J724- and tighten bolt to 8 Nm.
© satelettronica
• The turbocharger 1 control unit - J724- moves back and forth
between the stops several times to determine the voltage val‐
ue.
• Then the turbocharger 1 control unit - J724- moves into instal‐
lation position.
– While the voltage value is being determined, keep tapping
gently on the housing of turbocharger 1 control unit - J724-
until the display indicates the following:
1- X.XXX V
2- [↑][↓][OK]
– Note voltage value.
• Specification: 3.3 ... 3.7 V
Note
♦ If the display indicates “FAULT [OK]” or the voltage is less than

3.3 V or greater than 3.7 V, unplug tester - VAS 6395 A/1- and
repeat the complete procedure ⇒ page 436 .
♦ The turbocharger must be renewed if no voltage value can be
read out.

1- X.XXX V
2- [↑][↓][OK]
– By pressing buttons ↑ -item 5- and ↓ -item 6-, adjust turbo‐
charger 1 control unit - J724- so that coupling rod can be
accessed easily for removal.
– Unclip circlips -arrows- and dispose of them, detach coupling

rod.
© satelettronica
1- X.XXX V
2- [↑][↓][OK]
– By pressing buttons ↑ -item 5- and ↓ -item 6-, adjust turbo‐
charger 1 control unit - J724- so that bolts for -J724- can be
accessed easily.

– Disconnect connection lead - VAS 6395/2- from turbocharg‐

er 1 control unit - J724- .
Caution
Power supply for tester - VAS 6395 A/1- must remain connec‐
ted.
– Remove bolts -1, 2, 3- and dispose of them.
Note
– Remove old turbocharger 1 control unit - J724- and dispose of

it.
© satelettronica
Caution
Check that the three insulating washers are fitted between tur‐
bocharger 1 control unit - J724- and the bracket.
– Install new turbocharger 1 control unit - J724- in reverse se‐

quence of removal.
– Fit new bolts as follows:
1- M6x15 with tapered shank
2- M6x15 with tapered shank
3- M6x15
– Initially hand-tighten bolts.
• Turbocharger 1 control unit - J724- must rest on retaining plate
so there is no play; it must still be possible to move control unit
by hand.
– Connect connection lead - VAS 6395/2- to new turbocharger 1


1- > 1. START
2- 2. NEXT [>]
– Select menu item “NEXT” with ↓ button -item 6-.
© satelettronica
• The tester - VAS 6395 A/1- runs through the adjustment range
of the turbocharger 1 control unit - J724- and checks that the
end positions are reached; display indicates “CHECK”.
1- X.XXX V
2- [OK]
Note
If the display indicates “FAULT”, the new turbocharger 1 control

unit - J724- must be renewed for a second time.

1-
2- [OK]


1- X.XXX V (voltage determined with first measurement)
2- [OK]
• Turbocharger 1 control unit - J724- moves into installation po‐
sition.
– Insert coupling rod.
© satelettronica
• Installation position: The thicker eyelet is fitted onto the shaft
of turbocharger 1 control unit - J724- .
– Fit circlips -arrows-.
• The circlips must engage audibly.
– Press turbocharger 1 control unit - J724- towards the rear

without applying force -arrow- until lever -1- rests lightly on
bracket - VAS 6395/6- .
– Hold -J724- in this position.
– Tighten bolts -1, 2, 3- to 5 Nm.

• Turbocharger 1 control unit - J724- moves back and forth be‐
tween the stops several times and is adjusted to the voltage
value determined with the first measurement.
1- X.XXX V (voltage determined with first measurement)
2- [OK]
Note
♦ If [OK] is indicated on display, terminate adjustment

⇒ page 443 .
♦ If “CHECK” is indicated on display, proceed as follows.
Procedure if display indicates “CHECK”:
© satelettronica
1- [<<<]
2- CHECK
Or
1- [>>>]
2- CHECK
– Loosen bolts -1, 2, 3- until turbocharger 1 control unit - J724-

can just be moved by applying light force in the direction
stated:
• If display indicates [<<<], move -J724- slightly in direction of
travel.
• If display indicates [>>>], move -J724- slightly towards rear of
vehicle.


• Turbocharger 1 control unit - J724- again moves back and
forth between the stops several times and is adjusted to the
voltage value determined with the first measurement.
1- X.XXX V
2- [OK]
Terminating adjustment:
© satelettronica

1- X.XXX V
2- [OK]
– Unbolt bracket - VAS 6395/6- -arrow-.

• Turbocharger 1 control unit - J724- moves to end positions.
Note
If the display indicates “FAULT”, the new turbocharger 1 control

unit - J724- must be renewed ⇒ page 439 .
© satelettronica
1-
2- [OK]
• Adjustment is completed.
– Unplug electrical connectors for tester - VAS 6395 A/1- .
1.3.2 Removing and installing turbocharger 1

control unit - J724- - vehicles with two
turbochargers, manual mode
♦ Tester for E-positioner - VAS 6395- / -VAS 6395A- or -VAS
6395B-
♦ Bracket -VAS 6395 /7-

Modifying bracket -VAS 6395 /7- (if necessary)

If there is already a recess -arrow- as shown in illustration -A-, no
modification is necessary.
– If there is no recess, modify bracket -VAS 6395 /7- as shown
in illustration -B-.
Removing
Note

– Release cover -3- and swivel to side -arrow-.
© satelettronica
– Connect tester - VAS 6395- to positive terminal -2- and earth
-1- with connection lead - VAS 6395/2- .
Note
♦ The following procedure is described for using tester - VAS

6395 /1- / -VAS 6395 A/1- .
♦ Depending on the equipment and tools available in your work‐
shop, tester - VAS 6395 B/1- may also be used.
♦ Although the buttons are arranged in different positions, the
designations/functions are the same (see illustration).
Procedure for tester for E-positioner - VAS 6395 B/1- and E-box
- VAS 6395 A/1- :
– Select software version SW Hella using buttons ↑ -item 5-
and ↓ -item 6-.
– To confirm software version, press v button -item 4-.
Note
In this example, software version Hella -item 1- is selected.
Procedure for tester for E-positioner - VAS 6395 /1- :
© satelettronica
Checking software version of tester - VAS 6395 /1- :
Caution
Risk of damage to turbocharger 1 control unit - J724- .

♦ Before continuing, check whether the correct software
version is loaded in the tester - VAS 6395 /1- . To do so,
proceed as follows:
Display on -VAS 6395 /1- (2 seconds after connecting to power

supply) if correct software version is loaded:
1- > 1. START
2- 2. NEXT [>]
Or
> 1. START Bi-Turbo
2. NEXT [>]
If the following appears on the display, an incorrect software ver‐
sion has been loaded:
1- > 1. TEST
2- 2. LEARN
Note
♦ German market: If this is the case, download the correct soft‐

ware version (“Hella”) from the “Audi Partner Portal (under
Service)” in the section “Workshop Equipment”.
♦ Rest of the world: If this is the case, download the correct soft‐
ware version (“Hella”) from your Importer's information plat‐
form.

Continuation for all testers:

– Unplug electrical connector for turbocharger 1 control unit -
J724- .
– Connect connection lead - VAS 6395/2- to turbocharger 1
control unit - J724- and to tester - VAS 6395- .
Display on -VAS 6395- :

– Press ↓ button -item 6- twice to select MANUAL mode.
– Confirm MANUAL mode by pressing v button -item 4-.
1- 2. NEXT [>]
2- > 3. MANUAL
© satelettronica
Note
– Fit bracket -VAS 6395 /7- on centring hole of bracket for tur‐
bocharger 1 control unit - J724- and tighten -bolt- to 7 Nm.
Note
Centring pin on bracket -VAS 6395 /7- must engage in hole in

bracket for turbocharger 1 control unit - J724- .
Determining voltage value:
– Press ↑ button -item 5- on -VAS 6395- to move coupling rod

-1- onto bracket -VAS 6395 /7- .
© satelettronica
Note
If the control unit stops moving during this process, assist it by

pushing gently with your finger -arrow-.

1- X.XXX V
2-
– Note down voltage value -1-.

– Press ↓ button -item 6- on -VAS 6395- to move coupling rod

-1- back off bracket -VAS 6395 /7- .
– Repeat process for determining voltage value two more times
and note down voltage values.
Note
If it is necessary to assist the control unit by pushing the coupling

rod -3- with your finger in order to determine the voltage value,
you must do this each time the process is repeated (try to apply
the same amount of pressure) -arrow-.
– Calculate average of 3 recorded voltage values.
– Unclip securing clip.
© satelettronica
– Disengage coupling rod -4- at turbocharger 1 control unit -
J724- and lay coupling rod down.
Caution
Do not bend coupling rod.
– Remove bolts -1, 2, 3- and dispose of them.
Note
– Remove old turbocharger 1 control unit - J724- and dispose of

it.
– Install new turbocharger 1 control unit - J724- in reverse se‐
quence of removal.
Note
Only exchange the coupling rod from the replacement part kit if
necessary (e.g. due to damage).
– Fit new bolts -1, 2, 3-, M6x15 with tapered shank:

– Initially hand-tighten bolts.
• Turbocharger 1 control unit - J724- must rest on retaining plate
so there is no play; it must still be possible to move control unit
by hand.
– Connect connection lead - VAS 6395/2- with adapter to new

turbocharger 1 control unit - J724- .
– Set new turbocharger 1 control unit - J724- to a value 0.020 -

0.030V higher than value calculated previously.
• To set voltage value, press ↑ button -item 5- or ↓ -item 6-.
© satelettronica
1- X.XXX V

– Insert coupling rod -3-.

– Attach securing clip -2-.
• The securing clip must engage audibly.
– Now turn turbocharger 1 control unit - J724- so that arm -1-

rests against bracket -VAS 6395 /7- .
© satelettronica
Set voltage value on new turbocharger 1 control unit - J724- as

follows:
Caution
Setting the turbocharger 1 control unit - J724- incorrectly can

lead to problems with noise and/or poor driveability.

© satelettronica
1- X.XXX V
– Compare voltage value -1- with calculated average.
Note
The voltage of the new turbocharger 1 control unit must not differ
from the average value for the old control unit by more than +/-
0.020V.


If voltage value is not within range of tolerance:
– Loosen bolts -1, 2, 3- just enough so that turbocharger 1 con‐

trol unit - J724- can be moved by applying light force.
© satelettronica
– Push turbocharger 1 control unit in appropriate direction and
tighten bolts -1, 2, 3- to 5 Nm.
♦ If voltage value is too high, push turbocharger 1 control unit
downwards.
♦ If voltage value is too low, push turbocharger 1 control unit
upwards.
Measure voltage with new turbocharger 1 control unit - J724- as

follows:

© satelettronica
1- X.XXX V
– Compare voltage value -1- with calculated average.

Voltage value outside range of tolerance
– Re-adjust turbocharger 1 control unit - J724- ⇒ page 453 .

Voltage value within range of tolerance

– Check voltage value again.

1- X.XXX V
Voltage value outside range of tolerance
– Re-adjust turbocharger 1 control unit - J724- ⇒ page 453 .
Voltage value within range of tolerance
© satelettronica
– Remove bolt -arrow- and detach bracket -VAS 6395 /7- .
– Screw bolt back in and tighten ⇒ Item 5 (page 418) .
• Adjustment is completed.
– Unplug electrical connectors for tester - VAS 6395- .
1.4 Adjusting vacuum unit for turbocharger

⇒ “1.4.1 Adjusting vacuum unit for low-pressure turbocharger”,
page 455
⇒ “1.4.2 Adjusting vacuum unit for turbine changeover”,
page 458
1.4.1 Adjusting vacuum unit for low-pressure

turbocharger
Note
Adjustment only applies to a new vacuum unit.

equipment required
© satelettronica
♦ Turbocharger tester - V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS 6341-
♦ Pressure control valve - VAS 6342-
Procedure
Note

– Secure universal dial gauge bracket - VW 387- using a nut

-arrow- on catalytic converter.
– Attach dial gauge - VAS 6341/1- with flat probe - VAS 6341/4-
to universal dial gauge bracket - VW 387-
– Align dial gauge so that it is aligned with operating rod of vac‐
uum unit.
– Set dial gauge to 20... 25 mm preload.
– Connect hand vacuum pump - VAS 6213- and pressure con‐

trol valve - VAS 6342- to vacuum unit -arrow- and connection
“II” of turbocharger tester -V.A.G 1397A- , as shown in illus‐
tration.
– Close pressure control valve - VAS 6342- .
• Lever -1- should be horizontal.
– Move adjuster ring on hand vacuum pump - VAS 6213- to po‐
sition for “vacuum”.
© satelettronica
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position “II”.
– Make sure that dial gauge can move freely.
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates the following value:
• 580 ± 5 mbar.
Note
The turbocharger tester - V.A.G 1397A- cannot display values

greater than 580 mbar.

– Note measured value.
– Vent vacuum using pressure control valve - VAS 6342- .
• 440 mbar.
Note
If too much vacuum is vented, bring pressure back up to 580 mbar

and then adjust by venting again.
• The operating rod should have moved in the direction of the

dial gauge by 0.8 ... 1.2 mm from the previously recorded val‐
ue.
– Vent vacuum using pressure control valve - VAS 6342- .
• 100 mbar.
• The operating rod should have moved in the direction of the
dial gauge by 7 ... 9.5 mm from the previously recorded value.
– If specification is not attained, loosen lock nut -1-.

– Remove securing clip -3- and detach operating rod -2- from
mounting pin.
– Lengthen or shorten front part of operating rod by turning it to
left/right.
– Fit operating rod -2- on mounting pin again.
– Repeat test with hand vacuum pump - VAS 6213- and dial
gauge - VAS 6341/1- .
– If specification is attained, fit securing clip and tighten lock nut.
1.4.2 Adjusting vacuum unit for turbine

changeover
Note
The vacuum unit for turbine changeover controls the generation

of charge pressure between the low-pressure turbocharger and
© satelettronica
the high-pressure turbocharger.

♦ Turbocharger tester - V.A.G 1397A-

♦ Pressure control valve - VAS 6342-
Procedure
Note
© satelettronica
Note
– Disconnect vacuum line to vacuum unit for turbine changeover

at turbine changeover valve - N529- -arrow-.
– Connect hand vacuum pump - VAS 6213- and pressure con‐

trol valve - VAS 6342- to disconnected vacuum line and con‐
nection “II” of turbocharger tester -V.A.G 1397A- , as shown
in illustration.
– Close pressure control valve - VAS 6342- .
• Lever -1- should be horizontal.
– Move adjuster ring -2- on hand vacuum pump - VAS 6213- to
select “vacuum”.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position “II”.
– On vehicle diagnostic tester select function 02-Measured

values in Guided Fault Finding 01-Engine electronics .
– Select measured value Bypass valve turbocharger hp

turbine inlet, raw voltage from list.
– Operate hand vacuum pump - VAS 6213- until turbocharger

tester - V.A.G 1397A- indicates the following value:
• 200 mbar.
– Read voltage level off vehicle diagnostic tester :
• Specification: 4090 ... 4190 mV
– Check setting by operating hand vacuum pump - VAS 6213-
until pressure tester of -VAS 6213- indicates the following
value:
• 700 mbar.
Note

© satelettronica
If specification is not attained:

– Vent system via pressure control valve - VAS 6342- so that
vacuum reading drops to approx. 100 mbar.
Note
Counterhold operating rod -2- when loosening lock nut -3-.
– Loosen lock nut -3- using crow foot wrench.

– Unclip securing clip -1- and detach operating rod from adjust‐
ing lever.
– Lengthen or shorten upper part of operating rod -2- by turning
it about its own axis.
Note
A half turn of the operating rod -2- corresponds to a change in

voltage of 68 mV.

– Slide operating rod -2- onto adjusting lever.

– Repeat test with hand vacuum pump - VAS 6213- and vehicle
diagnostic tester .
Note
Counterhold operating rod -2- when tightening lock nut -3-.
– If specification is attained, fit securing clip -1- and tighten lock

nut -3-.
– Check setting again by operating hand vacuum pump - VAS
6213- until pressure tester of -VAS 6213- indicates the follow‐
ing value:
• 700 mbar.
Note

© satelettronica
If the specification is attained:
1.5 Renewing vacuum unit for turbocharger

⇒ “1.5.1 Renewing vacuum unit for low-pressure turbocharger”,
page 461
⇒ “1.5.2 Renewing vacuum unit for turbine changeover”,
page 462
1.5.1 Renewing vacuum unit for low-pressure

turbocharger
Removing
Note

– Detach securing clip -2-.
– Remove nuts -arrows- and detach vacuum unit for low-pres‐
sure turbocharger.
Installing
– Adjust vacuum unit for low-pressure turbocharger
⇒ page 455 .
Tightening torques
1.5.2 Renewing vacuum unit for turbine

changeover
Removing
Note
© satelettronica

– Unplug electrical connector -1- and move wiring -arrow- clear.
– Unclip securing clip -1-.

– Unscrew bolts -arrows- and detach vacuum unit for turbine
changeover.
Installing
– Adjust vacuum unit for turbine changeover ⇒ page 458 .
Tightening torques

2 Charge air system

page 466
⇒ “2.4 Removing and installing charge pressure sender G31 / in‐
take air temperature sender G42 ”, page 472

⇒ “2.1.1 Exploded view - charge air system, vehicles with one
⇒ “2.1.2 Exploded view - charge air system, vehicles with two
2.1.1 Exploded view - charge air system, vehicles with one turbocharger
© satelettronica
⇒ page 467
2 - Hose clip
⇒ page 466
3 - Air hose
❑ To charge air cooler
❑ Must be free of oil and
4 - Hose clip
⇒ page 466
5 - Bolt
❑ 9 Nm
6 - Air pipe (right-side)
7 - Bolt
❑ 9 Nm
8 - Hose clip
⇒ page 466
9 - Air hose
❑ To turbocharger
10 - Hose clip
⇒ page 466
11 - Hose clip
❑ Tightening torque ⇒ page 466
12 - Air hose


13 - Hose clip
14 - Not fitted
15 - Air pipe (left-side)
16 - O-ring
❑ Renew
17 - Bolt
❑ 5 Nm
19 - Bush
20 - Nut
❑ 9 Nm
21 - Rubber grommet
22 - Hose clip
© satelettronica
23 - Air hose
24 - Hose clip
25 - Bolt
❑ 7 Nm

2.1.2 Exploded view - charge air system, vehicles with two turbochargers

⇒ page 467
2 - Hose clip
⇒ page 466
3 - Air hose
4 - Hose clip
⇒ page 466
5 - Bolt
❑ 9 Nm
© satelettronica
❑ From turbocharger
7 - Retainer
8 - Grommet
9 - Sleeve
10 - Nut
❑ 9 Nm
11 - Bolt
❑ 9 Nm
12 - O-ring
❑ Renew
13 - Bolt
❑ 9 Nm
14 - Intermediate pipe
15 - Bolt
❑ 9 Nm
16 - O-ring
❑ Renew
17 - Hose clip
18 - Air hose
19 - Hose clip
20 - Bolt
❑ 9 Nm
21 - O-ring
❑ Renew

22 - Bolt
❑ 5 Nm
24 - Air pipe (left-side)
25 - Hose clip
26 - Air hose
27 - Hose clip
28 - Bolt
❑ 7 Nm

charge air system
© satelettronica
Note




er
one turbocharger”, page 467

er - vehicles with one turbocharger
Removing
Note

© satelettronica
ments .
– Remove air intake grille (left and right) ⇒ General body re‐
WARNING

radiator cowl.

cooler.
cooler.
Installing
© satelettronica
Note

Tightening torques
♦ ⇒ “2.1.1 Exploded view - charge air system, vehicles with one
tem”, page 466

er - vehicles with two turbochargers

Removing
Note

ments .
© satelettronica
Note
Disregard -item 2-.
– Remove air intake grille -1- (left and right) ⇒ General body
repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing and
WARNING

radiator cowl.
– Unclip air ducts -1 and 2- and detach.

noise insulation .

Note
Collect drained coolant in a clean container for re-use or disposal.
gine.
tor.
upwards -arrows-.
© satelettronica
– Remove bolt -1- (right-side) and pull radiator bracket with ra‐
diator on right side slightly to front -arrow-.
– Remove bolt -arrow- and detach radiator bracket -1-.

– Move radiator back into installation position and fit retaining

pins (left and right) for radiator -arrows-.
cooler.
© satelettronica

cooler.
– Detach charge air cooler by pulling upwards.
– Remove charge air cooler, paying special attention to air ducts
(left-side).
Installing
Note
– Install radiator
⇒ “4.1 Exploded view - radiator/radiator fans”, page 393 .
© satelettronica
Note

Tightening torques
♦ ⇒ “2.1.2 Exploded view - charge air system, vehicles with two
tem”, page 466

sure sender - G31- / intake air tempera‐
ture sender - G42-
Removing


– Remove bolts -1- and pull charge pressure sender - G31- /
intake air temperature sender - G42- out of air pipe.
Installing
Note
Fit new O-ring.
Tightening torques
(front)
© satelettronica
⇒ “2.5.1 Checking charge air system for leaks, vehicles with one
⇒ “2.5.2 Checking charge air system for leaks, vehicles with two
2.5.1 Checking charge air system for leaks,

vehicles with one turbocharger
♦ Charge air system tester - V.A.G 1687- with adapters -V.A.G
1687/11- , -1687/16- and -1687/17- .
Procedure
Note

Caution

© satelettronica
– Seal connection for crankcase breather on turbocharger with

adapter -1687/17- .
– Connect end seal -V.A.G 1687/3- to turbocharger with adapter

-1687/16- .

– Release hose clip -arrow- and detach air hose.
– Connect adapter - 1687/11- to air hose going to throttle valve

module - J338- .
– Connect hose -1- of charge air system tester - V.A.G 1687- to
adapter.
© satelettronica


valves -3- and -4-.
valve -2-.
Note
water.
– Open valve -3-.
Caution

© satelettronica
Note

Attaching
Note
Tightening torques
tem”, page 466
2.5.2 Checking charge air system for leaks,



1687/11- and -V.A.G 1687/18-
Procedure
Note
© satelettronica

-1- from connection-2-.
– Remove bolts -arrows- and detach connection from turbo‐
charger.
– Connect adapter -V.A.G 1687/18-1- with -V.A.G 1687/18-2- to

turbocharger.

– Connect adapter - 1687/11- to air hose going to throttle valve

module - J338- .
– Connect hose -1- of charge air system tester - V.A.G 1687- to
adapter.
© satelettronica


valves -3- and -4-.
valve -2-.
Note
water.
– Open valve -3-.
Caution

© satelettronica
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.
Attaching
Note
Tightening torques
tem”, page 466


1 Injection system
page 482

❑ Do not unscrew
❑ Exploded view
⇒ page 556
© satelettronica
3 - Fuel rail
❑ For cylinder bank 1
(right-side)
valve - N276-
❑ With deformable sealing
lip
❑ Cannot be re-installed
❑ After renewing, perform
adaption ⇒ Vehicle di‐
agnostic tester using
Guided Functions
⇒ page 547
⇒ Fig. ““ Fuel pressure
regulating valve -N276-
- tightening torque”“ ,
page 481
G247-
lip
⇒ page 551
sender -G247- - tighten‐
ing torque”“ , page 481
6 - Fuel rail
❑ For cylinder bank 2 (left-side)
7 - Injector
8 - Fuel return hoses

❑ Renew together with restrictor

9 - Restrictor
❑ Maintains a residual pressure in fuel return hoses
❑ Cannot be renewed separately; if defective, renew fuel return hoses
10 - Fuel system pressurisation pump - G6-
11 - Fuel filter
Fuel pressure regulating valve - N276- - tightening torque

– Position fuel pressure regulating valve - N276- so that electri‐
cal wiring is not under tension when connector -arrow- is
plugged in.
– Tighten union nut on regulating valve in 4 stages as follows
(counterhold hexagon flats on housing):
Stage Tightening torque
1. Screw in by hand until contact is made
2. 60 Nm
3. Turn back by 90°
© satelettronica
4. 85 Nm
Fuel pressure sender - G247- - tightening torque

– Tighten fuel pressure sender - G247- in 4 stages as follows:
Note

ing.

♦ Socket - T40218-
♦ Torque wrench
Stage Tightening torque
1. Screw in by hand until contact is made
2. 60 Nm
3. Turn back by 180°
4. 85 Nm

1.2 Overview of fitting locations - injection

system
with one turbocharger”, page 482
with two turbochargers”, page 492
1.2.1 Overview of fitting locations - injection system, vehicles with one turbo‐
charger
Engine compartment

⇒ page 489
❑ Exploded view
⇒ page 369
© satelettronica
N145-
❑ Integrated in engine
mounting (right-side)
❑ Exploded view
⇒ page 509
- G505-
⇒ page 488
❑ Exploded view
⇒ page 563
sender 4 - G648-
❑ Exploded view
⇒ page 634
G28-
❑ Exploded view
⇒ page 673
sender 1 - G235-
❑ Exploded view
⇒ page 634
sender 3 - G495-
11 - Instrument cluster with control unit in dash panel insert - J285-
❑ Removing and installing ⇒ Electrical system; Rep. gr. 90 ; Dash panel insert; Exploded view - dash
panel insert


14 - Lambda probe - G39- with Lambda probe heater - Z19-
❑ Integrated in engine mounting (left-side)
Engine (top view)

valve - N276-
© satelettronica
lip
⇒ page 551
page 481
❑ Exploded view
⇒ page 556
3 - Glow plug 1 - Q10-
❑ Exploded view
⇒ page 673
❑ Exploded view
⇒ page 556
⇒ page 488
❑ Exploded view
⇒ page 673
❑ Exploded view
⇒ page 673
❑ Exploded view
⇒ page 556


10 - Control unit for turbocharger 1 - J724-
❑ On turbocharger
12 - Exhaust gas recirculation control motor - V338-
❑ With deformable sealing lip
❑ Tightening torque ⇒ Fig. ““ Fuel pressure sender -G247- - tightening torque”“ , page 481
14 - Glow plug 6 - Q15-
© satelettronica
16 - Glow plug 5 - Q14-
18 - Glow plug 4 - Q13-
21 - Exhaust gas recirculation temperature sensor - G98-
Engine (front view)


sender - G266-
❑ Exploded view
⇒ page 318
❑ Integrated in oil filter
housing; cannot be re‐
newed individually
3 - Oil temperature sender 2 -
G664-
⇒ page 489
❑ Exploded view
⇒ page 176
❑ Exploded view
⇒ page 335
© satelettronica
❑ Exploded view
⇒ page 335
N345-
7 - Intake manifold flap motor -
V157-
❑ Exploded view
⇒ page 512
J338-
❑ Exploded view

⇒ page 512
A - Fuel pump control unit - J538-
B - Injector for reducing agent - N474-
❑ Only fitted on vehicles with SCR system
C - NOx sender 2 - G687- with control unit for NOx sender 2 - J881-
❑ Fitting location for engine code CKVB ⇒ page 490
❑ Fitting location for engine code CPNB ⇒ page 491
© satelettronica
D - NOx sender - G295- with control unit for NOx sender - J583-
E - Control unit for reducing agent metering system - J880-
F - Exhaust gas temperature sender 4 - G648-
G - Exhaust gas temperature sender 2 - G448-
❑ Fitted on vehicles with SCR system (depending on version)
H - Particulate sensor - G784-


♦ -Item 1- in plenum chamber (left-side)

Note

© satelettronica

-G185- .

Fitting location of fuel pump control unit - J538-

♦ Fuel pump control unit - J538- -arrow- is located between floor
panel and fuel tank level with rear seat bench (right-side).
Note
For illustration purposes, the floor panel is cut open in the illus‐
tration.
Removing and installing ⇒ Fuel supply system - diesel engines;

Rep. gr. 20 ; Fuel pump; Removing and installing fuel pump con‐
trol unit - J538-


♦ -Item 2- at rear right of engine

♦ -Item 2- on cylinder head cover, cylinder bank 1 (right-side)
© satelettronica
Fitting location of fuel metering valve - N290-
♦ -Item 2- in high-pressure pump
Fitting location of charge pressure sender - G31- / intake air tem‐

♦ -Item 2- at air pipe (left-side) in engine compartment


regulation - G694-
♦ -Item 1- at front left of cylinder block

G83-
© satelettronica
Oil temperature sender 2 - G664-

Injector for reducing agent - N474- for vehicles with SCR system
Injector for reducing agent - N474- - not water-cooled
2 - Electrical connector for injector for reducing agent - N474-
Injector for reducing agent - N474- - water-cooled

© satelettronica
Components at bottom of tank (engine code CKVB only)
1 - Control unit for reducing agent metering system - J880-
2 - Reservoir
3 - Control unit for NOx sender 2 - J881- and NOx sender 2 -
G687-
4 - Electrical connector for heater for reducing agent line - Z104-
5 - Reducing agent line
The following components are located in the reservoir -item 2-:
♦ Tank sender for reducing agent - G684-
♦ Temperature sender for reducing agent - G685-
♦ Pressure sender for reducing agent metering system - G686-
♦ Pump for reducing agent - V437-
♦ Heater for reducing agent tank - Z102-
Exploded view ⇒ page 620 .

Fitting locations of exhaust gas temperature sensors (engine

code CPNB only)
1- Exhaust gas temperature sender 3 - G495-
3- NOx sender - G295-
5- Electrical connector for exhaust gas temperature sender 2
- G448-
- G495-
7- Electrical connector for Lambda probe - G39-
Control unit for NOx sender - J583- with NOx sender - G295- (en‐
gine code CPNB only)
1- Electrical connector for control unit for NOx sender - J583-
3- Control unit for NOx sender - J583-
© satelettronica
Control unit for NOx sender 2 - J881- and NOx sender 2 - G687-
(engine code CPNB only)
1- Electrical connector for control unit for NOx sender 2 - J881-
2- NOx sender 2 - G687-
3- Control unit for NOx sender 2 - J881-

Particulate sensor - G784- (engine code CPNB only)

1- Electrical connector for particulate sensor - G784-
2- Particulate sensor - G784-
3- Control unit for particulate sensor - G784-
Fitting location of NOx sender 2 - G687- (engine codes CTCB and

CTCC only)
© satelettronica
1- NOx sender 2 - G687-
Fitting location of control unit for NOx sender 2 - J881- (engine

codes CTCB and CTCC only)
1- Electrical connector for control unit for NOx sender 2 - J881-
2- Control unit for NOx sender 2 - J881-
1.2.2 Overview of fitting locations - injection system, vehicles with two turbo‐
chargers
Engine compartment


⇒ page 552
⇒ page 499
❑ Exploded view
⇒ page 673
3 - Electrical connector for ex‐
haust gas recirculation tem‐
perature sensor - G98-
⇒ page 499
❑ For map-controlled en‐
gine cooling system
thermostat - F265- , fuel
metering valve - N290-
and exhaust gas recir‐
culation control motor -
V338-
© satelettronica
⇒ page 499
5 - Restrictor
❑ In fuel return line
⇒ page 499
- G505-
⇒ page 501
7 - Fuel temperature sender -
G81-
8 - Control unit for structure-borne sound - J869-
❑ Exhaust gas temperature sender 1 - G235-
❑ Charge pressure sender 2 - G447-
11 - Regulating flap potentiometer - G584-


18 - Injectors
❑ Cylinder bank 2
19 - Turbine changeover valve - N529-
© satelettronica
22 - Intake manifold flap motor - V157-
24 - Map-controlled engine cooling system thermostat - F265-
❑ Integrated in oil filter housing; cannot be renewed individually
⇒ “6.3 Removing and installing fuel pressure regulating valve N276 ”, page 547
❑ Tightening torque ⇒ Fig. ““ Fuel pressure regulating valve -N276- - tightening torque”“ , page 481
29 - Injectors
❑ Cylinder bank 1
Engine (top view)


valve - N276-
lip
⇒ page 551
page 481
❑ Exploded view
⇒ page 556
❑ Exploded view
⇒ page 673
❑ Exploded view
© satelettronica
⇒ page 556
⇒ page 499
❑ Exploded view
⇒ page 673
❑ Exploded view
⇒ page 673
❑ Exploded view
⇒ page 556
❑ On turbocharger
15 - Glow plug 6 - Q15-


17 - Glow plug 5 - Q14-
22 - Glow plug 4 - Q13-
© satelettronica
26 - Electrical connector for charge pressure control solenoid valve - N75-
27 - Electrical connector coolant valve for cylinder head - N489-
30 - Restrictor in fuel return line
Engine (front view)


sender - G266-
❑ Exploded view
⇒ page 318
❑ Integrated in oil filter
housing; cannot be re‐
newed individually
G664-
⇒ page 500
❑ Exploded view
⇒ page 176
❑ Exploded view
⇒ page 335
© satelettronica
❑ Exploded view
⇒ page 335
N345-
V157-
❑ Exploded view
⇒ page 512
J338-
❑ Exploded view

⇒ page 512
9 - Turbine changeover valve - N529-
A - Fuel pump control unit - J538-
B - Injector for reducing agent - N474-
C - NOx sender - G295- with control unit for NOx sender - J583-
❑ Fitting location of NOx sender - G295- ⇒ page 502
❑ Fitting location of control unit for NOx sender - J583- ⇒ page 503
© satelettronica
D - NOx sender 2 - G687- with control unit for NOx sender 2 - J881-
E - Control unit for reducing agent metering system - J880-
Fitting locations (driver's side)

2 - Clutch position sender - G476- with clutch pedal switch for
engine start - F194- and clutch pedal switch - F36- (manual gear‐
box only)
Removing and installing ⇒ Rep. gr. 30 ; Clutch mechanism; Re‐
moving and installing clutch position sender - G476-
Radiator fan control unit - J293-

1 - Radiator fan control unit - J293-
2 - Electrical connector for radiator fan - V7-
3 - Electrical connector for radiator fan 2 - V177-


♦ -Item 2- on cylinder head cover, cylinder bank 1 (right-side)
1- For exhaust gas recirculation temperature sensor - G98-
2- For map-controlled engine cooling system thermostat -
F265- , fuel metering valve - N290- and exhaust gas recir‐
culation control motor - V338-
3- Restrictor in fuel return line
© satelettronica
Fitting location of fuel metering valve - N290-
♦ -Item 2- in high-pressure pump
Fitting location of charge pressure sender - G31- / intake air tem‐

♦ -Item 2- at air pipe (left-side) in engine compartment


regulation - G694-
♦ -Item 1- at front left of cylinder block

G83-
© satelettronica
Regulating flap potentiometer - G584-
Oil temperature sender 2 - G664-

Fuel pressure sender - G247- -arrow-
© satelettronica
Lambda probe - G39-

3 - Connection from pressure pipe for pressure differential sender
- G505-
♦ -Item 2- at rear right of engine

Fitting locations on turbocharger

The turbocharger 1 control unit - J724- can be seen on the left.
Exhaust gas temperature sender in turbocharger

2 - Electrical connector for exhaust gas temperature sender 1 -
G235-
© satelettronica
Exhaust gas temperature sender
1 - Electrical connector for bank 2 exhaust gas temperature send‐
er 4 - G649-
2 - Exhaust gas temperature sender 4 for cylinder bank 2 - G649-
Note
♦ The exhaust gas temperature sender 4 for bank 2 - G649- is

shown as an example.
♦ Exhaust gas temperature sender 4 - G648- is fitted on the op‐
posite side.
Fitting location of NOx sender - G295-

NOx sender - G295- -arrow-

Fitting location of control unit for NOx sender - J583-

2 - Electrical connector for control unit for NOx sender - J583-
3 - Control unit for NOx sender - J583-
Fitting location of NOx sender 2 - G687- with control unit for NOx
sender 2 - J881-
© satelettronica
Engine mounting (left-side)
2 - Electrical connector for left electrohydraulic engine mounting
Engine mounting (right-side)

1 - Electrical connector for right electrohydraulic engine mounting
2 - Right electrohydraulic engine mounting solenoid valve - N145-

Engine speed sender - G28-

If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled.
© satelettronica
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.
Proceed as follows to fill high-pressure pump with fuel.

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
♦ Drive train
♦ Activate fuel pump
♦ Press Carry out check
♦ Select 120 seconds.
– The fuel pump must run for 120 seconds to ensure that the
fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.


– Then inspect high-pressure section again for leaks.

Procedure
renewed.
– Then inspect high-pressure section of fuel system again for
leaks.
© satelettronica

2 Vacuum system

⇒ “2.1.1 Connection diagram - vacuum system, vehicles with one
⇒ “2.1.2 Connection diagram - vacuum system, vehicles with two
2.1.1 Connection diagram - vacuum system, vehicles with one turbocharger

N345-
head - N489-
3 - Vacuum unit
© satelettronica
lation cooler
5 - To brake servo
6 - Shut-off valve
❑ For coolant
7 - Vacuum connection
❑ On sump (top section)
❑ To vacuum pump

2.1.2 Connection diagram - vacuum system,

Caution

1 - To vacuum pump
❑ In sump (bottom sec‐
tion)
2 - Turbine changeover valve -
N529-
tion
© satelettronica
N345-
5 - Charge pressure control
head - N489-
7 - Actuator
lation cooler
8 - Vacuum unit
❑ For charge pressure
control
9 - Vacuum unit
❑ For turbine changeover
valve - N529-
❑ With regulating flap po‐
tentiometer - G584-
10 - To brake servo
12 - To vacuum reservoir


Procedure
♦ Cracks
© satelettronica
leading to the relevant component and also check the remain‐
ing vacuum lines in the system.
hoses for leaks.

3 Air cleaner
1 - Air duct
2 - Sealing element
3 - Mounting
⇒ page 510
© satelettronica
parts catalogue
Maintenance tables
let 411
6 - Lid
its or dirt
let 411
7 - Air pipe
hose clips ⇒ page 466
8 - Bolt
❑ For securing air mass
meter - G70- to air pipe (“version 1”) or repair method if retaining tabs on air pipe have broken off (“version
2”) ⇒ Electronic parts catalogue
❑ Thread-forming
❑ Fit and screw in bolt by hand so that it is screwed into old thread. Then tighten bolt to torque
❑ 3.5 Nm
10 - Heat shield
11 - Bolt
❑ 1.5 Nm
12 - Bolt
❑ 1.5 Nm
3. Air cleaner 509

13 - Heat shield
14 - Air duct
15 - Bolt
❑ 3.5 Nm

housing
Removing
ments .
Note
© satelettronica
Disregard -item 1-.


move clear.
Installing
Note

– Check air pipe (engine intake side) for salt residue, dirt and
leaves.
© satelettronica
note the following:
ments .
Tightening torques
3. Air cleaner 511

4 Intake manifold
⇒ “4.3 Removing and installing intake manifold flap motor V157
”, page 518
520
1 - Bracket
❑ For air pipe
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
© satelettronica
4 - Gasket
❑ Renew
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 9 Nm
V157-
⇒ page 518
8 - Gasket
❑ Renew
9 - Intake manifold
⇒ page 513
10 - Bolt
sequence
⇒ page 513
11 - Mounting pin
❑ For engine cover panel
❑ 5 Nm
12 - Bracket
❑ For electrical connector
13 - Bolt
❑ 4 Nm
14 - Cable guide
15 - Bolt
❑ 4 Nm
16 - Gaskets
❑ Renew

17 - Bracket
❑ For exhaust gas recirculation cooler change-over valve - N345-
18 - Bolt
❑ 9 Nm
19 - Mounting pin
❑ 5 Nm
20 - Air pipe
21 - Bolt
❑ 9 Nm
22 - Gasket
❑ Renew
24 - Air hose
© satelettronica
26 - Gasket
❑ Renew
27 - Pipe
28 - Bolt
❑ 9 Nm
29 - Pipe
30 - Gasket
❑ Renew
Intake manifold - tightening torque and sequence

1. -1 to 4-, Screw in by hand until contact is made
-arrows-
2. -1 to 4- 5 Nm, in sequence indicated
3. -1 to 4- -arrows- 9 Nm, in any sequence


© satelettronica
Removing
Caution
♦ Use an absorbent cloth to catch escaping fuel.

♦ No fuel must be allowed to spill onto components or seals
in the vicinity of the engine; this can ultimately lead to
damage caused by leaking seals.

– Use removal lever - 80 - 200- to move electrical wiring harness
and hoses clear at cable guide -1-.
– Pull coolant hose off to rear -arrow-.
– Unscrew bolts -2 and 3- and remove cable guide -1-.

– Unscrew bolts -1, 2- and detach retaining clamp -3-.

– Unscrew union nuts -arrows- and detach high-pressure pipe
(top).
– Detach electrical connectors -1 and 2- and remove non-return

valve -3- from bracket.
© satelettronica
– If fitted, remove bolt -2- at retaining clamp for high-pressure
pipe.
Note
Disregard -item 1-.
– Unplug electrical connector -2- at coolant valve for cylinder

head - N489- -item 1-.
– Unscrew bolts -arrows- and place bracket with coolant valve
for cylinder head - N489- to the side.

– Unplug electrical connector -arrow- at coolant temperature

sender - G62- .
– If fitted, remove electrical connector -arrow- for injector for re‐

ducing agent - N474- from bracket and unplug connector.
© satelettronica
– Unplug electrical connectors -1 and 2- and move wiring har‐
ness clear to left side.
– Remove bolt -3- from bracket (centre) for intake manifold.
– Pull out plug -3-.

Note
Disregard -item 1-.

– Release screw-type clip -2- on exhaust gas recirculation pipe.
Note
Disregard -item 1-.
– Remove bolts -2- from bracket (left-side) for air pipe.
Note
Disregard -item 1-.
© satelettronica
J338- .
– Release screw-type clip -3- and detach air hose.
Note
Disregard -item 2-.
– Unplug electrical connectors on glow plugs.

– Remove fuel pressure sender - G247- ⇒ page 551 .

– Remove bolts -1 ... 4- and -arrows- and detach intake mani‐

fold.
Installing
Note


Tightening torques
© satelettronica
♦ ⇒ Fig. ““Intake manifold - tightening torque and sequence”“ ,
page 513
♦ ⇒ Item 8 (page 321)
♦ ⇒ Fig. ““Exhaust gas recirculation pipe to intake manifold -
tightening torque and sequence”“ , page 659

flap motor - V157-
Removing
– Remove bolt -3- from bracket (centre) for intake manifold.
Note
Disregard -item 1-.

Note
– Release screw-type clip -2- on exhaust gas recirculation pipe.
© satelettronica
Note
Disregard -item 1-.
– Remove bolts -2- from bracket (left-side) for air pipe.
Note
Disregard -item 1-.


– Press air pipe -2- to left side and detach intake manifold flap
motor - V157- -item 1-.
Installing
Note

Tightening torques
♦ ⇒ Item 8 (page 321)
♦ ⇒ Fig. ““Exhaust gas recirculation pipe to intake manifold -
tightening torque and sequence”“ , page 659
© satelettronica
module - J338-
Removing
– Remove bolts -2- and detach throttle valve module - J338- .
Installing
Note
♦ Renew seal.
Tightening torques

(rail)
page 525
page 527
speed”, page 530
⇒ “5.7 Checking restrictor in fuel return line”, page 532
⇒ “5.9 Removing and installing high-pressure pipes”,
page 539
© satelettronica
page 541
Caution


1 - Support bracket
❑ Different tightening tor‐
ques:
♦ To camshaft bearing:
2.5 Nm
♦ To cylinder head: 9 Nm
2 - Clamping piece
❑ Use a coloured pen to
mark injectors and cor‐
responding clamping
piece and cylinder for
re-installation; pay at‐
tention to markings
when installing
❑ If the injector is installed
on another cylinder for
testing purposes, the
clamping piece must al‐
so be moved
❑ After looking for the
© satelettronica
fault, the injector and the
clamping piece must be
re-installed on their orig‐
inal cylinder
❑ The clamping pieces
can be re-used when in‐
stalling new injectors
3 - Bolt
❑ Renew
❑ Tighten initially to 6 Nm
❑ Then tighten 90° further
❑ From high-pressure
pump to fuel rail
❑ 25 Nm
5 - Retaining clamp
6 - Bolt
❑ 9 Nm
7 - Retaining clamp
8 - Bolt
❑ 9 Nm
❑ From fuel rail on opposite side


❑ 25 Nm
10 - Fuel rail
❑ To fuel tank
❑ From injectors
❑ After renewing, engine must be run at idling speed for approx. 2 minutes to bleed fuel system
❑ Then check fuel return hoses for leaks
13 - Ring connection for hose
14 - Banjo bolt
❑ 25 Nm
15 - Seals
❑ Renew
© satelettronica
❑ After renewing high-pressure pump and/or fuel pressure regulating valve - N276- , adaption must be
performed. Use ⇒ Vehicle diagnostic tester
17 - Bolt
❑ 22 Nm
❑ From fuel rail to injector
❑ Mark allocation for re-installation; pay attention to marking when installing
❑ 25 Nm
❑ From injectors
❑ After renewing, engine must be run at idling speed for approx. 2 minutes to bleed fuel system
❑ Then check fuel return hoses for leaks
20 - O-ring
❑ Renew
21 - Injector
❑ Use a coloured pen to mark allocation of injectors to corresponding clamping piece and high-pressure
pipe, and to corresponding cylinder for re-installation; pay attention to markings when installing
❑ If the injector is installed on another cylinder for testing purposes, the clamping piece must also be moved
❑ Always renew copper seal when removing and installing

❑ After looking for the fault (switching the injectors around), the injector and the clamping piece must be
re-installed on their original cylinder
❑ To remove carbon deposits 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)
22 - O-ring
❑ Renew
23 - Copper seal
❑ Always renew copper seal when removing and installing
❑ Copper seal without chamfer: has no specified installation position
❑ Copper seal with chamfer: note installation position ⇒ page 524
Note installation position for copper seal with chamfer:
© satelettronica
There are four different tests for checking the operation of the
injectors.
• ⇒ “5.3 Performing adaption of correction values for injectors”,
page 525
• ⇒ “5.4 Checking for injectors sticking open”, page 525
• ⇒ “5.5 Checking return flow rate of injectors with engine run‐
ning”, page 527
• ⇒ “5.6 Checking return flow rate of injectors at starter cranking
speed”, page 530
Perform the following tests first if the engine does not start at all:
♦ ⇒ “5.4 Checking for injectors sticking open”, page 525
♦ ⇒ “5.6 Checking return flow rate of injectors at starter cranking
speed”, page 530
♦ ⇒ “6.4 Checking fuel pressure regulating valve N276 ”,
page 549


ues for injectors
♦ The “Injector delivery calibration” and “Injector voltage cali‐

bration” serve to correct the injection rates for each cylinder of
a common rail system individually across the entire operating
range.
♦ The 7-digit adaption value -1- (example) is marked separately
© satelettronica
on each injector. It may consist of letters and/or numbers (AS‐
CII code).
♦ Reference table for reading out letters and/or numbers on
each injector

The adaption procedure is described in the “Guided Fault Find‐
ing”. (The procedure is also described under “Guided Functions”.)
– When a new injector is installed, the adaption value for the new
injector must be stored in the engine control unit.
– Additionally, check that the “Injector delivery calibration val‐
ues” with “Injector voltage calibration values” are correctly
entered for all the other injectors. Do NOT attempt to re-enter
these values if the correct values are already stored in the en‐
gine control unit.
– When the engine control unit is renewed, the appropriate “In‐
jector delivery calibration values” with “Injector voltage cali‐
bration” values must be written into the new engine control
unit.

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

♦ Use a return line to make an -adapter-.
© satelettronica
Procedure
– Clean all fuel rail connections with engine cleaner or brake
cleaner and dry.
Caution

Check all cylinders in turn.

Starting with cylinder 1

– Disconnect fuel return hoses from injectors you want to check;

to do so, press down both tabs and at the same time pull centre
piece up to release connection -arrow-.
Note
Illustration shows cylinder bank 1.
– Connect hand vacuum pump - VAS 6213- with improvised

adapter to return line connection of injector to be tested.
– 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.
In the case of a faulty injector, the vacuum 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 533 .
© satelettronica
Attaching
deformation.
Note
Lubricate all O-rings with engine oil or assembly oil before instal‐
ling.
pin down carefully.
Checking fuel system for leaks
automatically.
– Install engine cover panel ⇒ page 172 .

with engine running

© satelettronica
Caution


Measuring return flow rate of individual injectors
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Clamp off fuel return line downstream of restrictor using hose
clamp up to 25 mm - 3094- .

– Disconnect fuel return hoses from injectors on cylinder bank 1;


© satelettronica
– Connect hoses of return flow meter - VAS 6684- to all return
line connections of the six injectors.
– Start engine and run at idling speed for several minutes:
Caution
Risk of damage to injectors due to increased engine speed.

♦ Do NOT press the accelerator during this test; the engine
must only run at idling speed.
– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 6 injectors must not differ by more
than a small amount.
Evaluating return flow rate:

♦ 1 = injectors OK; return flow rate approx. identical on all injec‐
tors.
♦ 2 = injector for cylinder 3 not OK; return flow rate surpasses
value three times the volume of smallest measured return flow
rate.
Note
There is a mechanical fault at the injector if the return flow rate is

greater than three times the volume of the smallest measured
return flow rate.
– If one injector has a significantly higher return flow rate than

the others it must be renewed ⇒ page 533 .

– Remove hose clamp up to 25 mm - 3094- from fuel return line.

Attaching
deformation.
Note
ling.
pin down carefully.
automatically.
© satelettronica

Only perform this test if the engine does not start at all.

Caution

Measuring return flow rate of individual injectors
© satelettronica
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Clamp off fuel return line downstream of restrictor using hose
clamp up to 25 mm - 3094- .



– Connect hoses of return flow meter - VAS 6684- to all return

line connections of the six injectors.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
– If fuel comes out of one injector, that injector must be renewed
⇒ page 533 .
© satelettronica
– Remove hose clamp up to 25 mm - 3094- from fuel return line.
Attaching
deformation.
Note
ling.
pin down carefully.
automatically.
5.7 Checking restrictor in fuel return line

On vehicles with fuel systems with 6 bar, the restrictor maintains
a constant residual pressure in the fuel return line. This residual
pressure is required for the control function of the injectors.


♦ Tester for fuel return system - VAS 6330-
Caution

© satelettronica
– Clean return line connection on cylinder 1 (with commercial
cleaning solution or similar) before removing.
– Dry return line connection on cylinder 1.
– Cover return line connection on cylinder 1 with a cloth.
– Detach return line connection from cylinder 1. To do so, press
tabs down and pull centre piece up to release connection.
Note
No dirt must be allowed to get into the disconnected return line or

the open connection on the injector.
– Connect tester for fuel return system - VAS 6330- between

return line connection on injector and return line.
– Start engine.
– Check pressure indicated on tester.
♦ Specification: approx. 4 bar
If specification is not attained, renew fuel return line with restrictor
and ring/hose connector.


♦ Cleaning kit - VAS 6811-

♦ Puller - T10055-
© satelettronica
♦ Assembly sleeve - T10377-
♦ Socket - T40055-

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

tudinal member.
© satelettronica
Note

– Place coolant expansion tank to one side.
– Seal off open lines and connections with clean plugs.

Both sides (continued)
Caution

– Unscrew union nut -1- and bolt -2-.

– Unscrew bolts -2 and 3- and remove cable guide.
© satelettronica
– Unplug electrical connectors at injectors -arrows- and at fuel
pressure regulating valve - N276- -item 1-.
– Move clear electrical wiring harness at cylinder head cover
and fuel rail.
– Disconnect fuel return hoses from injectors; to do so, press

down both tabs and at the same time pull centre piece up to
release connection -arrow-.
Caution
Used injectors must always be re-installed on the same cylin‐

der.
♦ Mark injectors to ensure that they are re-installed at the
correct cylinders.

– Loosen union nuts for high-pressure pipes -2, 3 and 4- using

socket - T40055- .
– Mark position of clamping piece -1- in relation to injector with

paint for re-installation.
– Unscrew bolt -2- and detach clamping piece.
– Repeat work steps on remaining injectors.
© satelettronica

– Apply puller - T10055- with adapter -T10055/1- to injector, as

shown in illustration. Pull off injector by tapping gently.
– Place removed injectors on a clean cloth.
Installing new injectors
When installing a new injector, the following components must be
renewed:
♦ Copper seal
Installing used injectors
When re-installing a used injector in the same cylinder, the fol‐
lowing components must be renewed:
♦ Copper seal
© satelettronica
– Spray tip of injector nozzle with rust-solvent spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Continued (same procedure for used and new injectors):
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- .
– Fit new copper seal.

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

– Renew O-ring for injector bore using assembly sleeve -

T10377- .
– Install injectors.
note the following:
Note
ling.
– Push the return line connections carefully over the new seals
and onto the injectors. 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
⇒ page 525 .
© satelettronica
and “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these adaption
values if the correct values are already stored in the engine con‐
trol unit.
Note
– Interrogate the event memory again after road-testing.

Tightening torques

pipes

♦ Socket - T40055-
© satelettronica
Procedure
Note
♦ Before re-installation, check taper seats for deformation,

cracks, damage, scores and corrosion. Renew high-pressure
pipes if they are damaged or corroded.
♦ Check that bore in pipe is not distorted, restricted or damaged
in any other way.
♦ When re-installing "old" high-pressure pipe, observe marking
for installation position.
– Use vacuum cleaner to remove dirt from taper seat at fuel rail.
– Clean fuel pipe and end of pipe with engine cleaner or brake
cleaner and dry.
– Lubricate threads of union nuts with clean engine oil.
– Hand-tighten union nuts on high-pressure pipes until they
make contact (ensure that pipes are not under tension).
Union nuts (AF 17) on fuel rail:
– To secure high-pressure pipes, use torque wrench - V.A.G
1331- with tool insert, AF 17 - V.A.G 1331/6- .

Union nuts (AF 17) on injectors:

– To tighten unions of injectors, use torque wrench - V.A.G
1331- with ratchet - V.A.G 1331/1- and socket - T40055- .
accelerator) and then switch off.
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.

– Carefully check the complete fuel system including all 6 return
line connections for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
with full throttle at least once. Then inspect high-pressure sec‐
© satelettronica
tion of fuel system again for leaks.
Note
– Interrogate the event memory again after road-testing.

Tightening torques

reservoir (rail)

© satelettronica
♦ Socket - T40055-
Removing
– Remove bolts -2, 3- and move cable guide to rear.

– Unscrew union nut on fuel rail to be removed.
Note
♦ -Left arrow- for fuel rail on cylinder bank 1

♦ -Right arrow- for fuel rail on cylinder bank 2
Fuel rail on cylinder bank 1

© satelettronica
– Detach electrical connectors -1 and 2- and remove non-return
valve -3- from bracket.

valve - N276- .

– Remove union nut -1- on fuel rail.

– Remove banjo bolt ⇒ Item 14 (page 523) for fuel return lines
from fuel rail.
– Loosen union nuts of high-pressure pipes -2, 3 and 4-.

– Remove bolts -arrows- from fuel rail and place them down
carefully on a clean surface.
© satelettronica
Fuel rail on cylinder bank 2
– Place coolant expansion tank to one side.

-arrow-.

– Unclip bracket for electrical connectors -6 and 7-.

– Remove union nut of rear fuel supply line on fuel rail.
– Unscrew union nuts for high-pressure pipes between injectors
and fuel rail.
– Remove bolts from fuel rail and place them down carefully on
a clean surface.
Installing
Tightening torques
© satelettronica


⇒ “6.1 Removing and installing control unit for structure-borne
sound J869 and actuator for structure-borne sound R214 ”, page
546
⇒ “6.2 Removing and installing engine sound generator control
unit J943 ”, page 547
N276 ”, page 547
page 549
551
⇒ “6.6 Removing and installing air mass meter G70 ”,
page 552
”, page 553
6.1 Removing and installing control unit for
© satelettronica
structure-borne sound - J869- and ac‐
tuator for structure-borne sound - R214-
Removing
chamber cover .
Control unit for structure-borne sound - J869- :
– Unplug electrical connector -2- and unclip control unit for struc‐
ture-borne sound - J869- .
Actuator for structure-borne sound - R214- :

– Remove nut -arrow-.
– Detach actuator for structure-borne sound - R214- and dis‐
connect electrical connector -1-.
Installing
Installation is carried out in the reverse order; note the following.
chamber cover .
Tightening torques
♦ ⇒ Fig. ““ Actuator for structure-borne sound -R214- - tightening
torque”“ , page 420

6.2 Removing and installing engine sound

generator control unit - J943-
Removing
– Remove retaining frame (top) for control units ⇒ Electrical
– Unplug electrical connector -4- and unclip engine sound gen‐
erator control unit - J943- .
Note
Other items can be disregarded.
Installing
© satelettronica
♦ Open-end spanner insert, 30 mm - T10553-
Note
♦ The fuel pressure regulating valve - N276- maintains a con‐

stant pressure in the fuel rail and the injector pipes (high-
pressure fuel circuit).
♦ It is not possible to start engine if fuel pressure regulating valve
- N276- is defective.
♦ 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 hose.
♦ If the pressure in the high-pressure fuel circuit is too low, the
valve closes and seals off the high-pressure section of the
system from the low-pressure section.
sealing lip and can only be used once. Do not install it for test
purposes.
Removing
WARNING

– Clean thread and area all around fuel pressure regulating

valve with engine cleaner or brake cleaner and dry.

Note
♦ Clean carefully; cleaning solution must not enter the electrical

connector.
♦ Make sure no dirt gets into opening in fuel rail.
– Remove banjo bolt for fuel return hoses.

valve - N276- .
– Loosen union nut using open-end spanner insert, 30 mm -
housing). Then unscrew and remove by hand.
– Remove dirt from thread and sealing surface of fuel rail using
a vacuum cleaner. Do not use metal tools, etc.
Note
Seal off opening in fuel rail immediately with a suitable plug to
© satelettronica
prevent dirt from entering.
Installing
Note

sealing lip and no separate seal; it can therefore be used only
once.
♦ Check that deformable sealing lip and thread 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.
– Position fuel pressure regulating valve - N276- so that electri‐

cal wiring is not under tension when connector -arrow- is
plugged in.
– Tighten union nut using open-end spanner insert, 30 mm -
housing).
– Tighten banjo bolt for fuel return lines with new seals to 25 Nm.
After renewing high-pressure pump and/or fuel pressure regulat‐
ing valve - N276- , adaption must be performed. Use ⇒ Vehicle
diagnostic tester.
Tightening torques
♦ ⇒ Fig. ““ Fuel pressure regulating valve -N276- - tightening
torque”“ , page 481


- N276-

♦ Test hose for return line connection
© satelettronica
Procedure
WARNING

Note
Fuel temperature above 15 °C.
– Detach fuel return hose -2-.
Note

– Seal off open return line connection with a test hose -2- and a
hose clamp up to 25 mm - 3094- .
– Hold end of fuel return hose -1- in measuring container.
– Start engine and run at idling speed for one minute.
• Return flow rate (engine start): 0 ml
– Leave engine running at idling speed.
– While engine is running, empty measuring container, or ex‐
change it for an empty container and begin measurement.
– Leave engine running at idling speed for two minutes and
measure return flow rate.
• Return flow rate after 2 minutes: 0 ... 60 ml
Note
If specified values are obtained, fuel pressure regulating valve -

N276- is OK.
If values do not match specifications:
© satelettronica
Note
♦ The fuel pressure regulating valve - N276- and injectors were

checked during the preceding measuring process.
♦ To determine which component is defective, you must check
the return flow rate of the injectors.
– Measure return flow rate of injectors with engine running

⇒ page 527 .
– If return flow rate of injectors is OK, renew fuel pressure reg‐
ulating valve - N276- .
– If return flow rate of injectors is not OK, renew defective injec‐
tor.
automatically.
Note


sender - G247-
♦ Socket - T40218-
♦ Torque wrench
Removing
© satelettronica
Caution


– Clean thread and area all around fuel pressure sender with
engine cleaner or brake cleaner and dry.
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
and no separate seal; it can therefore be used only once.
♦ Clean carefully; cleaning solution must not enter the electrical
connector.
♦ Make sure no dirt gets into opening in high-pressure reservoir.


-arrow-.
– Unscrew fuel pressure sender - G247- using socket, 27 mm -
T40218- .
Note

ing.
– Remove dirt from opening in fuel rail using a vacuum cleaner.

Do not use metal tools, etc.
Seal off opening in fuel rail immediately with a suitable plug to
prevent dirt from entering.
Installing
Note
© satelettronica
♦ The fuel pressure sender - G247- has a deformable sealing lip
and no separate seal; it can therefore be used only once.
♦ Check that the deformable sealing lip and the thread on the
new fuel pressure sender - G247- are not damaged.
♦ Check sealing surface at opening in high-pressure reservoir.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure sender - G247- must be coated with diesel
fuel.
– Screw in fuel pressure sender - G247- by hand.

– Then tighten fuel pressure sender - G247- to specified torque.
Tightening torques
♦ ⇒ Fig. ““ Fuel pressure sender -G247- - tightening torque”“ ,
page 481

- G70-
Removing

Air pipe - version 1:

– Unscrew bolts -arrows- and detach air mass meter - G70- .
Air pipe - version 2:

– Release fasteners -arrows- all around and detach air mass
meter - G70- -item 2-.
Installing
© satelettronica
To ensure that the air mass meter - G70- functions correctly, it is
Note
values. This will cause a loss of power as the calculated in‐
♦ If fasteners on air pipe (“version 2”) have broken off, secure
air mass meter - G70- with bolts ⇒ Item 8 (page 509) ; for bolts,
refer to ⇒ Electronic parts catalogue .
Tightening torques

Note

deposits in the particulate filter.


Removing
Procedure for vehicles with one turbocharger
– Unclip pressure differential sender - G505- -2- from bracket
and detach.
– If hose is to be disconnected from pressure sender, release
hose clips (if fitted) and spray hose with silicone-free lubricant.
– To prevent hose connection from breaking off, carefully dis‐
connect hose and keep it straight when pulling it off.
Procedure for vehicles with two turbochargers
© satelettronica


– Unclip pressure differential sender - G505- from bracket and
detach.
– If hose is to be disconnected from pressure sender, release
hose clips (if fitted) and spray hose with silicone-free lubricant.
– To prevent hose connection from breaking off, carefully dis‐
connect hose and keep it straight when pulling it off.
Note
The short measuring line can be pulled off with the pressure dif‐
ferential sender - G505- removed.
Installing
Note
♦ Blow through hose (towards particulate filter) with compressed
© satelettronica
air to remove dirt or ice (frozen condensation).
leaks.
♦ If pressure pipes have been detached from particulate filter,
tighten connections to specified torque.
Adaption must be performed after renewing pressure differential

sender - G505- and/or particulate filter. Use ⇒ Vehicle diagnostic
tester.
Tightening torques
♦ ⇒ “8.1.1 Exploded view - Lambda probe, vehicles with one
turbocharger and without SCR system”, page 563

page 557
1 - Nut
❑ To loosen, counterhold
adapter -item 2- using
counterhold tool -
T40248- or counterhold
tool - T40292-
❑ 70 Nm
2 - Adapter
❑ For chain sprocket for
high-pressure pump
❑ Different types of adapt‐
ers are fitted depending
© satelettronica
on version
❑ To loosen nut -item 1-,
use counterhold tool -
T40248- or counterhold
tool - T40292-
❑ Install on new high-
pressure pump when re‐
newing high-pressure
pump
3 - O-ring
❑ Renew
Caution
Risk of malfunctions
caused by dirt.
Observe
♦
⇒ “3.1 Rules for cleanli‐
ness”, page 8 .
Running when dry cau‐
ses irreparable damage
to high-pressure pump.
After
♦ installing the high-
pressure pump, the
pump must first be filled
with fuel before the en‐
gine is started for the first
time ⇒ page 504 .

❑ Always renew high-pressure pipe when renewing high-pressure pump

❑ 25 Nm
8 - O-ring
❑ Renew
❑ 2 Nm
❑ Always renew high-pressure pipe when renewing high-pressure pump
❑ 25 Nm
11 - Bolt
❑ Renew
❑ 22 Nm
© satelettronica
pump
♦ Wrench, 21 mm - T40263-

♦ Counterhold tool - T40248- or counterhold tool - T40292- (dif‐

ferent types of adapters are fitted depending on version)
© satelettronica
Removing
– Remove coolant shut-off valve ⇒ page 375 .

– Unscrew bolts -arrows- and swivel bracket -1- for turbocharger

to side.
noise insulation .

© satelettronica
Caution

slips.
-arrow-.
– Turn crankshaft until chain sprocket for high-pressure pump

can be locked in position using locking pin -T40245- .
Caution



(right-side) -1-.

(left-side) -1-.
© satelettronica
– Release hose clips -3 and 4- and detach fuel hoses.
Note
Lay a cloth under the connection to catch escaping fuel.
Note
Disregard -item 1-.
– Unscrew bolts -arrows- and detach high-pressure pump.

Installing

– When renewing high-pressure pump, install adapter from old

high-pressure pump on new pump.
– Use counterhold tool - T40248- or counterhold tool - T40292-
to loosen and tighten nut -arrow-.
– Detach adapter from high-pressure pump -1-, as shown in il‐

lustration. Use commercially available pullers, e.g. Kukko
15-1/, 17-1/ and 18-1.
Note
♦ Different types of adapters are fitted depending on version.

♦ Always renew high-pressure pipes when renewing high-pres‐
© satelettronica
sure pump.

– Insert high-pressure pump into chain sprocket.

• The dual toothing -arrow A- on the chain sprocket must align
with the groove -arrow B- in the adapter on the high-pressure
pump shaft.
– Install coolant shut-off valve ⇒ page 375 .
Caution

sure pump.
♦ After installing the high-pressure pump, the pump must
first be filled with fuel before the engine is started for the
first time ⇒ page 504 .
© satelettronica
Tightening torques

8 Lambda probe
⇒ “8.3 Removing and installing NOx sender”, page 573

⇒ “8.1.1 Exploded view - Lambda probe, vehicles with one tur‐
bocharger and without SCR system”, page 563
⇒ “8.1.2 Exploded view - Lambda probe, vehicles with one tur‐
bocharger and with SCR system, version 1”, page 564
⇒ “8.1.4 Exploded view - Lambda probe, vehicles with two turbo‐
chargers and without SCR system”, page 567
⇒ “8.1.5 Exploded view - Lambda probe, vehicles with two turbo‐
chargers and with SCR system”, page 568
8.1.1 Exploded view - Lambda probe, vehicles with one turbocharger and without
SCR system
© satelettronica
1 - Pressure pipe
❑ For pressure differential
sender - G505-
❑ 45 Nm
⇒ page 569
❑ After renewing, learnt
ted; see ⇒ Vehicle diag‐
nostic tester
sembly paste
ture paste
slots on the Lambda
probe body
❑ 52 Nm
- G505-
⇒ page 553
❑ 4.5 Nm
sender 4 - G648-
8. Lambda probe 563


8.1.2 Exploded view - Lambda probe, vehicles with one turbocharger and with
SCR system, version 1
1 - Nut
❑ 2 Nm
2 - NOx sender 2 - G687- with
control unit for NOx sender 2 -
J881-
⇒ page 576
NOx sender 2 - G687- :
52 Nm
© satelettronica
sender 3 - G495-
⇒ page 649
⇒ page 565
⇒ page 569
nostic tester
sembly paste
logue for high-temperature paste
❑ The assembly paste/high-temperature paste must not get into the slots on the Lambda probe body
❑ 52 Nm
7 - NOx sender - G295- with control unit for NOx sender - J583-
❑ Only installed on vehicles with engine code CPNB
❑ Tightening torque for NOx sender - G295- : 52 Nm
8 - Nut
❑ 2 Nm


10 - Pressure line for exhaust gas pressure sensor 1 - G450-
❑ Fit into particulate filter, clip into bracket and tighten.
❑ 45 Nm
11 - Bolt
❑ 4 Nm
14 - Turbocharger
© satelettronica
16 - SCR catalytic converter
17 - Particulate sensor - G784-
18 - Nut
❑ 2 Nm
Fitting locations
2- Exhaust gas temperature sender 2 - G448- (engine code
CPNB only)
- G448- (engine code CPNB only)
- G495-
7- Electrical connector for Lambda probe - G39-
8. Lambda probe 565

8.1.3 Exploded view - Lambda probe, vehicles with one turbocharger and with
SCR system, version 2
sender 3 - G495-
⇒ page 647
⇒ page 569
nostic tester
sembly paste
© satelettronica
ture paste
slots on the Lambda
probe body
❑ 55 Nm
sender 2 - G448-
⇒ page 646
5 - Union screw
- G505-
7 - Bracket
❑ For pressure differential sender - G505-
8 - Bolt
❑ 4.5 Nm
9 - Turbocharger
11 - Union screw
13 - Control unit for NOx sender 2 - J881- with NOx sender 2 - G687-

8.1.4 Exploded view - Lambda probe, vehicles with two turbochargers and without
SCR system

sender 4 for cylinder bank 2 -
G649-
⇒ page 652
2 - Pressure pipe
sender - G505-
❑ 45 Nm
sender 3 - G495-
⇒ page 649
© satelettronica
sender 1 - G235-
⇒ page 643
⇒ page 570
nostic tester
sembly paste
ture paste
❑ 52 Nm
8. Lambda probe 567

8.1.5 Exploded view - Lambda probe, vehicles with two turbochargers and with
SCR system

J881-
⇒ page 578
❑ Coat thread of NOx
sender 2 - G687- with
high-temperature paste;
for high-temperature
paste refer to ⇒ Elec‐
NOx sender 2 - G687- :
52 Nm
sender 4 - G648- / exhaust gas
temperature sender 4 for bank
2 - G649-
© satelettronica
⇒ page 652
❑ Which of the two ex‐
senders is fitted de‐
pends on the model
year; for allocation, refer
to ⇒ Vehicle diagnostic
tester
3 - Catalytic converter heater 1
- Z119- / catalytic converter
heater 2 - Z120-
4 - Electrical wire
❑ Remove using puller -
T40317-
5 - Nut
❑ 5 Nm
❑ Coat thread of NOx sender - G295- with high-temperature paste; for high-temperature paste refer to ⇒
Electronic parts catalogue .
❑ Tightening torque for NOx sender - G295- : 52 Nm
❑ After renewing, learnt values must be re-adapted; see ⇒ Vehicle diagnostic tester
❑ 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
❑ 52 Nm


11 - Pressure line for pressure differential sender - G505-
❑ 45 Nm
13 - Exhaust gas temperature sender 4 for bank 2 - G649- or exhaust gas temperature sender 4 - G648-
❑ Which of the two exhaust gas temperature senders is fitted depends on the model year; for allocation,
refer to ⇒ Vehicle diagnostic tester

⇒ “8.2.1 Removing and installing Lambda probe G39 - vehicles
with one turbocharger”, page 569
⇒ “8.2.2 Removing and installing Lambda probe G39 - vehicles
© satelettronica
- G39- - vehicles with one turbocharger
♦ Tool set - T10395 A- with suitable tool insert
8. Lambda probe 569

Removing
WARNING

system ⇒ page 7 .

– Unscrew Lambda probe - G39- -item 4- using a tool from tool
set - T10395 A- .
Installing
Note
© satelettronica
body.
Tightening torques
Adapting learnt values if Lambda probe was renewed
– Select and start Diagnosis .
– Choose Select own test and select following options one
after the other:
♦ Drive train
♦ 01 - Engine electronics J623
♦ 01 - Lambda probe - Adapt learnt values

- G39- - vehicles with two turbochargers

© satelettronica
8. Lambda probe 571

Removing
WARNING

system ⇒ page 7 .

Installing
Note
© satelettronica
body.
Tightening torques
Adapting learnt values if Lambda probe was renewed
after the other:
♦ Drive train
♦ 01 - Lambda probe - Adapt learnt values

8.3 Removing and installing NOx sender

⇒ “8.3.1 Removing and installing NOx sender G295 - vehicles with
one turbocharger”, page 573
⇒ “8.3.2 Removing and installing NOx sender G295 - vehicles with
⇒ “8.3.3 Removing and installing NOx sender 2 G687 - vehicles
with one turbocharger and with SCR system, version 1”,
page 576
with one turbocharger and with SCR system, version 2”,
page 577
8.3.1 Removing and installing NOx sender -

G295- - vehicles with one turbocharger
© satelettronica
Removing
WARNING

system ⇒ page 7 .
8. Lambda probe 573


Note
Different spanner sizes are required depending on the NOx send‐

er fitted.
– Unscrew NOx sender - G295- -2- with appropriate size tool.

Installing
Note
Coat thread with high-temperature paste; for high-temperature

paste refer to ⇒ Electronic parts catalogue .
© satelettronica
Tightening torques
♦ ⇒ “8.1.2 Exploded view - Lambda probe, vehicles with one
turbocharger and with SCR system, version 1”, page 564

G295- - vehicles with two turbochargers

Removing
WARNING

system ⇒ page 7 .

Note
© satelettronica
– Lift retaining clip and disconnect coolant line -2-.
– Remove bolt -3- and place coolant expansion tank to one side.
Note

er - G295- fitted.
– Unscrew NOx sender - G295- -arrow- with appropriate size

tool.
8. Lambda probe 575


– Unscrew nut -1- and detach control unit for NOx sender - J583-
-item 3- from bracket.
– Move electrical wiring harness clear and detach NOx sender
- G295- with control unit for NOx sender - J583- .
Installing
Note

Tightening torques
♦ ⇒ “8.1.5 Exploded view - Lambda probe, vehicles with two tur‐
bochargers and with SCR system”, page 568
tem”, page 466
© satelettronica
8.3.3 Removing and installing NOx sender 2 -
and with SCR system, version 1

Removing
WARNING

system ⇒ page 7 .
– Detach underbody trim (rear left) ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Underbody trim; Removing and installing
underbody trim .
Note
© satelettronica
er 2 - G687- fitted.
– Unscrew NOx sender 2 - G687- -2- with appropriate size tool.

Installing
Note

Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody trim

and with SCR system, version 2
8. Lambda probe 577

Removing
WARNING

system ⇒ page 7 .
© satelettronica
– Unscrew speed nut -2- for cable guide.
Note


– Unscrew nuts -arrows- and detach control unit for NOx sender
2 - J881- -item 2- from bracket.
Installing
Note

Tightening torques


© satelettronica
Removing
WARNING

system ⇒ page 7 .

underbody trim .
8. Lambda probe 579


– Unscrew nuts -arrows- for control unit for NOx sender 2 -
J881- .
Note


Installing
Note

© satelettronica
Tightening torques


page 582

♦ Isolator box, 198-pin - VAS 6606/1-1-
♦ Sheets -VAS 6606/1-1-
♦ Sheets -VAS 6606/2-1-
♦ Sheets -VAS 6606/3-1-
♦ Set of cables -VAS 6606/7-1- and -VAS 6606/7-2-
© satelettronica
Note
♦ Always make sure that the cables are properly connected.

♦ Do not use damaged or worn tools and accessories.
♦ Observe operating instructions.
– Connect both cable sets -VAS 6606/7-1- and -VAS 6606/7-2-

to the three isolator boxes -VAS 6606- .
– Use the following sheets:
♦ -VAS 6606/1-1- for isolator box, 198-pin - VAS 6606/1-1-
Note
Make sure that all plug-in bridges are inserted completely in all
isolator boxes.
– Connect earth strap to an isolator box and to an earth point on

the vehicle.
– Connect engine control unit to cable set -VAS 6606/7-1- .

– Connect vehicle wiring harness to cable set -VAS 6606/7-2- .

The connection on the engine control unit consists of a large and
a small connector.
The large connector has 105 pins and is assigned to the sheets
for the isolator box marked “A 1 to A 105”.
The small connector has 91 pins and is assigned to the sheets
for the isolator box marked “B 1 to B 91”.
When a push-in bridge is pulled out, the corresponding wiring
connection is disconnected.
Note
♦ The “In” contact -1- (red socket) leads to the engine control
unit.
♦ The “Out” contact -2- (blue socket) leads to the wiring harness.

© satelettronica
Note


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
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
Note
If the adaption values of the injectors cannot be read out of the

old (defective) engine control unit, they must be entered into the
new engine control unit manually and the adaption procedure
must be performed accordingly.

chamber cover .


-item 1-.
Note
Disregard -item 2-.
Installing
© satelettronica
– After the engine control unit - J623- has been renewed, the
“Injector delivery calibration” and the “Injector voltage calibra‐
tion” must also be re-adapted in the engine control unit (these
functions influence engine power and exhaust emissions).
– On vehicles with particulate filter the current mileage (km)
reading must be stored in the engine control unit - J623- via
an adaption procedure.
chamber cover .


⇒ “1.1.1 Exploded view - silencers, vehicles with one turbocharger
and without SCR system”, page 584
⇒ “1.1.2 Exploded view - silencers, vehicles with one turbocharger
and with SCR system”, page 587
⇒ “1.1.3 Exploded view - silencers, vehicles with two turbocharg‐
ers and without SCR system”, page 590
© satelettronica
⇒ “1.1.4 Exploded view - silencers, vehicles with two turbocharg‐
ers and with SCR system”, page 592
1.1.1 Exploded view - silencers, vehicles with one turbocharger and without SCR
system

1 - Y-pipe
original equipment
❑ Y-pipe and rear silencer
can be renewed sepa‐
rately as required
❑ Cutting point: Y-pipe /
rear silencer
⇒ page 600
⇒ page 602
2 - Mounting
❑ Check preload
tem”, page 602
❑ With flexible joint; do not
© satelettronica
bend flexible joint more
than 10° – otherwise it
can be damaged
❑ Protect against knocks
and impact
⇒ page 594
⇒ page 602
4 - Gasket
❑ Renew
❑ Mounting components:
♦ Vehicles with manual gearbox/multitronic gearbox ⇒ page 587
♦ Vehicles with dual clutch gearbox 0B5 ⇒ page 587
6 - Nut
❑ Renew
❑ 23 Nm
7 - Gasket
❑ Renew
8 - Turbocharger
9 - Nut
❑ Renew
❑ 23 Nm
10 - Clamp (front)


11 - Nut
❑ 23 Nm
12 - Rear silencer
❑ Combined with Y-pipe in one unit as original equipment
❑ Y-pipe and rear silencer can be renewed separately as required
❑ Cutting point: Y-pipe / rear silencer ⇒ page 600
13 - Trim
❑ For tailpipe
14 - Mounting
15 - Nut
❑ 23 Nm
© satelettronica
16 - Clamp (rear)
❑ For separate replacement of Y-pipe and rear silencers
17 - Nut
❑ 23 Nm
Installation position of front clamp - vehicles with one turbocharg‐

er
• Angle -α- = 10°

bottom of clamp.

Components of front exhaust pipe mountings - vehicles with man‐

ual gearbox/multitronic gearbox
1- Spacer sleeve
2- Bracket
3- Rubber buffer
4- Spacer sleeve
5- Bolt, 23 Nm
6- Bolt
7- Washer
9- Spacer sleeve
10 - Nut, 23 Nm
Components of mountings (front) for front exhaust pipe - vehicles

with dual clutch gearbox 0B5
© satelettronica
1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Rubber buffer
8- Bracket
9- Bolt, 23 Nm
10 - Bracket
11 - Nut
1.1.2 Exploded view - silencers, vehicles with one turbocharger and with SCR
system

1 - Y-pipe
original equipment
rately as required
rear silencer
⇒ page 600
⇒ page 602
2 - Bolt
❑ 23 Nm
3 - Mounting
❑ Check preload
tem”, page 602
© satelettronica
can be damaged
and impact
⇒ page 594
⇒ page 602
5 - Gasket
❑ Renew
❑ With pressure line for pressure differential sender - G505- ⇒ Item 10 (page 636)
7 - Nut
❑ Renew
❑ 23 Nm
8 - Gasket
❑ Renew
9 - Turbocharger
10 - Nut
❑ Renew
❑ 23 Nm
11 - Gasket
❑ Renew

12 - Nut
❑ 23 Nm
14 - Clamp
15 - Nut
❑ 23 Nm
16 - Rear silencer
17 - Trim
© satelettronica
❑ For tailpipe
❑ Depending on version
18 - Mounting
19 - Nut
❑ 23 Nm
20 - Clamp (rear)
❑ For separate replacement of double pipe and rear silencer
21 - Nut
❑ 23 Nm
22 - Bolt
❑ 23 Nm
23 - Mounting

1.1.3 Exploded view - silencers, vehicles with two turbochargers and without SCR
system
1 - Double pipe
original equipment
❑ Double pipe and rear si‐
lencers can be renewed
separately
❑ Cutting point between
double pipe and rear si‐
lencer ⇒ page 600
⇒ page 602
2 - Bolt
❑ 23 Nm
3 - Mounting
© satelettronica
4 - Bolt
❑ 23 Nm
5 - Mounting
6 - Nut
❑ Renew
❑ 23 Nm
7 - Gasket
❑ Renew
❑ Mounting components
⇒ page 592
⇒ page 605
9 - Nut
❑ Renew
❑ 23 Nm
10 - Gasket
❑ Renew
13 - Nut
❑ Renew
❑ 23 Nm

14 - Gasket
❑ Renew
16 - Nut
❑ 23 Nm
17 - Clamps (front)
18 - Nut
❑ 23 Nm
19 - Trim
❑ For tailpipe
© satelettronica
20 - Mounting
21 - Nut
❑ 23 Nm
22 - Rear silencer
❑ On right side with actuator 1 for engine sound generator - R257-
❑ On left side with actuator 2 for engine sound generator - R258-
❑ Combined in one unit with double pipe as original equipment
❑ Double pipe and rear silencers can be renewed separately
❑ Cutting point between double pipe and rear silencer ⇒ page 600
23 - Clamp (rear)
24 - Nut
❑ 23 Nm
Installation position of front clamps - vehicles with two turbo‐

chargers
bottom of clamp.

Components of mountings (front) for catalytic converter - vehicles

with two turbochargers
1- Bracket
2- Nut
3- Spacer sleeve
5- Washer
6- Bolt, 23 Nm
7- Bolt, 23 Nm
8- Spacer sleeve
9- Rubber buffer
10 - Bracket
11 - Spacer sleeve
12 - Bolt, 23 Nm
1.1.4 Exploded view - silencers, vehicles with two turbochargers and with SCR
© satelettronica
system
1 - Y-pipe
original equipment
rately as required
rear silencer
⇒ page 600
⇒ page 602
2 - Bolt
❑ 23 Nm
3 - Mounting
4 - Bracket
5 - Bolt
❑ 23 Nm
6 - Mounting
7 - Nut
❑ Renew
❑ 23 Nm
8 - Gasket
❑ Renew


can be damaged
❑ With catalytic converter heater 1 - Z119- / catalytic converter heater 2 - Z120-
❑ Mounting components ⇒ page 592
11 - Nut
❑ 23 Nm
12 - Gasket
❑ Renew
14 - Nut
❑ Renew
❑ 23 Nm
© satelettronica
15 - Gasket
❑ Renew
16 - Particulate filter with NOx storage catalytic converter
17 - Nut
❑ 23 Nm
18 - Clamps (front)
19 - Nut
❑ 23 Nm
20 - Mounting
21 - Nut
❑ 23 Nm
22 - Rear silencer
❑ On right side with actuator 1 for engine sound generator - R257-
❑ On left side with actuator 2 for engine sound generator - R258-
❑ Combined in one unit with double pipe as original equipment
❑ Double pipe and rear silencers can be renewed separately
❑ Cutting point between double pipe and rear silencer ⇒ page 600
23 - Clamp (rear)


24 - Nut
❑ 23 Nm
25 - Bolt
❑ 23 Nm
26 - Mounting

pipe
⇒ “1.2.1 Removing and installing front exhaust pipe - vehicles with
manual gearbox/multitronic gearbox”, page 594
dual clutch gearbox 0CK”, page 596
four-wheel drive”, page 597
© satelettronica
1.2.1 Removing and installing front exhaust

pipe - vehicles with manual gearbox/
multitronic gearbox
Removing
WARNING

system ⇒ page 7 .

– Remove nuts -2- (accessible from above) for front exhaust
pipe.
Note


noise insulation .
Caution

10°.

– Loosen bolt connections -arrows- on clamp.
– Push clamp back and lower front exhaust pipe slightly.
© satelettronica
– Release retaining clip -3- and detach injector for reducing
agent - N474- .
Note
Disregard -item 1-.
– Remove bolts -1- and nuts -2- and lower exhaust pipe slightly.


– Press front exhaust pipe with particulate filter up slightly and
unscrew nut -1-.
– Detach front exhaust pipe.
Installing
Note

Tightening torques
© satelettronica

pipe - vehicles with dual clutch gearbox
0CK
Removing
WARNING

system ⇒ page 7 .

pipe.
Note

noise insulation .


– Press front exhaust pipe with particulate filter up slightly and
unscrew nut -1-.
– Remove bolts -1- and nuts -2-.

Installing
Note
© satelettronica

Tightening torques

pipe - vehicles with four-wheel drive
Removing
WARNING

system ⇒ page 7 .


pipe.
Note

noise insulation .
Caution

10°.

© satelettronica

agent - N474- .
Note
Disregard -item 1-.


– Remove nut -1- and bolt -3- and detach front exhaust pipe.
Installing
Note

Tightening torques
♦ ⇒ “1.1.1 Exploded view - silencers, vehicles with one turbo‐
charger and without SCR system”, page 584

pipe - vehicles with two turbochargers
© satelettronica
Removing
WARNING

system ⇒ page 7 .

noise insulation .
– Remove bolts -2- and nuts -1-.

– Remove nuts -arrows- and detach front exhaust pipe.

Installing
Note

Tightening torques
♦ ⇒ “1.1.3 Exploded view - silencers, vehicles with two turbo‐
WARNING
© satelettronica
system ⇒ page 7 .
♦ The connecting pipe can be cut through at the point marked

in order to renew the Y-pipe/intermediate pipe or rear silencer
(s) separately.

Procedure
© satelettronica
bottom of clamp.
Tightening torques
1.4 Removing and installing silencers

Removing
WARNING

system ⇒ page 7 .

– Remove tunnel cross-piece (rear) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim; Removing and instal‐
ling tunnel cross-piece .


– If fitted, remove NOx sender 2 - G687- -item 2-.
Note
– Loosen and push back clamps -1, 2- and tie up particulate filter
to underbody.
Note
The illustration shows the fitting location on a vehicle with two

turbochargers as an example.
© satelettronica
WARNING
Risk of accident caused by weight of silencers.

♦ A second mechanic is required for removal of the rear si‐
lencer.

– Unscrew bolts -1- and nuts -2- and remove silencer(s).
Installing
Note

Tightening torques
♦ NOx sender 2 - G687-
♦ Tunnel cross-piece ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim

Procedure

Vehicles without clamps between Y-pipe/intermediate pipe and

rear silencers
– Loosen bolt connections for front clamp(s).
mountings for Y-pipe/intermediate pipe are preloaded by -a- =
6 ... 10 mm.
Vehicles with clamps between Y-pipe/intermediate pipe and rear

silencers
Note
On a vehicle with clamps fitted between Y-pipe/intermediate pipe

and rear silencers, it is also necessary to align the Y-pipe/inter‐
mediate pipe.
© satelettronica
mountings for Y-pipe/intermediate pipe are preloaded by -a- =
6 ... 10 mm.
– Tighten bolt connections on front clamp(s) evenly.

ded by -a- = 11 ... 15 mm.

Tightening torques


Procedure
WARNING

system ⇒ page 7 .

– Plug tailpipes during leak test (e.g. with cloth or plug).
– Listen for leaks at connection points between cylinder head/
exhaust manifold, exhaust manifold/intermediate pipe and tur‐
bocharger/intermediate flange etc.
© satelettronica


⇒ “2.2 Removing and installing particulate filter”, page 612

verter
⇒ “2.1.2 Removing and installing SCR catalytic converter”,
page 609
⇒ “2.1.3 Removing and installing catalytic converter heater con‐
trol unit 1 J1021 ”, page 611

verter - vehicles with two turbochargers
♦ Puller - T40317- for vehicles with SCR system
© satelettronica
Removing
WARNING

system ⇒ page 7 .
– Remove intermediate steering shaft ⇒ Running gear, axles,

– Remove Lambda probe ⇒ page 569 .
– Remove exhaust gas temperature sender 2 - G448-
⇒ page 646 .
cross brace .
Caution


– Remove bolts -arrows- on longitudinal member (left-side) and

detach heat shield -1-.
© satelettronica
– If fitted, remove bolts -arrows-.
– Unplug electrical connector -1- and move gearbox oil cooling
valve - N509- to side with coolant hoses -2- attached.
– Unscrew bolts and nuts -arrows- and detach heat shield -1-.


Note
Disregard -item 2-.

side.
© satelettronica
– Remove bolts -1, 2- and detach bracket.


– Remove cover (left-side) -1- for drive shaft in wheel housing.
(left-side).
© satelettronica
– Remove nuts -1, 2-. If necessary, disengage catalytic convert‐
er at turbocharger with the help of a second mechanic.
– For better access when performing the next step, turn catalytic
converter to side.
♦ Item -1- = catalytic converter heater 1 - Z119-
♦ Item -2- = catalytic converter heater 2 - Z120-


Z119- / catalytic converter heater 2 - Z120- using puller -
T40317- .
– Detach catalytic converter.
Installing
Note
– Install Lambda probe ⇒ page 570 .

– Install NOx sender 2 - G687- ⇒ page 576 .
– Secure electrical wiring to catalytic converter heater 1 - Z119- /
catalytic converter heater 2 - Z120- ⇒ Item 5 (page 568) .
© satelettronica
Tightening torques
634
♦ Heat shield for drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Exploded view - drive shaft
2.1.2 Removing and installing SCR catalytic

converter

Removing
WARNING

system ⇒ page 7 .
– If fitted, remove NOx sender 2 - G687- -item 1- using a tool

from tool set - T10395A- .
Note
Disregard -item 2-.
© satelettronica
Note
Disregard -item 1-.


Installing
Adapting learnt values if SCR catalytic converter has been re‐
newed
after the other:
♦ Drive train
♦ Engine code
© satelettronica
♦ 01 - Adapt learnt values - after component re-
placement
Note

Tightening torques
♦ ⇒ “1.1.2 Exploded view - silencers, vehicles with one turbo‐
charger and with SCR system”, page 587

verter heater control unit 1 - J1021-
Removing
Note
Fitting location: catalytic converter heater control unit 1 - J1021-

is fitted in plenum chamber partition panel on right side (as seen
in direction of travel).

chamber cover .

– Unplug electrical connectors -1, 2 and 3-.

– Remove nuts -arrows- and detach catalytic converter heater
control unit 1 .
Installing
chamber cover .
2.2 Removing and installing particulate filter

⇒ “2.2.1 Removing and installing particulate filter - vehicles with
manual gearbox/multitronic gearbox”, page 612
dual clutch gearbox 0CK”, page 613
four-wheel drive”, page 616
© satelettronica
2.2.1 Removing and installing particulate filter

- vehicles with manual gearbox/multi‐
tronic gearbox
Removing
WARNING

system ⇒ page 7 .



plug.
Note
– Detach particulate filter.

Installing
Note

© satelettronica
– Secure electrical wiring to catalytic converter heater 1 - Z119-
⇒ Item 5 (page 568) .
Tightening torques

- vehicles with dual clutch gearbox 0CK
♦ Puller - T40317- for vehicles with catalytic converter heater
Removing
WARNING

system ⇒ page 7 .

noise insulation .

Note
♦ The nuts -2- are removed at a later stage.


Note
Disregard -item 1-.
© satelettronica
– Take electrical connector -1- for exhaust gas temperature
sender 3 - G495- -item 2- out of bracket and unplug.
Note
Disregard -item 3-.

sender 2 - G448- -item 1- from bracket, unplug connector and

– Take electrical connector -2- for Lambda probe - G39-

-item 1- out of bracket, unplug connector and move wiring
clear.
– Release retaining clip -1-, detach injector for reducing agent -

N474- and push to one side with coolant hoses -2- attached.
© satelettronica
– Unplug electrical connector for catalytic converter heater 1 -
Z119- using puller - T40317- .

– If fitted, detach heat shield -1-.

– Remove nuts -2- (accessible from above) and detach partic‐

ulate filter.
Installing
Note

– Secure electrical wiring to catalytic converter heater 1 - Z119-
⇒ Item 5 (page 568) .
© satelettronica
Tightening torques

- vehicles with four-wheel drive
Removing
WARNING

system ⇒ page 7 .

noise insulation .
Caution

10°.



Note

– Secure front exhaust pipe with clamp.


© satelettronica
plug.
Note

– Remove nuts -arrows- and detach particulate filter from tur‐
bocharger.

– Remove nuts -2- (accessible from above) and detach partic‐

ulate filter.
Note
Disregard -item 3-.
Installing
Note

© satelettronica
Tightening torques

- vehicles with two turbochargers
Removing
WARNING

system ⇒ page 7 .
– Detach underbody trim (centre) in direction of exhaust system

and press downwards slightly ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Underbody trim; Removing and installing
underbody trim .
– Detach electrical connector -1- on both sides from bracket and
unplug.
Note
Disregard -item 2-.

– Loosen and push back clamps -1, 2- and remove particulate

filter.
Installing
Note
© satelettronica

Tightening torques
♦ ⇒ “1.1.3 Exploded view - silencers, vehicles with two turbo‐

3 SCR (selective catalytic reduction)

system
⇒ “3.1 Exploded view - reducing agent tank”, page 620
⇒ “3.2 Exploded view - reducing agent supply line”, page 621
⇒ “3.3 Exploded view - delivery unit for reducing agent”,
page 623
⇒ “3.4 Exploded view - control unit for reducing agent metering
system J880 ”, page 624
⇒ “3.5 Draining reducing agent tank”, page 625
⇒ “3.6 Removing and installing reducing agent tank”,
page 625
⇒ “3.7 Removing and installing delivery unit for reducing agent”,
page 628
⇒ “3.8 Removing and installing injector for reducing agent N474
”, page 630
⇒ “3.9 Removing and installing control unit for reducing agent
metering system J880 ”, page 633
© satelettronica
3.1 Exploded view - reducing agent tank
1 - Nut
❑ 2 Nm
2 - Cover
❑ For reducing agent tank
3 - Bolt
❑ 20 Nm
4 - Sleeve
5 - Grommet
6 - Sleeve
7 - Tank
❑ For reducing agent
❑ Fitting location: Beneath
left rear seat on under‐
side of vehicle.
⇒ page 625
8 - Filler line
❑ From filler neck
WARNING
Safety risk due to escap‐
ing reducing agent.
Observe
♦ safety meas‐
ures for handling reduc‐
ing agent ⇒ page 6 .

9 - Breather line
❑ To filler neck
3.2 Exploded view - reducing agent supply

line
⇒ “3.2.1 Exploded view - reducing agent supply line, not water-
cooled”, page 621
⇒ “3.2.2 Exploded view - reducing agent supply line, water-
cooled”, page 622
3.2.1 Exploded view - reducing agent supply line, not water-cooled

2 - Retaining clamp
❑ Renew
3 - Bolt
❑ 5 Nm
© satelettronica
4 - Gasket
❑ Renew
5 - Injector for reducing agent -
N474-
⇒ page 630
❑ Lugs in injector for re‐
ducing agent - N474-
must be inserted in cor‐
responding mountings
in front exhaust pipe.
6 - Metering line
❑ From reducing agent
pump - V437-
❑ With heater for reducing
agent line (heater circuit
2) - Z104-
disconnect
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 7 .
3. SCR (selective catalytic reduction) system 621

3.2.2 Exploded view - reducing agent supply line, water-cooled
2 - Injector for reducing agent -
N474-
⇒ page 631
❑ Lugs in injector for re‐
must be inserted in cor‐
responding mountings
in front exhaust pipe.
3 - O-ring
❑ Renew
4 - Metering line
❑ From reducing agent
pump - V437-
❑ With heater
© satelettronica
disconnect
❑ Clip onto fuel tank
WARNING
ing reducing agent.
To
♦ prevent large
amounts of reducing
agent from escaping
⇒ page 7 .
5 - Coolant hoses
6 - Gasket
❑ Renew
7 - Retaining clamp
❑ Renew
8 - Bolt
❑ 5 Nm

3.3 Exploded view - delivery unit for reducing agent
1 - Tank
❑ For reducing agent
⇒ page 625
3 - Seal
❑ Renew
❑ Install dry
4 - Reservoir
❑ With:
♦ Filter
♦ Pump for reducing agent -
V437-
♦ Tank sender for reducing
agent - G684-
© satelettronica
♦ Temperature sender for re‐
ducing agent - G685-
♦ Pressure sender for reduc‐
ing agent metering system
- G686-
♦ Heater for reducing agent
tank - Z102-
reservoir ⇒ page 628
❑ Do not kink heating
mats when installing
5 - Locking ring
❑ Release and lock with
wrench -T40268-
❑ Always renew after re‐
moving
6 - Metering line
❑ To injector for reducing agent - N474-
❑ With heater for reducing-agent line - Z104-
❑ Press release tabs to disconnect
WARNING
ing reducing agent.
To
♦ prevent large
amounts of reducing
agent from escaping
⇒ page 7 .

3.4 Exploded view - control unit for reducing agent metering system - J880-
Note
Fitting location: control unit for reducing agent metering system - J880- is underneath tank.
1 - Base plate
❑ For control unit for re‐
ducing agent metering
system - J880-
❑ Part of tank
2 - Clip nut
3 - Control unit for reducing
agent metering system - J880-
agnostic tester
❑ After renewal, parame‐
© satelettronica
ters of control unit for re‐
system - J880- must be
set; see Guided Func-
tions ⇒ Vehicle diag‐
nostic tester
⇒ page 633
4 - Bolt
❑ 4.5 Nm

3.5 Draining reducing agent tank

Procedure
WARNING

⇒ page 6 .
ing agent has been drawn back automatically ⇒ page 7 .

– Open tank flap.
– Unscrew filler cap -2- from filler neck for reducing agent.
© satelettronica
Note
Disregard -item 1-.
– Remove bolt and nuts -arrows- and detach cover -1- for tank.
– Place drip tray underneath.
Note

reducing agent.
– Press release tab to remove plug -arrow-, drain off reducing

agent into a drip tray and refit plug.
After re-filling, the following step must be carried out:
– Adapt learnt value after draining reducing agent or renewing
components ⇒ page 10 .
3.6 Removing and installing reducing agent

tank

© satelettronica
Removing
WARNING

⇒ page 6 .
– Drain reducing agent tank ⇒ page 625 .

underbody trim .
– If fitted, unplug electrical connector -1-.
– Unscrew nuts -arrows- for control unit for NOx sender 2 -
J881- .
Note
Disregard -item 1-.

– Press release tabs and disconnect metering line -2-.

– Unplug electrical connectors -1, 3- and move electrical wiring
harness clear.
Note

reducing agent.
– Press release tab and disconnect filler line -1-.

– Press blue slider -4- to release catch -3- and disconnect
© satelettronica
breather lines -2-.
WARNING

♦ 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 -1- by hand).
Note
For greater clarity the tank is shown without the engine and gear‐
box jack.
– Lower tank using engine and gearbox jack - V.A.G 1383 A-

(also guiding tank down by hand).

Installing
– Push filler line -1- and breather line -2- onto connection so that
they engage audibly.
– Pull to check that plug-in connectors are correctly engaged.
– Press in catch -3- to secure.
– Check that lines are clipped onto tank.
Note
Disregard -item 4-.

Tightening torques
♦ ⇒ “3.1 Exploded view - reducing agent tank”, page 620
3.7 Removing and installing delivery unit for
© satelettronica
reducing agent
♦ Key - T40268-
Removing
WARNING

⇒ page 6 .
– Remove reducing agent tank ⇒ page 625 .


– Turn locking ring -1- anti-clockwise with wrench -T40268- to

release and detach.
– Pull reservoir with pump for reducing agent - V437- out of tank.
Installing
Caution
© satelettronica
Note
♦ Renew seal.
♦ Clean the sealing surfaces for seal thoroughly.
Caution
Risk of malfunctions.
♦ The seal must not be twisted.
♦ Do not kink heating mats when installing.
– Move reservoir into installation position:

• Lug -2- on flange must be between tabs -1- and -3-.
• Direction of installation for lug -2- as shown in illustration.

– Turn locking ring -1- clockwise with wrench -T40268- to lock.
• Locking ring is properly locked when lugs on locking ring are

opposite lugs on support ring of tank -arrows A, B-
– Install reducing agent tank ⇒ page 625 .
© satelettronica
3.8 Removing and installing injector for re‐
⇒ “3.8.1 Removing and installing injector for reducing agent N474
- not water-cooled”, page 630
⇒ “3.8.2 Removing and installing injector for reducing agent N474
- water-cooled”, page 631
3.8.1 Removing and installing injector for re‐

ducing agent - N474- - not water-cooled
Removing
WARNING

⇒ page 6 .

noise insulation .

Note

reducing agent.
– Press release tabs -1- and disconnect metering line from in‐
jector for reducing agent - N474- .
agent - N474- .
Installing
Note
Renew gasket and retaining clip.
© satelettronica
• Installation position: lugs in injector for reducing agent - N474-
-item 2- must be inserted in corresponding mountings in front
exhaust pipe -1-.
Tightening torques
♦ ⇒ “3.2.1 Exploded view - reducing agent supply line, not water-
cooled”, page 621
3.8.2 Removing and installing injector for re‐

ducing agent - N474- - water-cooled
Removing
WARNING

⇒ page 6 .


– Take electrical connector -arrow- out of bracket, unplug it and

move it clear.
Note

reducing agent.
– Press release tabs -arrows- and disconnect metering line -1-

from injector for reducing agent - N474- .
© satelettronica
– Fold up heat insulation sleeves on coolant hoses.
– Clamp off coolant hoses -2- with hose clamps -3094- and de‐
tach.
agent - N474- .
Installing
Note
Renew retaining clip and gasket.
• Installation position: lugs in injector for reducing agent - N474-

-item 2- must be inserted -arrows- in corresponding mountings
in particulate filter -1-.
Tightening torques
♦ ⇒ “3.2.2 Exploded view - reducing agent supply line, water-
cooled”, page 622


reducing agent metering system - J880-
Removing
– Remove bolt and nuts -arrows- and detach cover for tank.
– Remove bolts -arrows- and detach control unit for reducing

agent metering system - J880- .
© satelettronica
Installing
– After renewal, parameters of control unit for reducing agent
metering system - J880- must be set; see Guided Func-
tions ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ “3.4 Exploded view - control unit for reducing agent metering


page 634
⇒ “4.2 Removing and installing exhaust gas temperature sender”,
page 641
4.1 Exploded view - exhaust gas tempera‐

ture control
⇒ “4.1.1 Exploded view - exhaust gas temperature control, vehi‐
cles with one turbocharger and without SCR system”,
page 634
cles with one turbocharger and with SCR system, version 1”, page
636
cles with one turbocharger and with SCR system, version 2”, page
637
cles with two turbochargers and without SCR system”,
© satelettronica
page 639
cles with two turbochargers and with SCR system”, page 640
4.1.1 Exploded view - exhaust gas temperature control, vehicles with one turbo‐
charger and without SCR system

1 - Pressure pipe
sender - G505-
❑ 45 Nm
⇒ page 569
- G505-
⇒ page 553
sender 4 - G648-
⇒ page 650
© satelettronica
parts catalogue
❑ 45 Nm
sender 1 - G235-
⇒ page 641
parts catalogue
❑ 45 Nm
sender 3 - G495-
❑ 45 Nm

charger and with SCR system, version 1
1 - Nut
J881-
⇒ page 576
sender 3 - G495-
⇒ page 647
© satelettronica
parts catalogue
❑ 45 Nm
⇒ page 569
7 - NOx sender - G295- with
control unit for NOx sender -
J583-
cles with engine code
CPNB
⇒ page 573
8 - Nut
❑ 45 Nm
10 - Pressure pipe for pressure differential sender - G505-
❑ 45 Nm
11 - Bolt

❑ 45 Nm
14 - Turbocharger
❑ 45 Nm
17 - Particulate sensor - G784-
❑ 52 Nm
18 - Nut
❑ 2 Nm
© satelettronica
charger and with SCR system, version 2
sender 3 - G495-
⇒ page 647
parts catalogue
❑ 45 Nm
⇒ page 569
sender 2 - G448-
⇒ page 646
parts catalogue
❑ 45 Nm
5 - Union screw
- G505-
⇒ page 553
7 - Bracket
sender - G505-

8 - Bolt
9 - Turbocharger
❑ 45 Nm
11 - Union screw
❑ 45 Nm
13 - Control unit for NOx sender 2 - J881- with NOx sender 2 - G687-
© satelettronica

4.1.4 Exploded view - exhaust gas temperature control, vehicles with two turbo‐
chargers and without SCR system

sender 4 for cylinder bank 2 -
G649-
⇒ page 652
parts catalogue
❑ 45 Nm
2 - Pressure pipe
sender - G505-
© satelettronica
sender 3 - G495-
⇒ page 649
parts catalogue
❑ 45 Nm
sender 1 - G235-
⇒ page 643
parts catalogue
❑ 45 Nm
❑ 45 Nm
❑ 45 Nm

4.1.5 Exploded view - exhaust gas temperature control, vehicles with two turbo‐
chargers and with SCR system

J881-
⇒ page 576
sender 4 - G648- / exhaust gas
temperature sender 4 for bank
2 - G649-
⇒ page 653
❑ Which of the two ex‐
senders is fitted de‐
pends on the model
year; for allocation, refer
to ⇒ Vehicle diagnostic
tester
© satelettronica
parts catalogue
❑ 45 Nm
3 - Catalytic converter heater 1
- Z119- / catalytic converter
heater 2 - Z120-
4 - Electrical wire
❑ Remove using puller -
T40317-
5 - Nut
sender 2 - G448-
❑ 45 Nm
❑ 45 Nm
❑ 45 Nm

11 - Pressure line for pressure differential sender - G505-

13 - Exhaust gas temperature sender 4 for bank 2 - G649- or exhaust gas temperature sender 4 - G648-
❑ Which of the two exhaust gas temperature senders is fitted depends on the model year; for allocation,
refer to ⇒ Vehicle diagnostic tester
❑ 45 Nm

temperature sender
⇒ “4.2.1 Removing and installing exhaust gas temperature sender
1 G235 - vehicles with one turbocharger”, page 641
1 G235 - vehicles with two turbochargers”, page 643
© satelettronica
er 4 G648 / exhaust gas temperature sender 4 for bank 2 G649 -
vehicles with two turbochargers and without SCR system”,
page 652
er 4 G648 / exhaust gas temperature sender 4 for bank 2 G649 -
vehicles with two turbochargers and SCR system”, page 653
⇒ “4.2.10 Removing and installing particulate sensor G784 ”,
page 654

temperature sender 1 - G235- - vehicles
with one turbocharger

Removing
WARNING

system ⇒ page 7 .
© satelettronica
Note

♦ When removing, the electrical wiring must not be cut, other‐
wise a fault diagnosis would no longer be possible.

Caution




charger.

Installing
© satelettronica
Note

♦ Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.
♦ Coat thread with high-temperature paste; for high-temperature

Tightening torques
634


Removing
WARNING

system ⇒ page 7 .
© satelettronica
Note


– Remove exhaust gas temperature sender 1 - G235- -item 1-.
Installing
Note


– Observe correct installation position.

• Distance -a- to clamp = min. 5 mm.
Tightening torques
♦ ⇒ “4.1.4 Exploded view - exhaust gas temperature control,
page 639

© satelettronica
Removing
WARNING

system ⇒ page 7 .

Vehicles with SCR system, version 1:
– Unplug electrical connector -5- from exhaust gas temperature
sender 2 - G448- .

Vehicles with SCR system, version 2:

Installing
Note
Tightening torques
634

© satelettronica
Removing
WARNING

system ⇒ page 7 .
Note
When removing, the electrical wiring must not be cut, otherwise

a fault diagnosis would no longer be possible.


Note
Installing
Note

© satelettronica
Tightening torques
page 639

Removing
WARNING

system ⇒ page 7 .

Note


Exhaust temperature sender 3 - G495- - version 1:
© satelettronica
Note
♦ On vehicles without bracket -5-, remove nut -4- and install

bracket.
♦ Route electrical wiring as shown in illustration.
♦ Attach cable tie -2- as shown in illustration.


Note
Disregard -item 3-.
Installing
Note

© satelettronica
♦ Following installation, check that the distance between the
electrical wiring leading to the exhaust gas temperature send‐
er 3 - G495- and the catalytic converter is at least 20 mm
(check entire length of wiring).
Note
♦ On vehicles without bracket -5-, remove nut -4- and install

bracket.
♦ Route electrical wiring as shown in illustration.
♦ Attach cable tie -2- as shown in illustration.
Tightening torques
634


Removing
WARNING

system ⇒ page 7 .
© satelettronica
Note


Installing
Note


Tightening torques
page 639


Removing
WARNING

system ⇒ page 7 .
© satelettronica
Note


Caution



– Detach bracket for electrical connector -2-, move electrical

connector clear and unplug it.
Installing
Note

Tightening torques
634
© satelettronica
tem”, page 466

temperature sender 4 - G648- / exhaust
gas temperature sender 4 for bank 2 -
and without SCR system
Removing
WARNING

system ⇒ page 7 .

Note
♦ The removal of the exhaust gas temperature sender 4 for bank

2 - G649- is shown as an example.
– Remove underbody trim (centre) in direction of exhaust sys‐

tem and press downwards slightly ⇒ General body repairs,
ling underbody trim .
– Unscrew exhaust gas temperature sender 4 for bank 2 - G649-
-item 2-.
Installing
Note
© satelettronica
Tightening torques
page 639

temperature sender 4 - G648- / exhaust
gas temperature sender 4 for bank 2 -
and SCR system

Removing
WARNING

system ⇒ page 7 .
Note

– Remove underbody trim (centre) in direction of exhaust sys‐

tem and press downwards slightly ⇒ General body repairs,
ling underbody trim .
© satelettronica
– Unscrew exhaust gas temperature sender 4 - G648- / exhaust
gas temperature sender 4 for bank 2 - G649- -item 2-.
Installing
Note

Tightening torques
vehicles with two turbochargers and with SCR system”,
page 640
4.2.10 Removing and installing particulate sen‐

sor - G784-

© satelettronica
Removing
WARNING

system ⇒ page 7 .

underbody trim .


Note
Different spanner sizes are required depending on the particulate

sensors fitted.
– Unscrew particulate sensor - G784- -2- with appropriate size

tool.
Installing
Note
♦ New particulate sensors are coated with an assembly paste.

♦ When re-installing, coat thread of particulate sensor with high-
© satelettronica
temperature paste; for high-temperature paste refer to ⇒
Electronic parts catalogue .
Tightening torques
vehicles with one turbocharger and with SCR system, version
1”, page 636


page 657
page 660
⇒ “5.3 Removing and installing exhaust gas recirculation control
motor V338 ”, page 662
⇒ “5.4 Removing and installing exhaust gas recirculation temper‐
ature sensor G98 ”, page 663

pipe
sequence
⇒ page 659
© satelettronica
2 - Bolt
sequence
⇒ page 659
3 - Gasket
❑ Renew
temperature sensor - G98-
⇒ page 663
❑ 35 Nm for aluminium ex‐
haust gas recirculation
cooler
❑ 45 Nm for steel exhaust
5 - Bolt
❑ 9 Nm
cooler
⇒ page 660
❑ Before fitting, grease
tion pipe at exhaust gas
recirculation cooler
⇒ page 659
7 - Seal
❑ Renew
8 - Bleeder screw
9 - Gasket
❑ Renew
10 - Connection
11 - O-rings
❑ Renew

12 - Gasket
❑ Renew
❑ With exhaust gas recirculation potentiometer - G212-
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 9 Nm
17 - Gasket
❑ Renew
18 - Bolt
© satelettronica
❑ Exhaust gas recirculation pipe and screw-type clip must always be renewed if screw-type clip -item 21-
has been loosened
❑ Before fitting, grease exhaust gas recirculation pipe at exhaust gas recirculation cooler ⇒ page 659
20 - Gasket
❑ Renew
❑ Renew
❑ If screw-type clip has been unfastened, exhaust gas recirculation pipe -item 19- and screw-type clip must
always be renewed
22 - Bolt
❑ 9 Nm
23 - O-ring
❑ Renew
25 - Bolt
❑ Renew
27 - Gasket
❑ Renew

Exhaust gas recirculation pipe to intake manifold - tightening tor‐

que and sequence
• Collar of exhaust gas recirculation pipe must not be distorted
or bent.
– Fit exhaust gas recirculation pipe with gaskets and screw-type
clip.
Note
Coat threads of bolts with high-temperature paste; for high-tem‐

perature paste refer to ⇒ Electronic parts catalogue .
Stage Bolts/screw- Tightening torque

type clip
1. -1, 2- Screw in by hand until bolt heads
make contact
2. -3- Position as illustrated
2.5 Nm
3. -1, 2- 9 Nm
© satelettronica
Greasing exhaust gas recirculation pipe at exhaust gas recircu‐
lation cooler before fitting
– Before fitting, grease illustrated areas -1- and -2- lightly with
commercially available grease.

Exhaust gas recirculation pipe to turbocharger - tightening torque

and sequence
Note
♦ Illustration shows installation position on vehicles with one tur‐

bocharger as an example.
♦ Renew exhaust gas recirculation pipe and screw-type clip if
screw-type clip has been unfastened
– Fit exhaust gas recirculation pipe with gaskets and screw-type

clip.
Note
Coat threads of bolts with high-temperature paste; for high-tem‐

perature paste refer to ⇒ Electronic parts catalogue .
© satelettronica
Stage Bolts/screw- Tightening torque
type clip
1. -2, 3- Screw in by hand until bolt heads
make contact
2. -1- Position according to tab on exhaust
gas recirculation pipe
Tightening torque:
♦ Part number 059 131 548 C: 5 Nm
♦ Part number 059 131 548 D: 3.5
Nm
♦ Part number 059 131 548 E: 3.5
Nm
3. -2, 3- 5 Nm
4. -2, 3- Turn 90° further

circulation cooler
Removing
– Take electrical connector -2- and retention valve -3- out of
bracket.


– Loosen clamp -2- and push to rear.
– Remove bolts -arrows- and lift exhaust gas recirculation cooler
off connection.
Note
Disregard -item 3-.
Installing
Note
♦ Renew gaskets, seals and O-rings.
© satelettronica
Note

Tightening torques
page 657


circulation control motor - V338-
Removing
– Remove exhaust gas recirculation cooler
⇒ “5.2 Removing and installing exhaust gas recirculation cool‐
er”, page 660 .
Note
Note installation position of exhaust gas recirculation control mo‐

tor .

– If fitted, detach bracket between exhaust gas recirculation
cooler and exhaust gas recirculation control motor - V338- .
– Pull exhaust gas recirculation control motor - V338- out of ex‐
haust gas recirculation cooler.
© satelettronica

Note

tor .

– Move coolant line and fuel line clear.
– Press coolant line and fuel line back and pull exhaust gas re‐
circulation control motor - V338- out of exhaust gas recircula‐
tion cooler.
Installing
Note

tor .
© satelettronica
Tightening torques
page 657

circulation temperature sensor - G98-
Removing
– Unscrew bolts -arrows- and push bracket -2- with exhaust gas
recirculation cooler change-over valve - N345- -item 1- to one
side.

– Unscrew exhaust gas recirculation temperature sensor - G98-
-item 2-.
Installing
Tightening torques
page 657

6 Exhaust manifolds

⇒ “6.1.1 Exploded view - exhaust manifold, vehicles with one tur‐
⇒ “6.1.2 Exploded view - exhaust manifold, vehicles with two tur‐
6.1.1 Exploded view - exhaust manifold, vehicles with one turbocharger
Note
The illustration shows the exhaust manifold for cylinder bank 2 (left-side).
1 - Nut
© satelettronica
❑ Renew
parts catalogue
❑ Observe tightening tor‐
que and sequence
⇒ page 665
ling:
♦ Left-side ⇒ page 666
♦ Right-side ⇒ page 670
3 - Gasket
❑ Renew
4 - Gasket
❑ Renew
5 - Bolt
❑ Renew
parts catalogue
❑ 30 Nm +90°

Exhaust manifold - tightening torque and sequence
Note
♦ Renew nuts.

2. -1 … 8- 15 Nm
3. -1 … 8- 25 Nm
6.1.2 Exploded view - exhaust manifold, vehicles with two turbochargers
Note
© satelettronica
1 - Nut
❑ Renew
parts catalogue
❑ Observe tightening tor‐
que and sequence
⇒ page 666
ling:
♦ Left-side ⇒ page 666
♦ Right-side ⇒ page 670
3 - Gasket
❑ Renew
4 - Seal
❑ Renew
5 - Clamp
♦ Exhaust manifold (left-side)
⇒ page 666
♦ Exhaust manifold (right-
side) ⇒ page 666

❑ 8 Nm
Exhaust manifold - tightening torque and sequence
Note
♦ Renew nuts.
– Tighten nuts in three stages as follows:

2. -arrows- Starting from the centre, tighten in di‐
agonal sequence to 15 Nm
3. -arrows- Starting from the centre, tighten in di‐
agonal sequence to 25 Nm
© satelettronica
Installation position of clamp for exhaust manifold (left-side)
• Angle α = 90° ± 10°.
Installation position of clamp for exhaust manifold (right-side)

• Angle α = 18° ± 10°.

folds
page 666
page 670

fold (left-side)

Removing
WARNING

system ⇒ page 7 .
© satelettronica
tudinal member.


– Lift retaining clip and disconnect coolant line -2-.
– Remove bolt -3- and place coolant expansion tank to one side.
noise insulation .
– If fitted, remove nuts -arrows- and press bracket -1- to one

side.
© satelettronica
Caution


– If fitted, remove bracket -1-.
– Push A/C compressor to one side.

Note
Disregard -item 2-.

– Loosen and remove nuts in the sequence: -8 ... 1- and detach

exhaust manifold.

© satelettronica
– Remove nuts -arrows- and detach exhaust manifold.
Installing
Note
– Tighten nuts for exhaust manifold (vehicles with one turbo‐

charger) ⇒ page 665 .
– Tighten nuts for exhaust manifold (vehicles with two turbo‐
chargers) ⇒ page 666 .
– Connect coolant line with plug-in connector ⇒ page 394 .
– Install particulate filter ⇒ page 612 /install catalytic converter
⇒ page 605 .
Tightening torques
tem”, page 466


fold (right-side)
Removing
WARNING

system ⇒ page 7 .

noise insulation .
© satelettronica

– Press air pipe to the side.
Note
Disregard -item 1-.

– Loosen and remove nuts in the sequence: -8 ... 1- and detach

exhaust manifold.

© satelettronica
– Disconnect air pipe (right-side) -2- together with intermediate
pipe -1- from turbocharger unit and move clear to one side.
Note
Disregard -item 3-.
– Remove nut -1- and detach bracket -2-.

– Detach air pipe (right-side) towards rear.


Installing
Note
© satelettronica
– Tighten nuts for exhaust manifold (vehicles with one turbo‐
charger) ⇒ page 665 .
– Tighten nuts for exhaust manifold (vehicles with two turbo‐
chargers) ⇒ page 666 .
Tightening torques
tem”, page 466


1 Glow plug system
676
1 - Sender wheel
er - G28-
⇒ page 196
2 - Glow plug
© satelettronica
plug 3 - Q12-
❑ Depending on emission
standard, cylinder 2
combustion chamber
pressure sender -
G678- may be fitted on
cylinder 2 ⇒ page 674
plug 6 - Q15-
⇒ page 674
❑ 12 Nm
4 - Bolt
❑ 9 Nm
⇒ page 676
6 - O-ring
❑ Renew
8 - Bolt
❑ 9 Nm

Glow plug versions (depends on emission standard)

1 - Glow plug with combustion chamber pressure sender (only
installed on cylinder 2)
2 - Glow plug without combustion chamber pressure sender
Note
♦ Depending on the emission standard, a combustion chamber

pressure sender is integrated in the glow plug on cylinder 2.
♦ Designation: glow plug 2 - Q11- with cylinder 2 combustion
chamber pressure sender - G678-

© satelettronica
♦ Socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel - VAS
6454- (for glow plug for cylinder 2, depends on emission
standard)
Removing
– Detach glow plug connectors from glow plugs.
– Clean glow plug opening to make sure no dirt gets into cylin‐
ders.
– 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
apertures, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
WARNING
Risk of eye injury.

– Loosen glow plugs using tool and unscrew by hand:

Use U/J extension and socket, 10 mm - 3220- for cylinders 1, 3,
© satelettronica
4, 5 and 6.
Use socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel - VAS

6454- for cylinder 2.
– Then unscrew glow plugs carefully by hand or using a suitable
hose. Keep the glow plugs straight while unscrewing.
Installing
– Fit glow plugs carefully by hand or using a suitable hose. Keep
the glow plugs straight while screwing them back in.
– To tighten glow plugs, use U/J extension and socket, 10 mm
- 3220- / socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel
- VAS 6454- and a suitable torque wrench.
– Attach glow plug connectors correctly and make sure connec‐
tors are securely fitted.
quence.
Tightening torques


G40-
Removing
– Unscrew bolt -1- and remove Hall sender - G40- -item 2-.
Installing
Note
Fit new O-ring.
Tightening torques
© satelettronica
sender - G28-
Removing
noise insulation .
Vehicles with front-wheel drive:
– Unscrew bolt -2- and detach engine speed sender - G28- .

side.


– Unscrew bolt -1- and detach engine speed sender - G28- .

– Unscrew bolt from engine speed sender - G28- -1- and remove
engine speed sender.
Installing
© satelettronica
Tightening torques

Service
Workshop Manual
Audi A6 2011 ➤
6-cylinder TDI engine, 3.0 ltr. 4-valve common rail (EA
897 Gen. I)
Engine ID
CRT CRT CRT CZV CZV CZV CZV CZV CZVF
D F E D B E A C
© satelettronica
Edition 02.2018

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
© satelettronica

Copyright © 2018 Audi AG, Ingolstadt D4B80464BF8

6-cylinder TDI engine, 3.0 ltr. 4-valve common rail (EA 897 Gen. I) - Edition 02.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
© satelettronica
1.1 Exploded view - cylinder block (pulleypermitted end) unless
. . . .authorised
. . . . . by. .AUDI
. . .AG.. .AUDI
. . .AG. .does
. . .not. .guarantee
. . . . . or. accept
. . . . any 49
liability
1.2 Exploded view - sealing flange (pulley end) . . to. .the. .correctness
with respect . . . . . .of. information
. . . . . .in. this
. . document.
. . . . . .Copyright
. . . . . by. .AUDI
. AG. 51
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Contents i

1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.2 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
© satelettronica
2.1 Exploded view - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.2 Exploded view - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.5 Removing and installing thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.9 Removing and installing coolant temperature sender 2 G802 . . . . . . . . . . . . . . . . . . . . . . 94
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4 Radiator/radiator fans . . . . . .permitted
. . . . . unless
. . . .authorised
. . . . . .by. AUDI
. . . AG.
. . .AUDI
. . .AG
. .does
. . .not
. .guarantee
. . . . . or
. .accept
. . . .any
. .liability
... 104

1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

ii Contents

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.2 Removing and installing intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.3 Removing and installing intake manifold (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.4 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.4 Checking for injectors stickingProtectedopen . . .Copying
. . . . for
. .private
. . . .or.commercial
. . . . . . purposes,
. . . . . .in.part
. . or. in. .whole,
. . . is. not
...... 137
© satelettronica
by copyright.
5.5 Checking return flow ratepermitted
of injectors with engine
unless authorised by AUDI running
AG. AUDI AG.does . . .not. .guarantee
. . . . . or. .accept
. . . any
. . .liability
....... 137
5.7 Checking restrictor in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

6.3 Removing and installing fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.5 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 142
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.3 Removing and installing NOx sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2.3 Removing and installing emission control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Contents iii
3 SCR (selective catalytic reduction) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

3.1 Exploded view - reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.2 Exploded view - reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.3 Exploded view - delivery unit for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.4 Exploded view - control unit for reducing agent metering system J880 . . . . . . . . . . . . . . 169
3.5 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.6 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.7 Removing and installing delivery unit for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.8 Removing and installing injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 175
3.9 Removing and installing control unit for reducing agent metering system J880 . . . . . . . . 175
4.2 Removing and installing exhaust gas temperature senders . . . . . . . . . . . . . . . . . . . . . . . . 178
5.3 Removing and installing exhaust gas recirculation temperature sensor G98 . . . . . . . . . . 181
© satelettronica
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
iv Contents
1 Identification
(ARL005666; Edition 02.2018)
All information can be found in ⇒ Servicing 6-cylinder TDI engine,
common rail; Rep. gr. 00 ; Identification .
© satelettronica
1. Identification 1
common rail; Rep. gr. 00 ; Safety precautions .
© satelettronica

common rail; Rep. gr. 00 ; Repair instructions .
© satelettronica

page 29
1.1 Removing engine

equipment required
© satelettronica


♦ Supplementary set, Audi A8 >2002 - VAS 6131/11-

© satelettronica
Procedure
WARNING

system ⇒ Servicing 6-cylinder TDI engine, common rail;
Rep. gr. 00 ; Safety precautions; Safety precautions when
working on the exhaust system .

Note

♦ Fit cable ties in the same locations when installing.
♦ Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 00 ; Repair notes; Rules for
cleanliness .
♦ Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension compo‐
nents with bonded rubber bushes must be brought into a
position corresponding to the normal position while driving
(unladen position). Otherwise, the bush would be subject to
torsion loading and its service life shortened.
– Before starting work, determine unladen position ⇒ Running

gear, axles, steering; Rep. gr. 00 ; Repair notes; Lifting sus‐
pension to unladen position (vehicles with coil springs) or
determine reference position ⇒ Running gear, axles, steering;
Rep. gr. 00 ; Repair notes; Lifting suspension to unladen po‐
sition (vehicles with air suspension) .
© satelettronica
WARNING
moved.
must be empty. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The fuel system operates at extremely high pressure. This with
canrespect to the correctness of information in this document. Copyright by AUDI AG.
cause injury.

Note
♦ The electromechanical parking brake must be released before

disconnecting the battery so that the propshaft can be turned
during removal.
♦ If the turbocharger has to be removed for subsequent work,
the turbocharger 1 control unit - J724- must be moved into the
“closed” position.

If performing repair work for turbocharger, move turbocharger 1

control unit - J724- into “closed” position:
– Release hose clips -arrows- and remove air pipe -1-.
– Select 01 Engine electronics , Final control diagno-

sis in “Guided Fault Finding” ⇒ Vehicle diagnostic tester.
– Unplug electrical connector -arrow- as soon as turbocharger

1 control unit - J724- is in closed position (held 10 seconds).
This will cause an entry to be stored in the event memory of
the engine control unit.
• The de-energised turbocharger 1 control unit - J724- remains
in this position, allowing access to the bolts for the turbocharg‐
© satelettronica
er.
Removing engine (continued):
battery .
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station; Discharging
refrigerant circuit .
body brace .
ments .

WARNING

hot.
– Open filler capwith-arrow- oncorrectness
respect to the coolantofexpansion tank.
information in this document. Copyright by AUDI AG.

© satelettronica
noise insulation .
All vehicles:
gine.
tor.
– Lift retaining clip -arrow- and disconnect coolant hose (rear

right).
– Guide coolant hose downwards and drain off coolant.

– Disconnect fuel hoses -1, 2, 3- ⇒ Fuel supply system, diesel

engines; Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-
in connectors .
– Move coolant hoses clear and move to right side.
© satelettronica
rier.
permitted unlessNote
Disregard -item 1-.


move clear.
Note
Disregard -item 3-.
© satelettronica
– Press release tabs onauthorised
both sides
by AUDIand detach vacuum hose
permitted unless AG. AUDI AG does not guarantee or accept any liability
-2-. with respect to the correctness of information in this document. Copyright by AUDI AG.


– Lift retaining clip -2- and disconnect coolant hose (top left) from
radiator.
– Remove bolts -arrows- and disconnect refrigerant lines. or accept any liability
permitted unless authorised by AUDI AG. AUDI AG does not guarantee
© satelettronica
– Unscrew bolts -arrows- and detach brackets -1, 2-.
– Press coolant expansion tank slightly towards front.

– Use a screwdriver -1- to release catch -arrow- and move wiring
duct -2- clear.


box.
– Release catches -arrows-, detach relay carrier with fuse hold‐

er -1-, move clear and place on engine.
© satelettronica
Caution

– Remove bolt -arrow-, disconnect refrigerant line from air con‐

ditioner compressor and move to one side.
– Unplug electrical connector -1- for intake air temperature

Note
Disregard -item 2-.


© satelettronica

earth cables clear.
trical
Protected wiring harness
by copyright. clear.or commercial purposes, in part or in whole, is not
Copying for private


– Release catches -arrow- and detach engine/motor control unit

- J623- -item 1- from bracket.
© satelettronica
-arrow B-.
– Place wiring harness on engine and secureProtected
engine/motor con‐
trol unit - J623- to prevent it from dropping.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
catch).


© satelettronica

housing -arrows-.


Note
cross brace .
Vehicles with front-wheel drive
© satelettronica
All vehicles:

-1- for longitudinal member.


catch).
- J500- .
WARNING

⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr.
00 ; Safety precautions; Safety precautions when working
on the SCR system .
♦ Put on safety goggles. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
© satelettronica
reducing agent.

– Press release tabs and disconnect SCR metering line -1-.
– Unclip SCR metering line -arrows-.
– Unclip SCR metering line at subframe (rear left) and guide out
metering line.

– Unscrew bolts -3- and tie control unit for NOx sender 2 - J881-
-2- with bracket to SCR catalytic converter.
Note
Disregard -arrows-.

– Unscrew nuts -2- and detach SCR catalytic converter.
Note


VAS 6131/13-
© satelettronica
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /10-11
G6 /10-1 /10-2 /10-5 /10-11
A8+C8 /13-6 /13-2
F8+H8 /13-5 /13-2
B14 /10-1 /10-3 /10-5 /11-1
G14 /10-1 /10-4 /10-5 /11-1
assembly platform.
zontally.
engine/gearbox assembly. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
WARNING




© satelettronica
shown.


shown.


Note
Bolts -1- are already removed.
© satelettronica
Note
Bolts -1, 3- have already been removed.
Caution

bers.
Vehicles with four-wheel drive


– Press off securing clip -1- / loosen nut, and remove selector
lever cable from gearbox.
Note
© satelettronica
All vehicles:

Special tools andProtected
workshop equipment required
♦ Support - VAS 6131/11-4-


VAS 6131/13-
© satelettronica
♦ Wrench, 21 mm - T40263-


2- Nut M10
4- Support -VAS 6131/13-7-
© satelettronica
Procedure
– Release catch -arrow- and detach bracket with pressure dif‐
ferential sender - G505- from connection.
– Unplug electrical connector -2- at exhaust gas temperature

Disregard -item 1-.


ing clear.
– Unscrew bolt -2- and loosen retaining clip.

– Detach injector for reducing agent - N474- -item 1- and place
to one side.
© satelettronica
Note
Disregard -item 2-.
Note

– Remove bolt -3- on retainer.

– Open screw-type clip -1- and place it on intake funnel of emis‐
sion control module.
– Remove emission control module -2- with front exhaust pipe.
© satelettronica
Caution

hand.
with your hands.


– Remove bolts -arrows- and push ATF cooler to one side.
Note
Disregard items marked -1, 2-.

– Release hose clips -2- and detach coolant hoses -1-.

All vehicles:
© satelettronica
Caution

slips.
-arrow-.
– Counterhold crankshaft using wrench, 21 mm - T40263- and

adapter -T40314- when slackening bolts for dual-mass fly‐
wheel.



– Remove bolts -arrows- and move gear oil cooling valve -
N509- to one side.
Note
Disregard -item 1-.

support set for Audi - VAS 6131/10- , supplementary set -
VAS 6131/11- and support -VAS 6131/13-7- as follows:
Note
© satelettronica
VAS 6131/13-7-
F2 /13-7
B10 /10-1 /10-3 /10-5 /11-4
G10 /10-1 /10-3 /10-5 /11-4



VAS 6131/11- at front of gearbox, as shown in illustration.
VAS 6131/13-7-
F2 /13-7
C10 /10-1 /10-4 /10-5 /11-2
F10 /10-1 /10-4 /10-5 /10-9

© satelettronica
– Position support elements from -VAS 6131/10- and adapter -
VAS 6131/11-2- at left of gearbox, as shown.

– Position support elements from -VAS 6131/10- at right of gear‐

box, as shown.
– Turn spindles (left and right) upwards until all locating lugs
make contact with mounting points.
All vehicles:
© satelettronica
Note
Disregard -item A-.

gether with gearbox slightly towards rear -arrow-.

support

♦ Engine and gearbox support - VAS 6095A-
© satelettronica
♦ Universal mounting - VAS 6095/1- with bracket for 3.0 ltr. TDI
engine Gen2 Evo - VAS 6095/1-14-

Procedure
type assembly platform - VAS 6131- (with engine detached
from gearbox)
– Attach lift arm extension - VAS 6101- to workshop hoist -
VAS 6100- .
© satelettronica
– Attach lifting tackle - 3033- to engine lifting eyes and workshop
hoist as shown in illustration.

subframe.
Note
stalled.

Note
Disregard -item 1-.

© satelettronica

– Detach coolant pipe (left-side) -1- and move clear to side.
Disregard -item 2-.

– Remove nut -1- and bolts -arrows- and detach engine support
(right-side).
– Using universal mounting - VAS 6095/1- and bracket for TDI

engine 3.0 ltr. Gen2 Evo - VAS 6095/1-14- , secure engine to
engine and gearbox support - VAS 6095A- (40 Nm) as shown
in illustration.
© satelettronica
Protectedequipment required
♦ Ring spanner insert AF
with16 - V.A.G
respect 1332/14-

© satelettronica
Note

♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ Bolts securing engine to gearbox ⇒ Gearbox; Rep. gr. 34 ;
box

Procedure
Note
♦ After removing, renew bolts tightened with specified tightening

angle.

© satelettronica
– Install coolant pipe (left-side) ⇒ page 100 .
and gearbox:
– Insert assembly aid - T40169- into gearbox housing and dual-
mass flywheel from below, as illustrated.
Note


– Insert transport lock - T40170- into gearbox housing from be‐

low and clamp onto flange shaft -1-.
– Fit starter and end seal -1- (where present) in correct installa‐
tion position -arrows-.
© satelettronica

sleeves.
can be reused; if so, apply marking ⇒ Gearbox; Rep. gr. 34 ;
box .
-3 … 10-.

• End seal -1- must be correctly fitted -arrows- before installing

starter.
Note
Apply a small amount of lubricant to the end seal if the starter

cannot be installed easily.

Note
© satelettronica
wheel is straight and that it makes even contact with the drive
plate.
– Use assembly lever -1- to press dual-mass flywheel -2- slightly

against drive plate -3- in direction of -arrow-.
– Bolt dual-mass flywheel onto drive plate as follows:
Note

Caution

slips.
-arrow-.
– Turn crankshaft 180° further in normal direction of engine ro‐

tation with wrench, 21 mm - T40263- and adapter -T40314- .
– Tighten bolt accessible in this crankshaft position to specified
torque ⇒ Gearbox; Rep. gr. 30 ; Clutch; Exploded view - fly‐
wheel and dual clutch .
to specified torque ⇒ Gearbox; Rep. gr. 30 ; Clutch; Exploded
view - flywheel and dual clutch .
subframe.
– Install gearbox oil cooling valve - N509- ⇒ page 94 .
© satelettronica
– Install ATF cooler ⇒ Gearbox; Rep. gr. 34 ; ATF circuit; Re‐
moving and installing ATF cooler .
– Secure drive shafts (left and right) to gearbox flange shafts ⇒
Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Ex‐
ploded view - drive shaft .
– Install emission control module ⇒ page 164 .
– Install injector for reducing agent - N474- ⇒ page 175 .

platform - VAS 6131 B- initially as far as distance -a-.

– Carefully press ball socket -2- of selector lever cable in this

position onto gearbox selector lever.
Note
♦ Take care not to bend gearbox selector lever when pressing

on (counterhold if necessary).
– Secure selector lever cable with retaining clip -1-.

ing; Rep. gr. 40 ; with
Subframe;
respect to theExploded
correctness ofview - subframe
information . Copyright by AUDI AG.
in this document.
WARNING
© satelettronica
– Tighten bolts for tunnel cross-piece ⇒ Gearbox; Rep. gr. 34 ;

Assembly mountings; Exploded view - assembly mountings .
note the following:
– Install SCR catalytic converter ⇒ page 163 .
– Install cover for reducing agent tank ⇒ page 167 .
– Install control unit for NOx sender 2 - J881- ⇒ page 148 .
– Remove underbody trim (centre, left-side) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody trim; Removing and
installing underbody trim .
– Install subframe cross brace, anti-roll bar and heat shield ⇒
Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe .


– Install hose connections for charge air system ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 21 ; Charge air
system; Exploded view - hose connections for charge air sys‐
tem .
ing battery .
Caution
© satelettronica
sive voltage.
♦ Never use battery charging equipment
permitted for by
unless authorised boost starting.

ments .
411 .
Note

– Bleed fuel system ⇒ Servicing 6-cylinder TDI engine, common
rail; Rep. gr. 23 ; Injection system; Filling and bleeding fuel
system .
– Charge refrigerant circuit ⇒ Air conditioner with refrigerant
Wheels, tyres .

WARNING

– Check ATF level ⇒ Gearbox; Rep. gr. 34 ; ATF; Checking

ATF level .
insulation .
© satelettronica


Assembly mountings
1 - Bolt
❑ 20 Nm
2 - Bracket
❑ Renew retaining plate if Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

fective
© satelettronica
necessary
3 - Bolt
❑ 50 Nm
4 - Engine support
5 - Bolt
❑ 10 Nm
6 - Heat shield
7 - Bolt
❑ 90 Nm + 90°
8 - Engine mounting
trohydraulic engine
- N144-
- N145-
⇒ page 44
9 - Subframe
10 - Bolt
❑ 55 Nm

1 - Bolt
Assembly mountings;
bly mountings
assembly mountings
3 - Stop plate
⇒ page 47
5 - Bolt
© satelettronica
Assembly mountings;
bly mountings
6 - Nut
Assembly mountings;
bly mountings
7 - Bolt
Assembly mountings;
bly mountings
8 - Gearbox support
9 - Bolt
10 - Nut
❑ Tightening torque ⇒Protected
Gearbox; Rep.Copying
by copyright. gr. 34 ; Assembly
for private mountings;
or commercial Exploded
purposes, in part or in whole,view
is not - assembly mountings

tion
Procedure
WARNING
Risk of accident when weight of engine is shifted.

♦ In order to support the engine as described below, the
gearbox and tunnel cross members must be installed.
© satelettronica

and right) and longitudinal member (right-side) as illustrated.
– Unplug electrical connectors and move wiring clear.
and right).

ings
Removing


noise insulation .
– Remove nuts -arrows- and press bracket -1- to one side.
– Remove air conditioner compressor from bracket and tie up to
front ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner
compressor; Detaching and attaching air conditioner com‐
pressor at bracket .
© satelettronica
Note
side remain fitted.

– Move electrical connectors -2- (left and right) for electrohy‐
draulic engine mounting solenoid valves -N144- / -N145- clear.
– Remove bolts (left and right) -1- and -arrows- and place re‐
taining plate to one side.
Note
Disregard -item 2-.

Installing
Note

angle.

Tightening torques
© satelettronica
ploded view - subframe Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
(front)

mounting
mounting”, page 46
⇒ “2.4.2 Removing and installing gearbox mounting”, page 47

port with gearbox mounting
Removing
Installing
Tightening torques


mounting
Removing
Installing
Tightening torques
© satelettronica


panel
Removing
Installing
filler neck.
– First press engine cover panel onto rear retaining pins and
then onto front retaining pins with both hands.
© satelettronica

page 52
⇒ “1.5 Removing and installing vibration damper”,
Protected page
by copyright. 52 for private or commercial purposes, in part or in whole, is not
Copying
⇒ “1.6 Removing and installing bracket for
withancillaries”,
page 53
53
© satelettronica
1 - Poly V-belt
TDI engine, common
rail; Rep. gr. 13 ; Cylin‐
der block (pulley end);
Exploded view - cylinder
block (pulley end)
TDI engine, common
poly V-belt
TDI engine, common
vibration damper
3 - Bolt
Servicing 6-cylinder TDI
engine, common rail;
Rep. gr. 13 ; Cylinder
block (pulley end); Ex‐
ploded view - cylinder
block (pulley end)
4 - Idler roller
❑ For poly V-belt

5 - Bolt
Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block (pulley end); Exploded view
- cylinder block (pulley end)
6 - Cover
7 - Cover
8 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block (pulley
end); Exploded view - cylinder block (pulley end)
9 - Idler roller
❑ For poly V-belt
10 - Bolt
❑ Tightening torques ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
11 - Alternator
© satelettronica
12 - Bracket
❑ For alternator
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing bracket for ancillaries
13 - Bolt
14 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pump/ther‐
mostat assembly; Exploded view - coolant pump
15 - Pulley
❑ Tightening
permittedtorques ⇒ Servicing
unless authorised by AUDI AG. 6-cylinder
AUDI AG doesTDI engine,or common
not guarantee rail; Rep. gr. 13 ; Cylinder block (pulley
17 - Tensioner
❑ For poly V-belt
(pulley end); Removing and installing tensioner for poly V-belt
18 - Gasket
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block
(pulley end); Exploded view - cylinder block (pulley end)
19 - Bracket
(pulley end); Removing and installing bracket for ancillaries
20 - Bolt

21 - Dowel sleeves
23 - Bolt
1.2 Exploded view - sealing

permittedflange (pulleyby AUDIend)
unless authorised AG. AUDI AG does not guarantee or accept any liability
1 - Oil seal
end)
❑ Renewing ⇒ Servicing
6-cylinder TDI engine,
common rail; Rep. gr.
13 ; Cylinder block (pul‐
ley end); Renewing
crankshaft oil seal (pul‐
© satelettronica
ley end)
⇒ page 53
3 - Bracket
motor - V157-
4 - Bolt
block (pulley end); Ex‐
ploded view - sealing
flange (pulley end)
5 - O-rings
TDI engine, common
Exploded view - cylinder
block (pulley end)
G664-
⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch
7 - Bolt
end); Exploded view - sealing flange (pulley end)
8 - Gasket
9 - Bolt
mostat assembly; Exploded view - coolant pump

10 - Thermostat housing
11 - O-ring
12 - Gasket
13 - Dowel pin
❑ 2x
14 - Bolt
end); Exploded view - sealing flange (pulley end)

All procedures are described in ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 13 ; Cylinder block (pulley end);
© satelettronica

poly V-belt
Removing and installing tensioner for poly V-belt .

er
Removing
noise insulation .
All other procedures are described in ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing vibration damper .
Installing
Additional work:
Tightening torques


cillaries
⇒ “1.6.1 Removing and installing bracket for air conditioner com‐
pressor”, page 53
⇒ “1.6.2 Removing and installing bracket for alternator”,
page 53
1.6.1 Removing and installing bracket for air

conditioner compressor
Removing
for longitudinal member.
Removing and installing bracket for ancillaries .
Tightening torques
© satelettronica
1.6.2 Removing and installing bracket for al‐
ternator
Removing and installing bracket for ancillaries .

end) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
All procedures are described in
with⇒ Servicing
respect 6-cylinder
to the correctness TDI en‐
Renewing crankshaft oil seal (pulley end) .

(pulley end)
Removing
– Drain off engine oil ⇒ Maintenance ; Booklet 411 .
Removing and installing sealing flange (pulley end) .
Installing
Additional work:
– Install oil filter element and fill up with engine oil ⇒ Mainte‐
nance ; Booklet 411 .


cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block
(gearbox end) .
© satelettronica

3 Crankshaft
cylinder TDI engine, common rail; Rep. gr. 13 ; Crankshaft .
© satelettronica
3. Crankshaft 55
4 Balance shaft
cylinder TDI engine, common rail; Rep. gr. 13 ; Balance shaft .
© satelettronica


cylinder TDI engine, common rail; Rep. gr. 13 ; Pistons and
conrods .
© satelettronica


1 - Bolt
Rep. gr. 15 ; Timing
chain cover; Exploded
view - timing chain cover
2 - Sender wheel
er - G28-
© satelettronica
TDI engine, common
rail; Rep. gr. 13 ; Crank‐
shaft; Removing and in‐
stalling sender wheel
3 - Oil seal
end)
13 ; Cylinder block
(gearbox end); Renew‐
ing crankshaft oil seal
(gearbox end)
⇒ page 60
5 - Dowel sleeve
❑ 2x
6 - Gasket
TDI engine, common
rail; Rep. gr. 15 ; Timing chain cover; Exploded view - timing chain cover
7 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Timing chain cover;
Exploded view - timing chain cover
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Timing chain
cover; Removing and installing timing chain cover

10 - Reed valve
11 - Bolt
12 - Reed valve
13 - Bolt
14 - Cover
15 - Bolt
16 - O-ring
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Timing chain cover;
© satelettronica
17 - Bolt
18 - Line
19 - O-ring
20 - Pipe
21 - O-ring
22 - Pipe
23 - Bolt
24 - O-ring
25 - Gasket
26 - Clamping sleeve
❑ 3x
27 - Bolt
28 - Timing chain cover (right-side) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Timing chain
cover; Removing and installing timing chain cover

29 - Bolt
30 - Reed valve
31 - Bolt
32 - Gasket
33 - Bolt
34 - Reed valve
35 - Dowel sleeve
❑ 2x
© satelettronica
36 - Sealing element
❑ 2x
37 - Cover
38 - Bolt
❑ RemovingProtected
and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug system;
Removingpermitted
and installing engine speed sender - G28-

cover
⇒ “1.2.1 Removing and installing timing chain cover (top)”,
page 60
page 60

cover (top)
gine, common rail; Rep. gr. 15 ; Timing chain cover; Removing
and installing timing chain cover .

cover (bottom)
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 ; Removing and
All further procedures are described in ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 15 ; Timing chain cover; Removing
and installing timing chain cover .

2 Chain drive
cylinder TDI engine, common rail; Rep. gr. 15 ; Chain drive .
© satelettronica
2. Chain drive 61
3 Cylinder head

15 ; Cylinder head; Re‐
cylinder head .
© satelettronica
TDI engine, common
der head; Exploded
view - cylinder head
2 - Bolt
head; Exploded view -
cylinder head
3 - Bracket
4 - O-ring
TDI engine, common
der head; Exploded
5 - Coolant pipe
6 - Bolt
head; Exploded view -
cylinder head
7 - Seal
❑ Installation instructions ⇒ AG.
Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head;
permitted unless authorised by AUDI AUDI AG does not guarantee or accept any liability
Exploded view
with respect to the-correctness
cylinderofhead
information in this document. Copyright by AUDI AG.
8 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head; Ex‐
ploded view - cylinder head


10 - O-ring
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head;
Exploded view - cylinder head
11 - Coolant pipe
12 - Bolt
13 - Bolt
15 - Bolt
16 - Cylinder head
❑ Shown for cylinder bank 2 (left-side)
© satelettronica
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head;
Removing and installing cylinder head
Exploded view - cylinder head
3. Cylinder head 63
1 - Gasket
TDI engine, common
der head; Exploded
cover
2 - O-ring
TDI engine, common
der head; Exploded
cover
❑ Shown for cylinder bank
2 (left-side)
© satelettronica
⇒ page 66
4 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Installation instructions permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ Servicing 6-cylinder with respect to the correctness of information in this document. Copyright by AUDI AG.
TDI engine, common

der head; Exploded
cover
5 - Oil filler neck
6 - Bolt
head; Exploded view - cylinder head cover
7 - Grommet
8 - Seal
❑ For filler cap
Exploded view - cylinder head cover
9 - Filler cap
10 - Nut
ploded view - cylinder head cover
11 - Grommets
12 - Seal
❑ For injector
❑ Renewing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
installing seals for injectors

13 - Clamping piece
14 - High-pressure reservoir (rail)
❑ Do not attempt to bend high-pressure pipes to a different shape
❑ Installing high-pressure pipes ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/
high-pressure reservoir (rail); Removing and installing high-pressure pipes
15 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-pressure
reservoir (rail); Exploded view - injectors
16 - Bolt
18 - O-ring
Exploded view
Protected - cylinder
by copyright. head
Copying cover
19 - Injector with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-
© satelettronica
pressure reservoir (rail); Removing and installing injectors ⇒ page 138
20 - O-ring
21 - Copper seal
22 - Bolt
23 - Bracket
24 - Bolt
❑ With seal

Removing
gine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
installing cylinder head .
Installing
Additional work:
3. Cylinder head 65

cover
⇒ “3.4.1 Removing and installing cylinder head cover - bank 1
(right-side)”, page 66
⇒ “3.4.2 Removing and installing cylinder head cover - bank 2
(left-side)”, page 67

cover - bank 1 (right-side)
© satelettronica

Removing
– Press release tabs on both sides and detach vacuum hose
-1-.
– Move vacuum hose -arrow- clear and move to one side.

ferential sender - G505- -item 1- from connection.
© satelettronica
– Clamp off coolant hoses with hose clamps up to 25 mm -
3094- .
– Lift retaining clip -3-, release hose clips -1 and 2- and detach
coolant hoses.
– Unscrew bolts -arrows- and coolant pipe (right-side) from lon‐
gitudinal member.
Note

the engine removed.
All further procedures are described
with respectin ⇒ correctness
to the Servicing 6-cylinder
of information TDI
engine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
Installing
Additional work:
Tightening torques
♦ ⇒ Fig. ““Coolant pipe (right-side) - tightening torque”“ ,
page 98

cover - bank 2 (left-side)
3. Cylinder head 67

Removing
body brace .
© satelettronica
– Use a screwdriver -1- to release catch -arrow- and move wiring
duct -2- clear.
– Remove bolt -arrow- and detach bracket -1- for wiring channel.


-arrow B-.
– Push wiring harness slightly to right.
engine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
Installing
Additional work:
Tightening torques
strut, upper links

tors
gine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
© satelettronica
installing seals for injectors .

gine, common rail; Rep. gr. 15 ; Cylinder head; Checking com‐
pression .
3. Cylinder head 69
4 Valve gear
cylinder TDI engine, common rail; Rep. gr. 15 ; Valve gear .
© satelettronica


cylinder TDI engine, common rail; Rep. gr. 15 ; Inlet and exhaust
valves .
© satelettronica

17 – Lubrication
1 Sump/oil pump
page 76
er G266 ”, page 76

Exploded view - sump (bottom section)/oil pump ⇒ page 72
Exploded view - sump (top section) ⇒ page 74
© satelettronica
Note
Oil spray jet for piston cooling ⇒ Servicing 6-cylinder TDI engine,
common rail; Rep. gr. 13 ; Pistons and conrods; Exploded view
- pistons and conrods
Sump (bottom section)/oil pump


sender - G266-
TDI engine, common
rail; Rep. gr. 17 ; Sump/
oil pump; Removing and
installing oil level and oil
G266-
2 - Seal
TDI engine, common
oil pump; Exploded view
- sump/oil pump
3 - Bolt
Rep. gr. 17 ; Sump/oil
© satelettronica
pump; Exploded view -
sump/oil pump
TDI engine, common
installing sump (bottom
section)
5 - Bolt
pump; Exploded view - sump/oil pump
6 - Baffle plate
7 - Suction pipe
8 - Oil pump
❑ With vacuum pump for brake servo
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Sump/oil pump;
Removing and installing oil pump
9 - Chain sprocket
❑ For oil pump
10 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Sump/oil pump; Ex‐
ploded view - sump/oil pump
11 - Dowel sleeves
12 -unless
permitted Sealauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Sump/oil pump;
13 - Bolt
1. Sump/oil pump 73
14 - O-ring
15 - Bolt
16 - Seal
17 - Oil drain plug
18 - Bolt
Sump (top section)
© satelettronica
1 - Bolt
pump; Exploded view -
sump/oil pump
trol - N428-
TDI engine, common
rail; Rep. gr. 17 ; Oil fil‐
ter/oil pressure switch;
Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
valve for oil pressure

control - N428-
3 - O-ring
TDI engine, common
- sump/oil pump
4 - O-ring
TDI engine, common
- sump/oil pump
TDI engine, common
installing sump (top section)

6 - Dowel sleeve
7 - Guide tube
8 - Bolt
9 - O-rings
10 - Sealing plug
11 - Bolt
12 - Seal
13 - Bolt
© satelettronica
14 - Vacuum line
❑ Leading from vacuum pump
❑ Tightening torques with ⇒ Servicing 6-cylinder TDI inengine, common

Copyrightrail; Rep.
AG. gr. 17 ; Sump/oil pump; Ex‐
respect to the correctness of information this document. by AUDI
16 - O-ring
17 - Dowel sleeve
18 - Seal
19 - Plug
❑ For “TDC” marking
20 - Bolt
1.2 Engine oil

♦ Refer to ⇒ Maintenance ; Booklet 411 for instructions on
draining and filling up engine oil, checking oil level, removing
and installing oil filter element.
♦ Oil capacities, oil specifications and viscosity grades ⇒ Main‐
tenance tables .
1. Sump/oil pump 75

section)
gine, common rail; Rep. gr. 17 ; Sump/oil pump; Removing and
installing sump (bottom section) .

tion)
installing sump (top section) .

installing oil pump .

© satelettronica
installing oil level and oil temperature sender - G266- .

2 Engine oil cooler

cylinder TDI engine, common rail; Rep. gr. 17 ; Engine oil cooler .
© satelettronica


⇒ “3.2 Removing and installing oil pressure sender G10 ”,
page 79
”, page 80
⇒ “3.6 Removing and installing oil temperature sender 2 G664 ”,
page 80
1 - Bolt
Rep. gr. 17 ; Oil filter/oil
© satelettronica
pressure switch; Explo‐
ded view - oil filter
❑ With map-controlled en‐
gine cooling system
thermostat - F265-
⇒ page 80
TDI engine, common
rail; Rep. gr. 17 ; Oil fil‐
ter/oil pressure switch;
Exploded view - oil filter
3 - Seal
placement part
4 - Oil pressure sender - G10-
❑ Checking ⇒ Vehicle di‐
agnostic tester
⇒ page 79
Rep. gr. 17 ; Oil filter/oil
pressure switch; Explo‐
ded view - oil filter
5 - Oil filter element Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing ⇒ Maintenancepermitted
; Bookletunless411
6 - O-ring
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure
switch; Exploded view - oil filter

7 - Sealing cap
❑ With oil filter bypass valve
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure
8 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure
9 - Coolant temperature sender 2 - G802-
10 - O-rings
11 - Gasket
12 - O-ring
© satelettronica
sender - G10-
Removing
ments .
– Remove bolts -arrows-, detach air duct -2- from lock carrier
and unclip from air cleaner housing.
engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch;
Exploded view - oil filter .
Installing
Additional work:
ments .
– Install engine cover panel ⇒ page 48 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches
Checking oil pressure .

gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches;
Removing and installing oil filter housing .

gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches;
Removing and installing valve for oil pressure control - N428- .
3.6 Removing and installing oil temperature

sender 2 - G664-
Removing
© satelettronica
engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch ;
Removing and installing oil temperature sender 2 - G664- .
Installing
Additional work: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

19 – Cooling

Note
© satelettronica
1 - Radiator
2 - Restrictor
er 2 - G802-
6 - Cylinder block
side)
7 - Cylinder head
side)
er - G62-
cooler
10 - Turbocharger
© satelettronica
11 - Bleeder hole
V50-
Coolant circuit; Overview of fitting locations - coolant circuit
15 - ATF cooler
19 - Restrictor with respect to the correctness of information in this document. Copyright by AUDI AG.
20 - Cylinder head
21 - Cylinder block
22 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Cooling
system/coolant; Checking cooling system for leaks


26 - Coolant pump
© satelettronica
Note

1 - Radiator
2 - Restrictor
er 2 - G802-
© satelettronica
6 - Cylinder block
side)
V55-
ry heater; Removing
8 - Cylinder head
side)
er - G62-
cooler
11 - Turbocharger
valve - N279-
tioning; Rep. gr. 87 ; Coolant circuit; Overview of fitting locations - coolant circuit
13 - Bleeder hole

17 - ATF cooler
21 - Restrictor
22 - Cylinder head
23 - Cylinder block
24 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Cooling
system/coolant; Checking cooling systempermitted
for leaks

© satelettronica
28 - Coolant pump

gine, common rail; Rep. gr. 19 ; Cooling system/coolant; Check‐
ing cooling system for leaks .

♦ Safety goggles
Draining
WARNING

WARNING

hot.
© satelettronica

noise insulation .
gine.
tor.

– Connect coolant hoses (version with plug-in connectors)
⇒ page 105 .
Preparing coolant mixture and filling cooling system
– Prepare coolant mixture and fill cooling system ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 19 ; Cooling
system/coolant; Draining and filling cooling system .

Bleeding cooling system

chamber cover .
hose.
clip.

it engages).
– Start engine.
© satelettronica
not lit
speed (= 0)
3 minutes Idling speed • Air conditioning system “OFF”

2 minutes 2500 rpm • Heating at “HI”
3 minutes Idling speed
2 minutes 2500 rpm
3 minutes Idling speed
1 minute with respect to theSwitch offof information
correctness engine in this document. Copyright by AUDI AG.
2 minutes 2500 rpm
Until both large coolant Idling speed
come warm
1 minute 2500 rpm

insulation .
chamber cover .

• The coolant level must be at the -MAX- marking when the en‐
gine is cold.
• The coolant level can be above the -MAX- marking when the
engine is warm.
© satelettronica


⇒ “2.1 Exploded view - coolant pump”, page 89
⇒ “2.2 Exploded view - thermostat”, page 90
page 92
⇒ “2.5 Removing and installing thermostat housing”, page 93
permitted⇒unless
“2.6authorised
Removing by AUDIand installing
AG. AUDI AG doesmap-controlled
not guarantee or acceptengine cooling
any liability
system
with respect to thethermostat F265 ”,inpage
correctness of information 93 Copyright by AUDI AG.
this document.

”, page 93
⇒ “2.9 Removing and installing coolant temperature sender 2
G802 ”, page 94
© satelettronica
2.1 Exploded view - coolant pump
1 - Bolt
Rep. gr. 19 ; Coolant
pump/thermostat as‐
sembly; Exploded view -
coolant pump
2 - Bolt
coolant pump
3 - Poly V-belt pulley for cool‐
ant pump
TDI engine, common
rail; Rep. gr. 19 ; Cool‐
ant pump/thermostat
assembly; Exploded
view - coolant pump
4 - Coolant pump
TDI engine, common
ant pump/thermostat
assembly; Removing
and installing coolant
pump

2.2 Exploded view - thermostat

Map-controlled engine cooling system thermostat - F265-
⇒ page 90
Coolant shut-off valve ⇒ page 91
Exploded view - map-controlled engine cooling system thermo‐
stat - F265-
1 - Bolt
pipes; Protected
Exploded view Copying
by copyright. - for private or commercial purposes, in part or in whole, is not
coolantpermitted
pipesunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Exploded view
⇒ page 96
3 - O-ring
© satelettronica
TDI engine, common
ant pump/thermostat
assembly; Exploded
view - thermostat
4 - Bolt
pipes; Exploded view -
coolant pipes
TDI engine, common
ant pump/thermostat
assembly; Removing
and installing map-con‐
trolled engine cooling
system thermostat -
F265-
6 - Seal
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pump/
thermostat assembly; Exploded view - thermostat
7 - Seal
8 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pipes; Ex‐
ploded view - coolant pipes
9 - Thermostat housing

10 - O-ring
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pump/
thermostat assembly; Removing and installing map-controlled engine cooling system thermostat - F265-
12 - Valve
❑ For coolant flap
thermostat assembly;
permitted Removing
unless authorised by AUDIand installing
AG. AUDI AG does map-controlled
not guarantee or acceptengine cooling system thermostat - F265-
any liability
13 - O-ring
Exploded view - coolant shut-off valve
1 - Seal
© satelettronica
TDI engine, common
ant pump/thermostat
assembly; Exploded
view - thermostat
2 - Bolt
thermostat
4 - Coolant hose
5 - Bolt
thermostat
TDI engine, common
ant pump/thermostat
assembly; Removing
valves
7 - Seal

Gearbox oil cooling valve - N509- - tightening torque

1 - Bolt
© satelettronica
coolant temperature
senders
er - G62-
⇒ Servicing 6-cylinder Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
TDI engine, common permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
rail; Rep. gr. 19 ; Cool‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ant pump/thermostat
assembly; Removing
G62-
3 - O-rings
TDI engine, common
ant pump/thermostat
assembly; Exploded
ture senders
4 - O-rings
TDI engine, common
ant pump/thermostat
assembly; Exploded
ture senders
5 - Coolant temperature sender 2 - G802-
thermostat assembly ; Removing and installing coolant temperature sender 2 - G802-
6 - Bolt
mostat assembly; Exploded view - coolant temperature senders

7 - O-rings
thermostat assembly; Exploded view - coolant temperature senders
9 - Bolt
mostat assembly; Exploded view - coolant temperature senders

gine, common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Removing and installing coolant pump .

housing
gine, common rail (EA 897 Gen I); Rep. gr. 19 ; Coolant pump/
© satelettronica
thermostat assembly; Removing and installing thermostat hous‐
ing .
2.6 Removing and installing map-controlled

engine cooling system thermostat -
F265-
sembly; Removing and installing map-controlled engine cooling
system thermostat - F265- .

ature sender - G62-
sembly; Removing and installing coolant temperature sender -
G62- .

tion - G694-
Removing
engine, common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Removing and installing temperature sender for engine
temperature regulation - G694- .
Installing
Additional work:


ature sender 2 - G802-
Removing
engine, common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly ; Removing and installing coolant temperature sender 2 -
G802- .
Installing
Additional work:

⇒ “2.10.1 Removing and installing coolant shut-off valve”,
⇒ “2.10.2 Removing and installing gearbox oil cooling valve N509

”, page 94
© satelettronica
2.10.1 Removing and installing coolant shut-off
valve
sembly; Removing and installing coolant valves .
2.10.2 Removing and installing gearbox oil

cooling valve - N509-

Removing
noise insulation .
© satelettronica
– Unscrew bolts -arrows- and remove gear oil cooling valve -
N509- .
Installing
Note
To avoid
♦ Protected loss ofCopying
by copyright. coolant, insert
for private new gearbox
or commercial purposes, inoil
partcooling valve
or in whole, is not
- N509- immediately.

Tightening torques
♦ ⇒ Fig. ““ Gearbox oil cooling valve -N509- - tightening torque”“ ,
page 92

3 Coolant pipes
Note
1 - Bolt
❑ 9 Nm
⇒ page 98
3 - Bolt
© satelettronica
❑ 9 Nm
4 - O-ring
5 - O-ring
⇒ page 98
7 - Seal
8 - O-ring
9 - Bolt
❑ 9 Nm
10 - Coolant pipe (front) for tur‐
bocharger
❑ Removing and
with respect to the installing
⇒ page 101
11 - Bolt
❑ 9 Nm
12 - O-ring
13 - O-ring
14 - Bolt
❑ 9 Nm
15 - Coolant pipe (rear) for turbocharger
16 - Bolt
❑ 9 Nm

17 - Bolt
❑ 9 Nm
18 - Bolt
❑ 9 Nm
19 - O-ring
20 - Coolant pipe
❑ For cylinder head
21 - O-ring
22 - Bolt
❑ 9 Nm
23 - Plug
❑ For cylinder block
24 - Gasket
© satelettronica
25 - Bolt
❑ 9 Nm
26 - Housing cover
❑ Protected
For cylinder block
27 - Bolt
❑ 9 Nm
28 - Bolt
❑ 9 Nm
29 - Bolt
❑ 9 Nm
30 - Connection
31 - O-ring
32 - Bracket
33 - O-ring
3. Coolant pipes 97
Coolant pipe (right-side) - tightening torque


page 98
page 100
© satelettronica
⇒ “3.2.4 Removing and installing coolant pipe (front) for turbo‐
⇒ “3.2.5 Removing and installing coolant pipe (rear) for turbo‐

(top)
Removing
– Unscrew bolts -arrows- and remove coolant pipe (top) -1-.
Installing
Note
Renew seal and O-ring after removing.

Tightening torques

(front)

Removing
ments .
© satelettronica
Note
Disregard -item 1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3. Coolant pipes 99

– Remove bolts -arrows- and detach coolant pipe (front) -2- from
map-controlled engine cooling system thermostat - F265- .
Installing
Note
♦ Renew O-ring after removal.


ments .
© satelettronica
Note

Tightening torques

(left-side)

Removing
– Release hose clip -2- and detach coolant hose from coolant
pipe.
– Detach coolant pipe (left-side) -1-.
Installing
© satelettronica
Note
– Install engine mounting and engine support ⇒ page 44 .

Tightening torques

(front) for turbocharger
Special tools and workshop equipment with
required

Removing
– Unscrew bolt -2- and detach coolant pipe -1- from turbocharg‐
er.
Installing
Note

© satelettronica
Note

Tightening torques

(rear) for turbocharger
Removing

– Remove emission control module ⇒ page 164 .

Note

– Unscrew bolts -arrows- and detach coolant pipe -1- from tur‐
bocharger.
Installing
Note
Renew O-ring after removal.

© satelettronica
Note

Tightening torques


Radiator and condenser
1 - Sealing strip
2 - Coolant hose
tach
❑ Connecting
⇒ page 105
3 - O-ring
© satelettronica
4 - Radiator
⇒ page 106
5 - Coolant hose
tach
❑ Connecting
⇒ page 105
6 - O-ring
7 - Coolant pipe
tank
tach
❑ Connecting
⇒ page 105
8 - O-ring
9 - Rubber bush
❑ For radiator
10 - Retaining pin
11 - Air duct
12 - Condenser
13 - Air duct
14 - Rubber bush
❑ For radiator

16 - Bolt
❑ 5 Nm
17 - Washer
18 - Bolt
❑ 4.5 Nm
19 - O-ring
20 - Coolant hose
❑ Connecting to radiator ⇒ page 105

• If damaged, renew retaining clip -4-.
© satelettronica
ant hose.
bly.


unit 2 - J671-
⇒ page 112
unit - J293-
⇒ page 112
3 - Radiator cowl
⇒ page 109 with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Bolt
❑ 3.5 Nm
5 - Fan wheel
6 - Bolt
© satelettronica
❑ 5 Nm
7 - Fan wheel
8 - Bolt
❑ 5 Nm
9 - Bolt
❑ 3.5 Nm
Note
gether.


Removing
noise insulation .
impact absorber .
gine.
– Pull out retaining clip -2- and disconnect coolant hose from
radiator.
© satelettronica
– Lift retaining clip -arrow- and detach connection (bottom left)
from radiator.
WARNING

–withUnplug electrical
respect to the correctnessconnector -1-
of information in thisand, if fitted,
document. -2-byfor
Copyright radiator
AUDI AG. fan
catch).

rier.
Note
Disregard -item 2-. with respect to the correctness of information in this document. Copyright by AUDI AG.
© satelettronica
– Lift retaining clips -1, 2- and detach connection from radiator.


Installing
Note
© satelettronica
cylinder TDI engine, common rail; Rep. gr. 00 ; Repair notes;
Installing radiators and condensers .

Note

Tightening torques


Removing
– Remove charge air cooler.
noise insulation .
gine.
© satelettronica
tor.

rier.

© satelettronica
WARNING


catch).


from below.
Installing
– Install charge air cooler.
Note

Tightening torques
© satelettronica
♦ ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ;
Charge air system; Exploded view - hose connections for
charge air system

V7-
Removing
Note

– Remove bolts -1- Protected
or -2- and detach
by copyright. corresponding
Copying fan wheel.
– Remove bolts -arrows- on radiator
with respect fan. of information in this document. Copyright by AUDI AG.
to the correctness
Installing
– Note installation position of fan wheel:
Tightening torques

1 Turbocharger
1 - Gasket
TDI engine, common
rail; Rep. gr. 21 ; Tur‐
bocharger; Exploded
view - turbocharger
© satelettronica
Rep. gr. 21 ; Turbo‐
charger; Exploded view
- turbocharger
4 - Studs
- turbocharger
5 - Gasket
TDI engine, common
bocharger; Exploded
view - turbocharger
6 - Gasket
TDI engine, common
bocharger; Exploded
view - turbocharger
7 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger; Explo‐
ded view - turbocharger
8 - Pipe
❑ To exhaust gas recirculation cooler
9 - Air pipe
10 - Bolt
1. Turbocharger 113
11 - O-ring
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger;
12 - Bolt
❑ Different securing methods - version 1 ⇒ page 143
13 - Connection
❑ For air hose
14 - Hose
15 - O-ring
© satelettronica
16 - Seal
17 - Nut
18 - Retaining clip
❑ Exploded view ⇒ page 177 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
20 - Turbocharger with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ With turbocharger 1 control unit - J724-

❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger;
Removing and installing turbocharger
21 - Seal
23 - Emission control module
24 - Gasket

27 - Bolt
28 - Bracket
29 - Bolt
30 - Bracket
31 - Bolt
❑ Tightening
with respect totorques ⇒ Servicing
the correctness 6-cylinder
of information in this document.TDI engine,
Copyright common
by AUDI AG. rail; Rep. gr. 21 ; Turbocharger; Explo‐

Removing
© satelettronica
engine, common rail; Rep. gr. 21 ; Turbocharger; Removing and
installing turbocharger .
Installing
Additional work:
Tightening torques
charge air system
1. Turbocharger 115
2 Charge air system

page 117
page 119
1 - Sealing strip
⇒ page 117
3 - Hose clip
© satelettronica
Rep. gr. 21 ; Charge air
system; Exploded view -
hose connections for
charge air system
4 - Air hose
❑ To charge air cooler
5 - permitted
Hose clip unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ withTightening torques ⇒

Rep. gr. 21 ; Charge air
charge air system
6 - Bolt
❑ 9 Nm
7 - Spacer sleeve
8 - Grommet
10 - Bolt
❑ 9 Nm
11 - O-ring
12 - Hose clip
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Charge air system;
Exploded view - hose connections for charge air system
13 - Air hose
❑ To turbocharger

14 - Hose clip
15 - Grommet
16 - Spacer sleeve
17 - Bolt
❑ 9 Nm
18 - O-ring
19 - Bolt
❑ 5 Nm
21 - Hose clip
22 - Air hose
© satelettronica
❑ Must be free of oil or grease with
when installing
23 - Hose clip
24 - Bolt
❑ 7 Nm

charge air system
All components are described in ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 21 ; Charge air system; Exploded
view - hose connections for charge air system .

er
Removing
– Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI en‐
cleanliness .
ments .
WARNING


Note
© satelettronica
illustration.
♦ This air duct cannot be removed and remains in its installation
position after the radiator has been unclipped.
cooler.

cooler.
– Detach charge air cooler by pulling upwards.
– Remove charge air cooler, paying special attention to air ducts
(left-side).
Installing
Note


© satelettronica
Note

Tightening torques

tem”, page 117

sure sender - G31-
Removing
engine, common rail; Rep. gr. 21 ; Charge air system; Removing
and installing charge pressure sender - G31- .
Installing
Additional work:


♦ Charge air system tester - V.A.G 1687- with adapters /6, /11, /
13-1, /13-2
Procedure
– Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI en‐
cleanliness .
© satelettronica
All further procedures are described in ⇒ Servicing 6-cylinder TDI Copying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
engine, common rail; Rep. gr. 21 ; Charge air system; Checking
charge air system for leaks .
Attaching
Additional work:
Tightening torques
charge air system


1 Injection system
page 122

3 - High-pressure reservoir
(rail)
❑ For cylinder bank 1
(right-side)
© satelettronica
valve - N276-
G247-
6 - High-pressure reservoir
(rail)
❑ For cylinder bank 2 (left-
side)
7 - Injector
8 - Fuel return hoses Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - Restrictor
❑ Maintains a residual
pressure in fuel return
hoses
10 - Fuel system pressurisa‐
tion pump - G6-
11 - Fuel filter


Engine compartment

❑ Exploded view
⇒ page 128
N145-
❑ Integrated in engine
mounting (right-side)
⇒ page 123
- G505-
❑ Exploded view
⇒ page 148
❑ Exploded view
© satelettronica
⇒ page 148
sender 3 - G495-
❑ Exploded view
⇒ page 177
6 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
⇒ page 123
⇒ page 123
⇒ page 152
9 - Intake air temperature
sender - G42-
❑ Integrated in engine mounting (left-side) ⇒ page 123
❑ Removing andProtected
installing ⇒ page
by copyright. 178for private or commercial purposes, in part or in whole, is not
Copying


Note


-G185- .
© satelettronica
Fitting location of intake air temperature sender - G42-

♦ On air pipe (left-side)

valve
♦ Integrated in engine mounting.
2 - Electrical connector for left electrohydraulic engine mounting
Engine (top view)


valve - N276-
⇒ page 146
2 - Injectors for cylinder bank 1
(right-side)
♦ Injector, cylinder 1 - N30-
❑ Exploded view
⇒ page 135
3 - Control unit for turbocharg‐
er 1 - J724-
❑ On turbocharger
❑ Exploded view
⇒ page 113
5 - Exhaust gas recirculation permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
control motor - V338- with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ With exhaust gas recir‐

culation potentiometer -
G212-
❑ Exploded view
⇒ page 180
G247-
⇒ page 142
7 - Injectors for cylinder bank 2
(left-side)
8 - Glow plugs for cylinder bank 2 (left-side)
♦ Glow plug 6 - Q15-
12 - Glow plugs for cylinder bank 1 (right-side)

Engine (front view)

G664-
❑ Exploded view
⇒ page 51
3 - Oil pressure sender - G10-
er 2 - G802- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Exploded view
⇒ page 92
V157-
❑ Exploded view
⇒ page 131
© satelettronica
G31-
❑ Exploded view
⇒ page 131
J338-
❑ Exploded view
⇒ page 131
head - N489-
N345-
- G694-
trol - N428-
Engine (side view, right-side)


G28-
❑ Exploded view
⇒ page 188
❑ Exploded view
⇒ page 188
sender - G266-
❑ Exploded view
⇒ page 72
© satelettronica
gine, common rail; Rep. gr. 23 ; Injection system; Filling and
bleeding fuel system .

gine, common rail; Rep. gr. 23 ; Injection system; Checking fuel
system for leaks .

2 Vacuum system

N345-
2 - Vacuum hose
❑ From exhaust gas recir‐
culation cooler change-
over valve - N345- to
vacuum unit at exhaust
3 - Vacuum unit
❑ At exhaust gas recircu‐
lation cooler
© satelettronica
4 - Vacuum unit
❑ At coolant shut-off valve
5 - Vacuum line
❑ From coolant valve for
cylinder head - N489- to
vacuum unit at coolant
shut-off valve
6 - Coolant valve for cylinderProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
head - N489- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
7 - Vacuum supply hose
❑ Leading from vacuum
pump to brake servo
8 - Vacuum supply hose
❑ To coolant valve for cyl‐
inder head - N489- and
tion cooler change-over
valve - N345-

gine, common rail; Rep. gr. 23 ; Vacuum system; Checking
vacuum system .

3 Air cleaner
1 - Mounting
⇒ page 129
3 - Cover
its or dirt
© satelettronica
let 411
4 - Grommet
❑ Not installed
withon all tover‐
respect the correctness of information in this document. Copyright by AUDI AG.
sions
❑ 3.5 Nm
⇒ page 140
7 - Air pipe
❑ Tightening torques for
hose clips ⇒ Servicing
21 ; Charge air system;
Exploded view - hose
connections for charge
air system
❑ Use genuine air filter element ⇒ Electronic parts catalogue
❑ Change intervals ⇒ Maintenance tables
9 - Air duct
10 - Bolt
❑ 3.5 Nm
11 - Air duct


housing
Removing
ments .
© satelettronica
Note
Disregard -item 1-.
3. Air cleaner 129

– Detach retaining clip -3- with fuel hoses from air cleaner hous‐
ing and push to one side.
move clear.
Installing
Note


© satelettronica
– Check air pipe (engine intake side) for salt residue, dirt and
leaves.
note the following:
ments .
Tightening torques
charge air system

4 Intake manifold
page 133
⇒ “4.3 Removing and installing intake manifold (bottom section)”,
page 133
⇒ “4.4 Removing and installing intake manifold flap motor V157
”, page 133
134
1 - Bolt
Rep. gr. 23 ; Intake
© satelettronica
manifold; Exploded
view - intake manifold
2 - Pipe
lation
3 - Seal
TDI engine, common
rail; Rep. gr. 23 ; Intake
manifold; Exploded
4 - Bolt
❑ Tightening torques ⇒ with respect to the correctness of information in this document. Copyright by AUDI AG.
manifold; Exploded
5 - Bolt
manifold; Exploded
6 - Bracket
❑ For air pipe
V157-
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold;
Removing and installing intake manifold flap motor - V157-
8 - Gasket
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold;

9 - Intake manifold (top section)

10 - Bracket
11 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold;
12 - Cable guide
13 - Bolt
14 - Mounting pin
15 - Bolt
© satelettronica
16 - Seal
17 - Bolt
18 - Seal
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold;
Removing and installing intake manifold (bottom section)
20 - Bolt
21 - Air pipe
22 - Seal
23 - Bolt
25 - Air hose
27 - Bracket permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ For air pipe with respect to the correctness of information in this document. Copyright by AUDI AG.

28 - Bolt
29 - Bolt
30 - O-ring
32 - Bolt
33 - Seal
© satelettronica
(top section)
Removing
– Disconnect fuel hoses -1, 2, 3- ⇒ Fuel supply system, diesel
engines; Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-
in connectors .
– Move coolant hoses clear and move to right side.
engine, common rail; Rep. gr. 23 ; Intake manifold; Removing
and installing intake manifold (top section) .
Installing
Additional work:
– Connect fuel hoses ⇒ Fuel supply system, diesel engines;
Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-in con‐
nectors .

(bottom section)
gine, common rail; Rep. gr. 23 ; Intake manifold; Removing and
installing intake manifold (bottom section) .

flap motor - V157-
All procedures are described inunless
permitted ⇒ Servicing
authorised by6-cylinder
AUDI AG. AUDITDI en‐not guarantee or accept any liability
AG does
gine, common rail; Rep. gr.with23 ; Intake
respect manifold;
to the correctness Removing
of information in this and
installing intake manifold flap motor - V157- .


module - J338-
Removing
engine, common rail; Rep. gr. 23 ; Intake manifold; Removing
and installing throttle valve module - J338- .
Installing
Additional work:
– Install engineProtected
coverbypanel ⇒ Copying
copyright. page for
48private
. or commercial purposes, in part or in whole, is not
© satelettronica

(rail)
page 137
page 137
speed”, page 138
⇒ “5.7 Checking restrictor in fuel return line”, page 138
⇒ “5.9 Removing and installing high-pressure pipes”, page 139
page 139
© satelettronica
Caution

♦ Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 00 ; Repair notes; Rules for
cleanliness .

1 - Support bracket
Rep. gr. 23 ; Injectors/
high-pressure reservoir
(rail); Exploded view -
injectors
2 - Clamping piece
TDI engine, common
rail; Rep. gr. 23 ; Injec‐
tors/high-pressure res‐
ervoir (rail); Exploded
view - injectors
3 - Bolt
Rep. gr. 23 ; Injectors/
© satelettronica
high-pressure reservoir
(rail); Exploded view -
injectors
❑ From injectors
TDI engine, common permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
rail; Rep. gr. 23 ; Injec‐
tors/high-pressure res‐
ervoir (rail); Exploded
view - injectors
❑ From high-pressure res‐
ervoir (rail) to injector
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-
pressure reservoir (rail); Exploded view - injectors
6 - High-pressure reservoir (rail)
❑ From high-pressure reservoir (rail) on opposite side
8 - Retaining clamp
9 - Bolt
❑ From high-pressure pump to high-pressure reservoir (rail)

11 - Bolt
13 - O-ring
14 - Injector
15 - O-ring
16 - Copper seal
© satelettronica
gine, common rail; Rep. gr. 23 ; Injectors/high-pressure reservoir
(rail); Checking injectors .

ues for injectors
(rail); Performing adaption of correction values for injectors .

gine, common rail; Rep. gr. 23 ; Injectors/high-pressure
Protected by copyright. Copying for private or reservoir
(rail); Checking for injectors sticking
permitted unlessopen . by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
with engine running
Procedure
– Cylinder bank 1 (right-side): Remove air cleaner housing
⇒ page 129 .
engine, common rail; Rep. gr. 23 ; Injectors/high-pressure res‐
ervoir (rail); Checking return flow rate of injectors with engine
running .
– Install air cleaner housing to perform test with engine running
⇒ page 129 .
Attaching
Additional work:
– Removing/installing air cleaner housing ⇒ page 129 .


Procedure
– Cylinder bank 1 (right-side): Remove air cleaner housing
⇒ page 129 .
ervoir (rail); Checking return flow rate of injectors at starter crank‐
ing speed .
– Install air cleaner housing for test ⇒ page 129 .
Attaching
Additional work:
– Removing/installing air cleaner housing ⇒ page 129 .
5.7 Checking restrictor in fuel return line
© satelettronica
Procedure
ervoir (rail); Checking restrictor in fuel return line .
Attaching
Additional work: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

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



tudinal member.
– Unscrew bolt -1- and detach coolant expansion tank.

– Unplug electrical connector -2- and move coolant expansion
tank to one side with coolant hoses attached.
ervoir (rail); Removing and installing injectors .
Installing
© satelettronica
Additional work:
Tightening torques
charge air system

pipes
(rail); Removing and installing high-pressure pipes .

reservoir (rail)
Removing
– Cylinder bank 1 (right-side): Release hose clips -arrows- and
remove air pipe -1-.
ervoir (rail); Removing and installing high-pressure reservoir
(rail) .
Installing
Additional work:
Tightening torques
charge air system


⇒ “6.1 Removing and installing intake air temperature sender G42
”, page 140
⇒ “6.3 Removing and installing fuel temperature sender G81 ”,
page 141
142
⇒ “6.5 Removing and installing fuel pressure sender for low pres‐
”, page 142
N276 ”, page 146
page 144
© satelettronica
Removing
–Protected
Unscrew bolt -2- and pull intake air temperature sender - G42-
outrespect
with of air pipe.
Installing
Note
Tightening torques
(front)

- G70-
Removing


– Release fasteners -arrows- all around and detach air mass
meter - G70- -item 2-. with respect to the correctness of information in this document. Copyright by AUDI AG.
Installing
To ensure that the air mass meter - G70- functions correctly, it is
© satelettronica
Note
values. This will cause a loss of power, as the calculated in‐
– Press air mass meter - G70- into air cleaner housing until it
clicks into place.
Tightening torques
charge air system
6.3 Removing and installing fuel tempera‐

ture sender - G81-
Removing
engine, common rail; Rep. gr. 23 ; Senders and sensors; Re‐
moving and installing fuel temperature sender - G81- .
Installing
Additional work:


sender - G247-
Removing
moving and installing fuel pressure sender - G247- .
Installing
Additional work:

sender for low pressure - G410-
Removing
engine, common rail; Rep. gr. 23 ; Removing and installing fuel
© satelettronica
pressure sender for low-pressure - G410- .
Installing
Additional work:

Note

deposits in the emission control module.

Removing
– Remove engine cover panel ⇒ page 48permitted
. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability


– Release catches -arrow- and detach bracket with pressure
differential sender - G505- -item 1- from connection.
Version 1
– Press release tabs on both sides and disconnect crankcase

breather hose -2-.
– Unscrew bolts -arrows- and detach intake connecting pipe
-1-.
Note
Disregard -item 3-.
© satelettronica
Version 2
– Press release tabs on both sides and disconnect crankcase

breather hose -2-.
– Unscrew bolt -1-, turn intake connecting pipe -1- anti-clock‐
wise and detach it.

– Detach pressure differential sender - G505- -item 1- from

bracket -2-; to do so, release catches -arrows- and move ho‐
ses clear.
– Release clips -3- and spray hoses with silicone-free lubricant.
– To prevent hose connections from breaking off, carefully dis‐
connect hoses and keep them straight when pulling them off.
Installing
Note

♦ Blow through hose (towards emission control module) with
compressed air to remove dirt or ice (frozen condensation).
leaks.
♦ If pressure pipes have been detached from emission control
module, tighten connections to specified torque.
© satelettronica

– If pressure differential sender - G505- has been renewed, per‐
form adaption in Guided Function 0001 - Adapt learnt
values - after component replacement ⇒ Vehicle diag‐
nostic tester.
Tightening torques
charge air system
Turbocharger; Exploded view - turbocharger

- N276-


♦ Test hose for return line connection
Procedure
WARNING
© satelettronica
cleanliness .
Note
Fuel temperature above 15 °C.
– Detach fuel return hose -2-.
Note

– Seal off open return line connection with a test hose -2- and a
hose clamp up to 25 mm - 3094- .
– Hold end of fuel return hose -1- in measuring container.
– Start engine and run at idling speed for one minute.
• Return flow rate (engine start): 0 ml
– Leave engine running at idling speed.
– While engine is running, empty measuring container, or ex‐
change it for an empty container and begin measurement.
– Leave engine running at idling speed for two minutes and
measure return flow rate.
• Return flow rate after 2 minutes: 0 ... 60 ml
Note
If specified values are obtained, fuel pressure regulating valve -

N276- is OK.
If values do not match specifications:
© satelettronica
Note
♦ The fuel pressure regulating valve - N276- and injectors were

checked during the preceding measuring process.
♦ To determine which component is defective, you must check
the return flow rate of the injectors.
– Measure return flow rate of injectors with engine running

⇒ page 137 .
– If return flow rate of injectors is OK, renew fuel pressure reg‐
ulating valve - N276- .
– If return flow rate of injectors is not OK, renew defective injec‐
tor.
Attaching
– Connect fuel return hose ⇒ Fuel supply system; Rep. gr. 20 ;

Removing
– Remove engine
Protected cover panel
by copyright. ⇒ page
Copying 48or.commercial purposes, in part or in whole, is not
for private
All further procedures are
with respect described
to the correctness in ⇒ Servicing
of information 6-cylinder
in this document. TDIby AUDI AG.
Copyright
moving and installing fuel pressure regulating valve - N276- .
Installing
Additional work:

cylinder TDI engine, common rail; Rep. gr. 23 ; High-pressure
pump .
© satelettronica

8 Lambda probe
⇒ “8.3 Removing and installing NOx sender”, page 149
1 - Not fitted Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - NOx sender 2 - G687- with with respect to the correctness of information in this document. Copyright by AUDI AG.

J881-
⇒ page 150
Rep. gr. 23 ; Lambda
probe; Exploded view -
Lambda probe
© satelettronica
3 - Not fitted
- G505-
⇒ page 142
❑ Tightening torques and
installation instructions
TDI engine, common
rail; Rep. gr. 23 ; Lamb‐
da probe; Exploded
view - Lambda probe
sender 3 - G495-
⇒ page 178
6 - NOx sender - G295- with
control unit for NOx sender -
J583-
⇒ page 149
engine, common rail; Rep. gr. 23 ; Lambda probe; Exploded view - Lambda probe
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
temperature control; Removing and installing exhaust gas temperature sender


Removing
engine, common rail; Rep. gr. 23 ; Lambda probe; Removing and
installing Lambda probe .
Installing
Additional work:
8.3 Removing and installing NOx sender

⇒ “8.3.1 Removing and installing
Protected by copyright. Copying forNOx
privatesender G295
or commercial ”, in part or in whole, is not
purposes,
⇒ “8.3.2 Removing and installing NOx sender 2 G687 ”,
page 150

G295-
© satelettronica
♦ High-temperature paste ⇒ Electronic parts catalogue

Removing
WARNING

8. Lambda probe 149


– Unscrew NOx sender - G295- -2-.
Installing
Note
Coat thread with high-temperature paste ⇒ Electronic parts cata‐

logue .
– Move control unit for NOx sender - J583- into installation po‐
sition and secure.
© satelettronica
Tightening torques
Lambda probe; Exploded view - Lambda probe

G687-
Removing
– Unscrew NOx sender 2 - G687- -arrow- using a tool from tool
set - T10395 A- .


– Unscrew nuts -arrows- and detach control unit for NOx sender
2 - J881- -item 2- from bracket.
Installing
Note


Tightening torques
© satelettronica
8. Lambda probe 151


page 152

Removing
Adaption must be performed after renewing engine control unit
If the adaption values of the injectors cannot be read out of the
old (defective) engine control unit, they must be entered into the
new engine control unit manually and the adaption procedure
must be performed accordingly.
chamber cover .
© satelettronica
– Release catches -arrow- and detach engine/motor control unit

- J623- -item 1- from bracket.
Installing
chamber cover .
• If engine/motor control unit - J623- has been renewed, perform
adaption in Guided Function 0001 - Adapt learnt values
- after component replacement ⇒ Vehicle diagnostic test‐
er.

⇒ “1.4 Removing and installing silencers”, page 158
WARNING

© satelettronica

1 - Nut
❑ 23 Nm
2 - Clamp (front)
❑ Before tightening, align
exhaust system so it is
free of stress
⇒ page 159
⇒ page 155
❑ Tighten bolted connec‐
tions evenly
3 - Y-pipe
original equipment
rately as required
rear silencer
⇒ page 157
© satelettronica
⇒ page 159
4 - Clamp (rear)
❑ For separate replace‐
ment of double pipeProtected
and by copyright. Copying for private or commercial purposes, in part or in whole, is not
rear silencer permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
free of stress
⇒ page 159
⇒ page 155
6 - Mounting
7 - Nut
❑ 20 Nm
8 - Nut
❑ 23 Nm
9 - Mounting
10 - Nut
❑ 20 Nm

11 - Rear silencer (right-side)

12 - Nut
❑ 23 Nm
13 - Clamp (rear)
14 - Bolt
❑ 20 Nm
15 - Mounting
© satelettronica
• Angle -α- = 10°

bottom of clamp.

pipe
Removing

WARNING

– Remove nuts (accessible from above) -2- for front exhaust

pipe.
Note

noise insulation .
© satelettronica
Caution

10°.
– Lower front exhaust pipe slightly at rear and unscrew nut -1-.
Installing
Note
Renew gaskets and self-locking nuts after removal.

Tightening torques
♦ ⇒ “2.1 Exploded view - emission control system”, page 161


♦ The connecting pipe can be cut through at the point marked
in order to renew the Y-pipe or rear silencer(s) separately.
© satelettronica
Procedure
WARNING




bottom of clamp.
Tightening torques

Removing
WARNING

© satelettronica
– Remove tunnel cross-piece (rear) ⇒ General body repairs,

ling tunnel cross-piece .
tie up SCR catalytic converter.

WARNING
Risk of accident caused by weight of silencers.

♦ A second mechanic is required for removal of the rear si‐
lencers.
– Unscrew bolts -1, 2- and remove silencers.

Installing
Note

Tightening torques
© satelettronica
♦ Tunnel cross-piece ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Overview of fitting locations - trim panels

Procedure
WARNING


Vehicles without clamps between Y-pipe and rear silencers
– Loosen bolt connections for front clamp(s). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
mountings for Y-pipe are preloaded by -a- = 6 ... 10 mm.


Vehicles with clamps between Y-pipe and rear silencers
Note
On a vehicle with clamps fitted between Y-pipe and rear silencers,

it is also necessary to align the Y-pipe.

mountings for Y-pipe are preloaded by -a- = 6 ... 10 mm.
– Tighten bolt connections on front clamp(s) evenly.

ded by -a- =Protected
11 ... by15copyright.
mm. Copying for private or commercial purposes, in part or in whole, is not
– Align rear silencers soto they
with respect are horizontal.
© satelettronica
Tightening torques

gine, common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Check‐
ing exhaust system for leaks .


⇒ “2.3 Removing and installing emission control module”,
page 164

tem
WARNING

© satelettronica
can be damaged
and impact
⇒ page 155
⇒ page 159
2 - Nut
❑ 23 Nm
3 - Gasket
4 - Emission control module
❑ With pressure line for
pressure differential
sender - G505- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 164
❑ After renewing, perform
adaption in Guided
Function 0001 - Adapt
learnt values - af-
ter component re-
placement ⇒ Vehicle
diagnostic tester
5 - Screw-type clip
⇒ page 162
❑ Tightening torque: 15 Nm

6 - Seal
7 - Turbocharger
8 - Mounting
9 - Bolt
❑ 23 Nm
11 - Nut
❑ 23 Nm
12 - Gasket
© satelettronica
Components of mountings (front) for front exhaust pipe on dual
clutch gearbox
1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Rubber buffer
8- Bracket
9- Bolt, 23 Nm
10 - Bracket
11 - Nut
Installation position of screw-type clip for emission control module

• Angle -α- = 90°

Mounting components for emission control module

1- Nut
2- Spacer sleeve
4- Washer
5- Bolt, 23 Nm
6- Bolt, 23 Nm
7- Spacer sleeve
8- Rubber buffer
9- Bracket
10 - Spacer sleeve

verter
© satelettronica
Removing
WARNING

Note
Disregard -item 1-.

– Unscrew NOx sender 2 - G687- -arrow- using a tool from tool

set - T10395 A- .

Note
© satelettronica
– Install NOx sender 2 - G687- ⇒ page 149 .

Tightening torques
2.3 Removing and installing emission con‐

trol module
Removing
WARNING


noise insulation .

Note

– Secure front exhaust pipe to SCR catalytic converter with a

nut.

ferential sender - G505- -item 1- from connection.
© satelettronica
– Unplug electrical connector -2- at exhaust gas temperature
Note
Disregard -item 1-.

ing clear.

– Unscrew bolt -2- and loosen retaining clip.

– Detach injector for reducing agent - N474- -item 1- and place
to one side.
– Remove bolt -3- on retainer.

– Open screw-type clip -1- and place it on intake funnel of emis‐
sion control module.
– Remove emission control module -2-.
Installing
© satelettronica
Note

– Install injector for reducing agent - N474- ⇒ page 175 .
– If emission control module has been renewed, perform adap‐
tion in Guided Function 0001 - Adapt learnt values -
after component replacement ⇒ Vehicle diagnostic tester.
Tightening torques

3 SCR (selective catalytic reduction)

system
⇒ “3.1 Exploded view - reducing agent tank”, page 167
⇒ “3.2 Exploded view - reducing agent supply line”, page 168
⇒ “3.3 Exploded view - delivery unit for reducing agent”,
page 168
⇒ “3.4 Exploded view - control unit for reducing agent metering
⇒ “3.5 Draining reducing agent tank”, page 170
⇒ “3.6 Removing and installing reducing agent tank”, page 171
⇒ “3.7 Removing and installing delivery unit for reducing agent”,
page 173
⇒ “3.8 Removing and installing injector for reducing agent N474
”, page 175
⇒ “3.9 Removing and installing control unit for reducing agent
metering system J880 ”, page 175
© satelettronica
3.1 Exploded view - reducing agent tank
1permitted
- Nut unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 2 Nm
2 - Cover
❑ For reducing agent tank
3 - Bolt
❑ 20 Nm
4 - Sleeve
5 - Grommet
6 - Sleeve
7 - Reducing agent tank
❑ Fitting location: Beneath
left rear seat on under‐
side of vehicle.
⇒ page 171
8 - Filler line
❑ From filler neck
9 - Breather line
❑ To filler neck

3.2 Exploded view - reducing agent supply

line
All components are described in ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 26 ; SCR (selective catalytic reduc‐
tion) system; Exploded view - reducing agent supply line .
3.3 Exploded view - delivery unit for reducing agent
1 - Reducing agent tank

⇒ page 171
3 - Seal
❑ Install dry
4 - Reservoir
❑ with:
♦ Filter
© satelettronica
♦ Pump for reducing agent -
V437-
♦ Tank sender for reducing
agent - G684-
♦ Temperature sender for re‐
ducing agent - G685-
♦ Pressure sender for reduc‐
ing agent metering system
- G686-
♦ Heater for reducing agent
tank - Z102-
reservoir ⇒ page 173
❑ Do not kink heating
mats when installing
5 - Locking ring
❑ Release and lock with
wrench -T40268-
6 - Metering line
❑ To injector for reducing agent Protected
- N474-by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ With heater for reducing-agent line - Z104-
❑ Press release tabs to disconnect

3.4 Exploded view - control unit for reducing agent metering system - J880-
1 - Base plate
❑ For control unit for re‐
system - J880-
❑ Is combined with reduc‐
ing agent tank
2 - Clip nut
3 - Control unit for reducing
agent metering system - J880-
❑ At bottom of reducing
agent tank
agnostic tester
❑ If control unit for reduc‐
ing agent metering sys‐
tem - J880- has been
renewed, perform adap‐
© satelettronica
tion in Guided Function
0001 - Adapt learnt
values - after com-
ponent replacement
⇒ Vehicle diagnostic
tester
⇒ page 175
4 - Bolt
❑ 4.5 Nm

3.5 Draining reducing agent tank

Procedure
WARNING

on the SCR system .
ing agent has been drawn back automatically ⇒ Servicing
6-cylinder TDI engine, common rail; Rep. gr. 00 ; Safety
precautions; Safety precautions when
Protected working
by copyright. onforthe
Copying private or commercial purposes, in part or in whole, is not
SCR system . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
© satelettronica
– Open tank flap.
– Unscrew filler cap -2- from filler neck for reducing agent.
Note
Disregard -item 1-.
ducing agent tank.
– Place drip tray underneath.

– Press release tab to remove plug -arrow-, drain off reducing
agent into a drip tray and refit plug.
– Adapt learnt value after filling with reducing agent or renewing
components ⇒ Servicing 6-cylinder TDI engine, common rail;
Rep. gr. 00 ; Repair notes; Adapting learnt values for SCR
system .

3.6 Removing and installing reducing agent

tank
© satelettronica
Removing
WARNING
Reducing agent can cause skinunless
permitted irritation.
on the SCR system .
– Drain reducing agent tank ⇒ page 170 .

underbody trim .

– Press release tabs and disconnect metering line -2-.

– Unplug electrical connectors -1, 3- and move electrical wiring
harness clear.
Note

reducing agent.
– Press release tab and disconnect filler line -1-.

– Press blue slider -4- to release catch -3- and disconnect
© satelettronica
breather lines -2-.
cleaned) from engine bung set - VAS 6122-
Protected by .copyright. Copying for private or commercial purposes, in part or in whole, is not
WARNING

♦ Reducing agent tank must be empty when it is removed.
– Position engine and gearbox jack underneath reducing agent

tank with a soft foam surface in between for support.
– Remove bolts -arrows- (have a second mechanic support the

reducing agent tank by hand).
Note
For greater clarity the reducing agent tank is shown without the
engine and gearbox jack.
– Lower reducing agent tank using engine and gearbox jack, si‐
multaneously guiding reducing agent tank down by hand.

Installing
– Push filler line -1- and breather line -2- onto connection so that
they engage audibly.
– Pull to check that plug-in connectors are correctly engaged.
– Press in catch -3- to secure.
– Check that lines are clipped onto reducing agent tank.
Note
Disregard -item 4-.
– Adapt learnt value after filling with reducing agent or renewing

components
Protected by⇒ Servicing
copyright. Copying6-cylinder TDI engine,
for private or commercial common
purposes, in part or in rail;
whole, is not
Rep. permitted
gr. 00unless
; Repair notes;
authorised Adapting
by AUDI AG. AUDI AG learnt values
does not for
guarantee SCRany liability
or accept
systemwith
. respect to the correctness of information in this document. Copyright by AUDI AG.
Tightening torques
© satelettronica
trim; Overview of fitting locations - trim panels
3.7 Removing and installing delivery unit for

reducing agent
♦ Key - T40268-

Removing
WARNING

on the SCR system .
– Remove reducing agent tank ⇒ page 171 .

© satelettronica
– Turn locking ring -1- anti-clockwise with wrench -T40268- to
release and detach.
– Pull reservoir with pump for reducing agent - V437- out of re‐
ducing agent tank.
Installing
Caution

cleanliness .
Note
♦ Renew seal after removing.

♦ Thoroughly clean sealing surfaces for seal.
Caution
Risk of malfunctions.
♦ The seal must not be twisted.
♦ Do not kink heating mats when installing.

– Move reservoir into installation position:

• Lug -2- on flange must be between tabs -1- and -3-.
• Direction of installation for lug -2- as shown in illustration.
– Turn locking ring -1- clockwise with wrench -T40268- to lock.
© satelettronica
• Locking ring is properly locked when lugs on locking ring are
opposite lugs on support ring of reducing agent tank
-arrows A, B-.
– Install reducing agent tank ⇒ page 171 .
– Adapt learnt value after filling withpermitted
reducing agent or renewing
components ⇒ Servicing 6-cylinder TDI engine, common rail;

Rep. gr. 00 ; Repair notes; Adapting learnt values for SCR

system .
3.8 Removing and installing injector for re‐

Removing
engine, common rail; Rep. gr. 26 ; SCR (selective catalytic re‐
duction) system; Removing and installing injector for reducing
agent - N474- .
Installing
Additional work:

reducing agent metering system - J880-

Removing
ducing agent tank.
– Remove bolts -arrows- and detach control unit for reducing

agent metering system - J880- .
Installing
– If control unit for reducing agent metering system - J880- has
been renewed, perform adaption in Guided Function 0001 -
© satelettronica
Adapt learnt values - after component replacement
Tightening torques
♦ ⇒ “3.4 Exploded view - control unit for reducing agent metering


page 177
⇒ “4.2 Removing and installing exhaust gas temperature send‐
ers”, page 178
4.1 Exploded view - exhaust gas tempera‐

ture control
WARNING

© satelettronica
J881-
⇒ page 149
2 - Nut
❑ Push on as far as stop
sender 3 - G495-
⇒ page 178
Rep. gr. 26 ; Exhaust
gas temperature con‐
trol; Exploded view - ex‐
control
sender 2 - G448-
⇒ page 178
engine,Protected
common rail;
Rep. gr.permitted
26 ; Exhaust
gas temperature
with respect con‐
trol; Exploded view - ex‐
control
⇒ page 149
temperature control; Removing and installing exhaust gas temperature sender

❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas temper‐
ature control; Exploded view - exhaust gas temperature control
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas temper‐
ature control; Exploded view - exhaust gas temperature control

temperature senders
⇒ “4.2.1 Removing and installing exhaust
permitted gas temperature
unless authorised by AUDI AG. AUDIsend‐
er 1 G235 ”, page 178 with respect to the correctness of information in this document. Copyright by AUDI AG.

er 2 G448 ”, page 178
er 3 G495 ”, page 178
© satelettronica
er 4 G648 ”, page 179

gine, common rail; Rep. gr. 26 ; Exhaust gas temperature control;
Removing and installing exhaust gas temperature sender .

Removing
engine, common rail; Rep. gr. 26 ; Exhaust gas temperature con‐
trol; Removing and installing exhaust gas temperature sender .
Installing
Additional work:

Removing
Installing
Additional work:


Removing
Installing
– Remove noise insulation (rear) to tighten exhaust gas tem‐
perature sender ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation; Removing and installing noise insula‐
tion .
Tightening torques
© satelettronica


page 180
page 181
⇒ “5.3 Removing and installing exhaust gas recirculation temper‐
ature sensor G98 ”, page 181

pipe
2 - Bolt
gas recirculation; Explo‐
© satelettronica
ded view - exhaust gas
recirculation
3 - Gasket
TDI engine, common
rail; Rep. gr. 26 ; Ex‐
haust gas recirculation;
Exploded view - exhaust
gas recirculation
4 - Bolt
gas recirculation; Explo‐
dedProtected
view - byexhaust gas for private or commercial purposes, in part or in whole, is not
copyright. Copying
recirculation
er - G62-
TDI engine, common
ant pump/thermostat
assembly; Removing
G62-
6 - O-rings
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
recirculation; Exploded view - exhaust gas recirculation
❑ With exhaust gas recirculation control motor - V338- and exhaust gas recirculation potentiometer - G212-
recirculation; Removing and installing exhaust gas recirculation cooler

8 - Nut
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas recircu‐
lation; Exploded view - exhaust gas recirculation
9 - Gasket
12 - Coolant hose
13 - Bolt
14 - Coolant hose
© satelettronica
15 - Bolt
16 - Vacuum hose
17 - O-ring permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
19 - Bolt

circulation cooler
gine, common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation cooler .

circulation temperature sensor - G98-
Removing
engine, common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation temperature
sensor - G98- .
Installing
Additional work:

6 Exhaust manifolds
WARNING

Note
© satelettronica
1 - Nut Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Tightening torques and permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
installation instructions
TDI engine, common
haust manifold; Explo‐
ded view - exhaust
manifold
⇒ page 183
3 - Gasket
TDI engine, common
haust manifolds; Explo‐
ded view - exhaust
manifold
4 - Gasket
TDI engine, common
haust manifolds; Explo‐
ded view - exhaust
manifold
5 - Screw-type clip
- turbocharger

❑ Mark position of screw-

type clip prior to removal

folds
page 183
page 185

fold (left-side)
© satelettronica
Removing
WARNING

– Remove emission control module ⇒ page

AG does164 .
permitted unless authorised by AUDI AG. AUDI not guarantee or accept any liability


tudinal member.
– Unscrew bolt -1- and detach coolant expansion tank.

– Unplug electrical connector -2- and move coolant expansion

tank to one side with coolant hoses attached.
noise insulation .
© satelettronica
– Remove nuts -arrows- and press bracket -1- to one side.
Caution

– Remove air conditioner compressor from bracket and tie up to

front ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner
compressor; Detaching and attaching air conditioner com‐
pressor at bracket .
– Use a felt-tip pen to mark installation position of screw-type

clip -1-.
– Unfasten and detach screw-type clip -1-.
Note
Disregard -item 2-.


Installing
Note
♦ Renew gaskets, seals, self-locking nuts and screw-type clip

after removal.
♦ If installation positions have been marked, pay attention to
these when installing parts.

Tightening torques
© satelettronica
Exhaust manifolds; Exploded view - exhaust manifold
charge air system
(front)

fold (right-side)

Removing
WARNING

– Remove emission control module ⇒ page 164 .

noise insulation .
– Clamp off coolant hoses with hose clamps -3094- .
– Lift retaining clip -3-, release hose clips -1 and 2- and detach
coolant hoses.
© satelettronica
– Unscrew bolts -arrows- and coolant pipe (right-side) from lon‐
gitudinal member.
Note

the engine removed.
– Release hose clip -4- and detach air hose from air pipe.
– Unscrew bolts -1 and 3- and move air pipe -2- to rear.
– Use a felt-tip pen to mark installation position of screw-type

clip -2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unfasten and detach screw-type
with respect clipof information
to the correctness -2-. in this document. Copyright by AUDI AG.
Note
Disregard -item 1-.


Installing
Note
♦ Renew gaskets, seals, self-locking nuts and screw-type clip

after removal.
♦ If installation positions have been marked, pay attention to
these when installing parts.

Tightening torques
Exhaust manifolds; Exploded view - exhaust manifold
© satelettronica
tion; Exploded
Protected view for
by copyright. Copying - noise
private orinsulation


1 Glow plug system
189
1 - Sender wheel
er - G28-
TDI engine, common
© satelettronica
rail; Rep. gr. 13 ; Crank‐
shaft; Removing and in‐
stalling sender wheel
2 - Glow plug
side):
side):
⇒ page 189
engine, common rail; Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Rep. gr. 28 ; Glow plug with respect to the correctness of information in this document. Copyright by AUDI AG.
glow plug system
4 - O-ring
TDI engine, common rail; Rep. gr. 28 ; Glow plug system; Exploded view - glow plug system
6 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug system;
Exploded view - glow plug system


8 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug system;
Exploded view - glow plug system
9 - Cover

Removing
engine, common rail; Rep. gr. 28 ; Glow plug system; Removing
and installing glow plug .
Installing
Additional work:
© satelettronica
G40-
Removing
and installing Hall sender - G40- .
Installing
Additional work:

sender - G28-
– Unbolt ATF cooler and press to side slightly ⇒ Gearbox; Rep.

gr. 34 ; ATF circuit; Removing and installing ATF cooler .
and installing engine speed sender - G28- .
Tightening torques
♦ ⇒ Gearbox; Rep. gr. 34 ; ATF circuit; Exploded view - ATF
circuit

Service
Workshop Manual
Audi A6 2011 ➤
6-cylinder direct injection engine with supercharger
(3.0 ltr. 4-valve TFSI, EA837evo)
© satelettronica
Engine ID
CRE CRE CTD CTD CRE
C D A B H
Edition 05.2018

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
© satelettronica

Copyright © 2018 Audi AG, Ingolstadt D4B8046B2D3

6-cylinder direct injection engine with supercharger (3.0 ltr. 4-valve TFSI, EA837evo) - Edition 05.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
© satelettronica

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i


2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.3 Exploded view - drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.7 Removing and installing drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
© satelettronica
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.3 Removing and installing hose for crankcase breather system . . . . . . . . . . . . . . . . . . . . . . 169
3.4 Removing and installing crankcase breather shut-off valve N548 . . . . . . . . . . . . . . . . . . 170
ii Contents

4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 173
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
© satelettronica
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1 Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.1 Exploded view - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.2 Exploded view - magnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
1.3 Exploded view - rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.4 Removing and installing supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.5 Checking supercharger for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.6 Removing and installing magnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.7 Removing and installing pulley for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.8 Removing and installing drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
1.9 Removing and installing rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.10 Renewing drive shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.11 Securing supercharger to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.12 Removing and installing sender 1 for turbocharger speed G688 . . . . . . . . . . . . . . . . . . . . 272
2.4 Removing and installing charge pressure sender G31 / G447 . . . . . . . . . . . . . . . . . . . . . . 280
Contents iii

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
4.2 Removing and installing intake manifold (bottom section) with fuel rail . . . . . . . . . . . . . . . . 297
4.4 Removing and installing regulating flap control unit J808 . . . . . . . . . . . . . . . . . . . . . . . . . . 303
4.5 Removing and installing fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
© satelettronica
5.4 Cleaning FSI injectors - vehicles with FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
6.1 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

3.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
4.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
iv Contents
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
© satelettronica
Contents v
© satelettronica
vi Contents
1 Identification
(ARL005810; Edition 05.2018)

Engine number
Note
The engine cover panel must be removed to make the engine

number visible.
♦ The engine number (engine code and serial number) is loca‐

ted on the top of the cylinder block at the front -arrow-.
© satelettronica
number.
Note

Engine data
♦ ⇒ Technical data for engines; Rep. gr. 00 ; Overview of en‐
gines
1. Identification 1
tem”, page 2
page 3
page 3
page 4
page 4

© satelettronica
may spray out.

fuel pump.


a road test
Or:
seat.

The cooling system is under pressure when the engine is hot. Risk
of scalding due to hot steam and hot coolant.
© satelettronica


wiring.

subframe
Caution


exhaust system
When working on the exhaust system please note the following:
© satelettronica
Caution
Risk of damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.

6

loosening.
© satelettronica


fitted.
Please note:
ranty.

and wiring

© satelettronica


page 28
1.1 Removing engine

equipment required
© satelettronica



© satelettronica

Procedure
Note

♦ All bolts on running gear components with bonded rubber
bushes must be tightened with suspension in unladen position
(vehicle unladen).
♦ Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension compo‐
nents with bonded rubber bushes must be brought into a
position corresponding to the normal position while driving
(unladen position). Otherwise, the bush would be subject to
torsion loading and its service life shortened.
♦ Before commencing work, use measuring tape or similar to
measure dimension -a- from wheel centre to lower edge of
wheel housing.
♦ This measurement must be taken with the suspension in the
© satelettronica
unladen position (vehicle unladen).
♦ Note down measurement. This will be needed when tightening
the bolts/nuts on the suspension.
WARNING
moved.
must be empty.
Note
Move the gearbox to position “N” and release the electromechan‐

ical parking brake before disconnecting the battery, so that the
propshaft can be turned during removal.
Caution


battery .
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant


body brace .
ments .
WARNING
© satelettronica
hot.

noise insulation .

– Release hose clips -2-, disconnect coolant hoses from coolant
pipes (front left) and drain off coolant.


tor.

ant pipe (left-side) on gearbox and drain off coolant.
© satelettronica
rier.
Note
Disregard -item 1-.

– Move hose -1- from activated charcoal filter system clear at air
pipe.

-arrow-.
© satelettronica
enoid valve 1 - N80- and detach vacuum hose -3- (press
release tabs).
Caution

supply system ⇒ “3.1 Rules for cleanliness”, page 5 .

WARNING

– Disconnect fuel hose -1- ⇒ Fuel supply system; Rep. gr. 20 ;

exchanger for heater (rear).
© satelettronica
Note

the plenum chamber partition panel removed.
– Lift retaining clip -arrow- and disconnect coolant line.

– Move coolant line clear and push to left side.

– Lift retaining clip and detach coolant hose -arrow- from coolant
pipe (front).
© satelettronica



earth cables clear.

© satelettronica


trical wiring.
holder -3-.

-arrow B-.
– Move wiring harness clear and place on top of engine.
– Secure engine control unit - J623- to prevent it falling.
© satelettronica
Note

– Remove air intake grille (right-side) ⇒ General body repairs,
attachments .


move hose clear.
Note
– Unplug electrical connector -1- at front wheel speed sensors

on both sides.
Note
Disregard -item 2-.
© satelettronica
– If fitted, unplug electrical connector -1- on front vehicle level
senders (both sides) and move electrical wiring clear -arrow-.
Caution

♦ Do not operate brake pedal with brake caliper removed.

housing -arrows-.


Note

cross brace .
Caution
© satelettronica

-1- for longitudinal member.
– Unscrew nuts -arrows- on both sides and detach front silencer.




VAS 6131/13-
© satelettronica
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /10-11
G6 /10-1 /10-2 /10-5 /10-11
A8+C8 /13-6 – – /13-2
F8+H8 /13-5 – – /13-2
B14 /10-1 /10-3 /10-5 /11-1
G14 /10-1 /10-4 /10-5 /11-1
assembly platform.
zontally.
WARNING

– Remove subframe bolt -1- on both sides.



© satelettronica
shown.


shown.


© satelettronica
Caution



from gearbox.
Note
– Remove refrigerant lines from air conditioner compressor ⇒

Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Detaching and attaching refrigerant lines at air con‐
ditioner compressor .

© satelettronica

VAS 6131/13-

Procedure
– Remove poly V-belt tensioner for supercharger
⇒ “1.3.1 Removing and installing tensioner for poly V-belt for
supercharger”, page 51 .
– Take electrical connector -2- for Lambda probe 2 after catalytic
© satelettronica
converter - G131- out of bracket, unplug and move wiring
clear.
Note
Disregard -item 1-.
– Remove nuts -arrows- and bolt -1- and detach catalytic con‐
verter (left-side).

Caution

chanic must “discharge static” by briefly touching vehicle
earth, heater or lifting platform.
with your hands.

– Unplug electrical connector -2- on gearbox oil cooling valve -

N509- and move electrical wire clear.
© satelettronica
Note
Disregard -item 2-.
– Remove nuts -arrows- and bolt -1- and detach catalytic con‐

– Lift retaining clips -arrows- and detach connection.

– Unplug electrical connector -1- at coolant circulation pump -
V50- .
(left-side).
© satelettronica
Note

and move wiring clear.
Note
Disregard -item 1-.


gine.
© satelettronica
Note



Note

VAS 6131/13-7-
F2 /13-7
B10 /10-1 /10-3 /10-5 /11-4
G10 /10-1 /10-3 /10-5 /11-4
– Secure support -VAS 6131/13-7- at tapped hole for poly V-belt

tensioner for air conditioner compressor at front of engine
© satelettronica
(right-side) as illustrated.


Note
Disregard -item A-.



equipment required
© satelettronica
♦ Lifting tackle - 2024A-

Audi A6 - VAS 6095/1-5-

Procedure
type assembly platform - VAS 6131 B- (with engine detached
from gearbox)
⇒ “1.2 Separating engine and gearbox”, page 22 .
⇒ “1.2.2 Removing and installing poly V-belt for ancillaries”,
page 48 .
WARNING
Risk of accident!
© satelettronica
– Attach lifting tackle - 2024A- to engine lifting eyes and work‐
shop hoist - VAS 6100- with lift arm extension (workshop hoist)
- VAS 6101- as shown in illustration.
Note

WARNING
Risk of accident.
– If fitted, take electrical connectors -2- for electrohydraulic en‐

gine mounting solenoid valves out of brackets and unplug
(both sides).
subframe.
Note
stalled.

Note
Disregard -item 1-.

© satelettronica
side).


to engine and gearbox support - VAS 6095- as shown in
illustration and tighten to 40 Nm.
© satelettronica

Tightening torques
Note

© satelettronica
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ Bolts securing engine to gearbox ⇒ 8-speed automatic gear‐
♦ Bolts securing engine to gearbox ⇒ 7-speed dual clutch gear‐

Procedure
Note
♦ Renew bolts tightened with specified tightening angle.

© satelettronica
– Install engine support and engine mounting
– Join engine and gearbox; the procedures for doing so are giv‐
en in the following sections:
♦ ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Installing gearbox
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Removing and
installing gearbox; Installing gearbox .
– Install ATF cooler ⇒ 7-speed dual clutch gearbox; Rep. gr.
34 ; ATF circuit; Removing and installing ATF cooler / ⇒ 8-
speed automatic gearbox; Rep. gr. 37 ; ATF circuit; Removing
– Install drive shafts and heat shield ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Exploded view - drive shaft
– Install catalytic converters


and body is -a-.
– Install selector lever cable and adjust if necessary.
♦ ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; Selector mech‐
anism; Removing and installing selector lever cable
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Selector mech‐
anism; Removing and installing selector lever cable
87 ; Air conditioner compressor; Detaching and attaching re‐
frigerant lines at air conditioner compressor .
– Tighten bolts for tunnel cross member:
♦ ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; Assembly
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mount‐
© satelettronica
ings; Exploded view - assembly mountings
WARNING


note the following:
– Install front silencers
⇒ “1.3 Removing and installing front silencers”, page 339 .
frame .
carrier .
– Install engine control unit
”, page 334 .


page 48 .
– Install poly V-belt tensioner for supercharger
supercharger”, page 51 .
© satelettronica
ments .
ing battery .
– Install fuel supply line
page 326 .
chamber cover .
page 43 .
Caution

sive voltage.
411 .
– Secure coolant pipes
⇒ “3.1 Exploded view - coolant pipes”, page 205 .
– Connect coolant hoses and connection with plug-in connector
⇒ page 223 .
Note


R134a .
– Align subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ;
Subframe; Removing and installing subframe with steering
rack .
Wheels, tyres .
WARNING

© satelettronica
– Fill up with ATF:
♦ ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; ATF
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; ATF
– Install underbody trim ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody trim; Exploded view - underbody trim .
insulation .


Engine mounting
1 - Engine mounting
left side may include left
- N144-
right side may include
right electrohydraulic
© satelettronica
engine mounting sole‐
noid valve - N145-
ings”, page 40
2 - Bolt
❑ 20 Nm
3 - Bracket
fective
4 - Bolt
❑ 40 Nm
5 - Bolt
❑ 20 Nm
6 - Engine support
❑ With bracket for air con‐
ditioner compressor
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 90 Nm +90°
10 - Subframe
11 - Bolt
❑ 55 Nm
Gearbox mounting
1 - Bolt
♦ ⇒ 7-speed dual clutch
gearbox; Rep. gr. 34 ; As‐
sembly mountings; Explo‐
ded view - assembly
mountings
♦ ⇒ 8-speed automatic gear‐
box; Rep. gr. 37 ; Assembly
mountings; Exploded view -
assembly mountings
ling:
gearbox; Rep. gr. 34 ; As‐
sembly mountings; Explo‐
ded view - assembly
mountings
♦ ⇒ 8-speed automatic gear‐
© satelettronica
box; Rep. gr. 37 ; Assembly
mountings; Exploded view -
assembly mountings
3 - Stop plate
installing gearbox
5 - Bolt
gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view - assembly mountings
6 - Nut
♦ ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
7 - Bolt
8 - Gearbox support
❑ Removing and installing ⇒ “2.4 Removing and installing gearbox mounting”, page 42
9 - Bolt
10 - Nut


tion
© satelettronica
Procedure
WARNING
Risk of accident when weight of engine is shifted.

♦ In order to support the engine as described below, the
gearbox and tunnel cross members must be installed.

page 43 .

– Engage spindles -10-222A/11- at engine lifting eyes (left and
right).

ings
Note

♦ Renew engine mounting and corresponding bracket.
Removing
– Support engine in installation position
⇒ “2.2 Supporting engine in installation position”, page 39 .
noise insulation .
© satelettronica
– Remove corresponding cover -1- for drive shaft in wheel hous‐
ing.

Note
Bolts -1 and 3- on left side and all bolts for subframe on right side
remain fitted.



– If fitted, take electrical connector -2- for relevant electrohy‐
draulic engine mounting solenoid valve out of bracket and
unplug connector.
plate to one side.
Note
Disregard -item 2-.
– Using spindle - 10-222A/11- -item 1-, raise engine through

Installing
© satelettronica
Note
Renew bolts tightened with specified tightening angle.
WARNING

Tightening torques
(front)

mounting
⇒ “2.4.2 Removing and installing gearbox mounting”, page 42

port with gearbox mounting
Removing
– Remove tunnel cross member:
Installing
© satelettronica
Tightening torques

mounting
Removing
box mounting”, page 42 .
Installing
box mounting”, page 42 .
Tightening torques



panel
Removing
Installing
– Position engine cover panel on engine and use both hands to
press it down into retaining clips.
© satelettronica

page 51
53

⇒ “1.1.1 Exploded view - poly V-belt drive, poly V-belt for super‐
charger”, page 44
⇒ “1.1.2 Exploded view - poly V-belt drive, poly V-belt for ancilla‐
ries”, page 45
© satelettronica
1.1.1 Exploded view - poly V-belt drive, poly V-belt for supercharger
1 - Poly V-belt
❑ Check for wear
supercharger”,
page 47
on pulleys
2 - Bolt
❑ Not available separate‐
ly; combined as a unit
with -item 5-
❑ 40 Nm
3 - Washer
with -item 5-
4 - Supercharger
❑ Exploded view
supercharger”,
page 239
5 - Idler roller
❑ For poly V-belt
-items 2 and 3-

❑ Can only be installed in one position (holes are off-set).

7 - Bolt
8 - Tensioner
❑ For poly V-belt
⇒ “1.3.1 Removing and installing tensioner for poly V-belt for supercharger”, page 51
9 - Bolt
❑ 40 Nm
1.1.2 Exploded view - poly V-belt drive, poly V-belt for ancillaries
1 - Bolt
❑ 20 Nm +90°
© satelettronica
❑ With double-sided poly
V-belt pulley
stalling vibration damp‐
er”, page 53
3 - Poly V-belt
❑ Check for wear
❑ Do not kink
on pulleys
4 - Cover
❑ Depending on version
5 - Bolt
6 - Alternator
⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
7 - Bolt
❑ 20 Nm
8 - Bracket
❑ For alternator

9 - Idler roller
❑ For poly V-belt
❑ 40 Nm
10 - Bolt
12 - Bolt
13 - Coolant pump
14 - Bolt
⇒ Fig. ““Sealing flange (pulley end) - tightening torque and sequence”“ , page 47
❑ Renewing ⇒ “1.5 Removing and installing sealing flange (pulley end)”, page 53
© satelettronica
16 - Bolt
❑ 40 Nm
17 - Tensioner
❑ For poly V-belt
⇒ “1.3.2 Removing and installing tensioner for poly V-belt for ancillaries”, page 51
18 - Cover
❑ For tensioner
20 - Bolt
22 - Bolt
23 - Dowel sleeve
❑ 2x


nal torque 9 Nm.
© satelettronica
page 47
⇒ “1.2.2 Removing and installing poly V-belt for ancillaries”, page
48

supercharger
♦ Locking pin - T10060A-
Removing
WARNING


page 43 .
noise insulation .

Caution

irreparable damage.
– To slacken poly V-belt, turn tensioner in clockwise direction

-arrow-.
A- .
Installing
1- Tensioner
2- Supercharger
© satelettronica
3- Idler roller
4- Vibration damper
– Fit poly V-belt onto idler roller -3- last.
Note

pulleys.

page 43 .
Tightening torques

ancillaries
♦ Special wrench, long reach -3320/2- (included with door align‐
ment tool - 3320- )

♦ Locking pin - T10060A-
Removing
– Remove poly V-belt for supercharger
page 47 .
– Remove bolt -arrow- using special wrench, long reach
-3320/2- .
– Push guide roller towards radiator cowl.
© satelettronica
Note
The guide roller cannot be detached.
Note

the engine removed.
Note
Disregard -item 2-.

Caution

irreparable damage.
– To slacken poly V-belt, turn tensioner clockwise -arrow- and

lock with locking pin - T10060 A- .
Installing
1- Alternator
2- Idler roller
© satelettronica
3- Coolant pump
5- Tensioner for poly V-belt
6- Vibration damper
Note

pulleys.

– Install poly V-belt for supercharger
page 47 .
Tightening torques


poly V-belt
⇒ “1.3.1 Removing and installing tensioner for poly V-belt for su‐
⇒ “1.3.2 Removing and installing tensioner for poly V-belt for an‐

poly V-belt for supercharger
Removing
page 47 .
Note
Ignore -T10060A- .
© satelettronica
Installing
page 47 .
Tightening torques

poly V-belt for ancillaries
Removing
WARNING


page 43 .

Note
Disregard -item 1-.
Note
Disregard -item 2-.
© satelettronica
– To slacken poly V-belt, turn tensioner in clockwise direction
-arrow-.
– Remove poly V-belt from tensioner and release tensioner.
Note
Ignore -T10060A- .
– Remove bolt -1- and detach poly V-belt tensioner -2- from cyl‐
inder block.
Installing
page 48 .
page 43 .
Tightening torques


er
Removing
© satelettronica
page 47 .
– Remove poly V-belt from tensioner and release tensioner
ancillaries”, page 51 .
– Loosen bolts -1- for vibration damper using counterhold tool -
3036- .
– Remove bolts and take off vibration damper.
Installing
Note

♦ Can only be installed in one position.
– Observe dowel sleeve when installing vibration damper.

page 48 .
Tightening torques

(pulley end)

♦ Assembly tool - T40048 A-
© satelettronica
♦ Safety goggles
Procedure
– Remove vibration damper

– Loosen bolts -arrows- in diagonal sequence and remove.

– Release sealing flange (pulley end) from bonded joint and take
off sealing flange.
Note
Renew sealing flange (pulley end) after removing.
© satelettronica
Caution

WARNING
Risk of eye injury.


Note

mm).

Caution


with sealant.
sealing surface.
Note

© satelettronica
– First position sealing flange -1- (with assembly sleeve -

T40048/2- inserted) on crankshaft.
ing surface. Then bolt on
⇒ Fig. ““Sealing flange (pulley end) - tightening torque and se‐
note the following:
– Install vibration damper
Tightening torques
♦ ⇒ Fig. ““Sealing flange (pulley end) - tightening torque and se‐


Note
1 - Bolt
❑ 60 Nm +90°
2 - Drive plate
© satelettronica
holes for torque convert‐
er for cracks and scoring
page 57
3 - Sender wheel
er - G28-
stalling sender wheel”,
page 66
❑ Checking
⇒ “3.6 Checking sender
wheel”, page 67
4 - Oil seal
end)
❑ Renewing
end)”, page 58
5 - Crankshaft
6 - Dowel pin


♦ Counterhold tool - 10-201-
Removing
• Gearbox removed:
installing gearbox
installing gearbox
© satelettronica
Caution

drive plate.
Installing
Note

bolts.
Tightening torques
page 57

end)


♦ Extractor tool - T20143/2-
© satelettronica
Procedure
installing gearbox
installing gearbox
– Pry out oil seal using extractor hook -T20143/2- .


© satelettronica
ing bolts -arrows-.
Caution


hand.

T10122/5- .
oil seal.

3 Crankshaft
Note
© satelettronica
❑ Renewing
2 - Bolt
sequence
⇒ Fig. ““Sealing flange
(pulley end) - tightening
page 47
3 - Crankshaft
ance
⇒ “3.3 Measuring axial
shaft”, page 65
ance
⇒ “3.4 Measuring radial
shaft”, page 65
4 - Dowel sleeve
❑ 4x
frame
⇒ Fig. ““Applying seal‐
ant to retaining frame,
position of dowel
5 - Seal
6 - Bolt
3. Crankshaft 61

7 - Bolt
❑ Use old bolts when measuring radial clearance
8 - Bolt
9 - Retaining frame
❑ With valve for oil pressure control - N428- ⇒ Fig. ““ Valve for oil pressure control -N428- ”“ , page 63
❑ Removing and installing valve for oil pressure control - N428-
© satelettronica
10 - Seal
11 - Thrust washer
12 - Bearing shell
❑ Install new bearing shells for retaining frame with correct coloured markings
⇒ Fig. ““Matching crankshaft bearing shells to bearings in retaining frame”“ , page 64
13 - Thrust washer
❑ Make sure it engages in cylinder block
14 - Bearing shell
❑ Install new bearing shells for the cylinder block with the correct coloured markings
⇒ Fig. ““Matching crankshaft bearing shells to bearings in cylinder block”“ , page 64
15 - Cylinder block

Note

2- O-ring - renew after removal
3- Bolt, 9 Nm
© satelettronica
with sealant.
sealing surface.
3. Crankshaft 63
Note

1. -1 … 16- 50 Nm
2. -1 … 16- Turn 90° further
3. -17 … 31- 15 Nm
4. -17 … 31- Turn 90° further
© satelettronica
shell thickness.
R = Red
G = Yellow
B = Blue
S = Black

gearbox flange on the crankshaft. The first letter in the se‐
“2”, etc.
R = Red
G = Yellow
B = Blue
S = Black


Honing dimension Crankshaft bearing journal ∅ Crankshaft conrod journal ∅
mm mm
Basic dimension 65.000 – 0.022 56.000 – 0.022
– 0.042 – 0.042

© satelettronica
Procedure
“0”.

shaft
♦ Plastigauge
3. Crankshaft 65
Procedure
Note
Use old bolts when measuring radial clearance.

ing shell.
– Fit retaining frame and secure with old bolts
⇒ Fig. ““Installing retaining frame”“ , page 64 without rotating
crankshaft.
Radial clearance:
• New: 0.015 ... 0.055 mm.
© satelettronica

Removing
installing gearbox
installing gearbox
Installing

Caution

wheel.

© satelettronica
Procedure
⇒ “3.5 Removing and installing sender wheel”, page 66 .
3. Crankshaft 67

A - Sender wheel OK
© satelettronica

4 Balance shaft
1 - Balance shaft
page 69
2 - Bolt
when loosening and
tightening
❑ 40 Nm +90°
© satelettronica
shaft
❑ With balance weight
(gearbox end)
4 - Bearing plate
5 - Bolt
❑ 15 Nm
sition.
7 - Bolt
when loosening and
tightening
❑ 40 Nm +90°

4. Balance shaft 69
Removing
installing gearbox
installing gearbox
© satelettronica
– Remove sealing flange (pulley end)
page 53 .
page 86 .
– Loosen bolt -arrow- by one turn (counterhold using locating
pin -T40116- ).
– Remove drive chain for valve gear
page 111 .
– Unscrew bolt -2- at pulley end of engine (counterhold balance

weight -1- with a suitable pin) and detach balance weight from
balance shaft.


shaft from engine (gearbox end).
Installing
T40069- .
Note
© satelettronica
tion.
– Install drive chain for valve gear

page 111 .
page 86 .
– Install sealing flange (pulley end)
page 53 .
Tightening torques
4. Balance shaft 71

page 76
Note

1 - Bolts
© satelettronica
ance
contact surface
❑ 50 Nm +90°
❑ Mark cylinder and con‐
rod allocation in colour
⇒ Fig. ““Marking con‐
rods”“ , page 73
conrod pairs
⇒ Fig. ““Conrod installa‐
tion position”“ ,
page 73
3 - Bearing shells
ed.
shells
❑ There are oversized
bearings available for
machined crankshaft
❑ Lugs on conrod bear‐
ings must be on the
same side
4 - Conrod
❑ Mark cylinder and conrod bearing cap allocation in colour ⇒ Fig. ““Marking conrods”“ , page 73

5 - Circlip
6 - Piston pin
7 - Piston
❑ Checking pistons and cylinder bores ⇒ “5.3 Checking pistons and cylinder bores”, page 75
8 - Piston rings
© satelettronica
Caution

a notch or similar.
• Arrows on piston crowns point to pulley end.
Marking conrods
Note
♦ Only renew conrods as a complete set.

♦ Do not interchange conrod bearings.




2- Oil spray jet with spray nozzle valve (opening pressure:
2 ... 2.4 bar)
Caution


♦ Pin - VW 222A-
© satelettronica
Removing
28
– Remove cylinder head
⇒ “3.2 Removing and installing cylinder head”, page 117 .
– Remove sump (top section)
page 160 .
to cylinder and to conrods for re-installation
⇒ Fig. ““Marking conrods”“ , page 73 .
Note

– Use drift - VW 222A- to drive out piston pin.
Installing

Note

– Install sump (upper section)
page 160 .
– Install cylinder head
⇒ “3.2 Removing and installing cylinder head”, page 117 .
Tightening torques
© satelettronica

Checking piston
Piston ∅ mm
• 1) Dimensions including coating (thickness approx. 0.02 mm).
The coating will wear down in service.

-B-.


of cylinder.
mm mm
Oil scraper ring 0.25 … 0.50 – 1)
• 1) Specification not yet available.

mm mm
© satelettronica

bearings
♦ Plastigauge
Procedure
Note

Radial clearance:
• New: 0.010 ... 0.052 mm.


1 - Bolt
sequence
ing torque and tighten‐
ing sequence”“ ,
page 80
© satelettronica
installing timing chain
cover (bottom)”,
page 86
3 - Oil seal
end)
❑ Renewing
end)”, page 58
4 - Dowel sleeve
❑ 2x
5 - Bolt
stalling engine oil cool‐
er”, page 165
7 - Gasket
8 - Bolt
⇒ Fig. ““Timing chain cover (bottom) - tightening torque and tightening sequence”“ , page 80
❑ Opening/closing pressure 2.5 ... 3.2 bar
❑ Grey insulation
❑ Removing and installing ⇒ “4.3 Removing and installing oil pressure switch F22 ”, page 173
❑ 20 Nm

10 - Seal
11 - Cylinder head gasket (left-side)
12 - Bolt
13 - Bracket
❑ Removing and installing ⇒ “1.2.1 Removing and installing timing chain cover (left-side)”, page 80
15 - Bolt
16 - Bracket
17 - Bracket
© satelettronica
18 - Bolt
19 - Seal
20 - Bracket
21 - Bolt
22 - Seals
23 - Bolt
24 - Bracket
❑ Removing and installing ⇒ “1.2.1 Removing and installing timing chain cover (left-side)”, page 80
26 - Bracket
27 - Bolt
28 - Dowel sleeve
❑ 2x
30 - Bolt


32 - Bolt
Note

♦ -Item 8- is a centre hex stud.

1. -1 … 8- 5 Nm
© satelettronica
Note

♦ -Item 8- is a centre hex stud.

1. -1 … 8- 5 Nm


sequence
Note

1. -arrows- 3 Nm
4. -arrows- 9 Nm
5. -6, 7, 8- 8 Nm
6. -6, 7, 8- Turn 90° further
7. -9- 20 Nm
© satelettronica
cover
⇒ “1.2.1 Removing and installing timing chain cover (left-side)”,
page 80
⇒ “1.2.2 Removing and installing timing chain cover (right-side)”,
page 83
page 86

cover (left-side)
♦ Safety goggles
Removing
Note
Re-install all cable ties in the same locations when installing.

page 43 .
– Unbolt combination valve (left-side) for secondary air system
from cylinder head ⇒ page 359 and place to one side.
– Remove coolant pipe (left-side)
⇒ “3.2.4 Removing and installing coolant pipe (left-side)”, page
213 .

– Unplug connectors -1- for camshaft control valve 2 - N208- and

for exhaust camshaft control valve 2 - N319- .
Note
Disregard -item 2-.
– Release retainers -arrow-, detach wiring duct -1- towards rear

and press to one side.
© satelettronica
– Detach electrical connectors -3, 4, 5- from bracket and place
to one side.
Note
– Unscrew bolts -arrows- and detach bracket -1- for electrical

connectors.


joint, e.g. using a spatula, and detach.
Installing
Note

Caution

© satelettronica
WARNING
Risk of eye injury.


Note

mm).

Caution

– Apply sealant bead -arrow- onto clean sealing surfaces of tim‐

ing chain cover as illustrated.
Note

– Fit timing chain cover (left-side) together with brackets

-arrows A and B- and tighten bolts
⇒ Fig. ““Timing chain cover (left-side) - tightening torque and
© satelettronica
note the following:
Note
– Install coolant pipe (left-side)

⇒ “3.2.4 Removing and installing coolant pipe (left-side)”, page
213 .
– Install combination valve for secondary air
page 43 .
Tightening torques

cover (right-side)
♦ Safety goggles
Removing
Note


page 43 .
page 292 .
⇒ “8.2.1 Removing and installing Lambda probe G39 / G130
”, page 330 .
– Press release tabs on both sides and disconnect secondary
air hoses -arrows-.
– Remove nuts -1, 3- and bolt -2-, move secondary air pipe to
side.
– Unbolt combination valve (right-side) for secondary air system
from cylinder head ⇒ page 362 and place to one side.
© satelettronica
– Unplug connectors -1- for camshaft control valve - N205- and
exhaust camshaft control valve 2 - N318- .
Note
Disregard -item 2-.
– Detach electrical connectors -1 ... 5- from bracket and place

to one side.


joint, e.g. using a spatula, and detach.
Installing
Note

Caution

© satelettronica
WARNING
Risk of eye injury.


Note

mm).

Caution

– Apply sealant bead -arrow- onto clean sealing surfaces of tim‐

ing chain cover as illustrated.
Note

– Fit timing chain cover (right-side) together with brackets

-arrows A and B- and tighten bolts
⇒ Fig. ““Timing chain cover (right-side) - tightening torque and
© satelettronica
note the following:
Note
– Install combination valve for secondary air

”, page 330 .
page 292 .
page 43 .
Tightening torques

cover (bottom)
♦ Safety goggles

Removing
installing gearbox
installing gearbox
Note

⇒ “1.2.1 Removing and installing timing chain cover (left-
side)”, page 80 ,
⇒ “1.2.2 Removing and installing timing chain cover (right-
side)”, page 83 .
© satelettronica
– Remove engine oil cooler
– Unplug electrical connector -arrow- at oil pressure switch -
F22- and move wiring clear.


– Detach connection with crankcase breather hose, move clear
and swivel to side.
Note
Disregard -item 2-.

Note
© satelettronica
cover (bottom).

Installing
Note

♦ Renew seals after removing.

• Dimension -x- = 6.5 mm
• Dimension -y- = 8 mm
Note
© satelettronica
Caution

WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover (bottom)

-1-, cylinder block and cylinder head using rotating plastic
brush or similar.

Note
© satelettronica
Caution

and do not kink.
Note
renewed.
– Carefully bend the ends of the cylinder head gaskets down

very slightly -arrows-, just far enough to be able to clean the
upper sealing surface on the cylinder head gasket and cylinder
head.
Note

mm).


sealant.
© satelettronica
Caution


with sealant.
sealing surface.
Note


tom).

– Fit timing chain cover (bottom), guiding it towards sealing sur‐

face on cylinder block and cylinder head at an angle and from
below.
ting the cover.
– Tighten bolts
⇒ Fig. ““Timing chain cover (bottom) - tightening torque and
tightening sequence”“ , page 80 .
note the following:
– Install crankshaft oil seal (gearbox end)
⇒ “2.3 Renewing crankshaft oil seal (gearbox end)”,
page 58 .
⇒ “1.2 Removing and installing timing chain cover”, page 80 .
© satelettronica
411 .
Tightening torques
page 167

2 Chain drive
⇒ “2.3 Exploded view - drive chain for oil pump”, page 98
page 98
page 108
page 111
⇒ “2.7 Removing and installing drive chain for oil pump”,
page 113

1 - Bolts
© satelettronica
for camshaft timing
chain (left-side)
3 - Bolt
❑ 80 Nm +90°
5 - Bolt
❑ 80 Nm +90°
side)
with a paint marker
2. Chain drive 93
8 - Bolt
❑ 9 Nm
9 - Slide
11 - Bearing plate
12 - Bolt
1 - Bolt
© satelettronica
❑ 80 Nm +90°
3 - Bolt
for camshaft timing
chain (right-side)
for drive sprocket for
page 97
chain (right-side)
for drive sprocket for
page 97
6 - Bolt

❑ 80 Nm +90°
9 - Thrust washer
page 97
© satelettronica
11 - Slide
12 - Bolt
❑ 9 Nm
2. Chain drive 95
1 - Guide rail
2 - Bolt
❑ 16 Nm
3 - Bolt
❑ 16 Nm
4 - Bolts
❑ 5 Nm +90°
for camshaft timing
chain (left-side)
chain (left-side)
© satelettronica
7 - Drive chain
with a paint marker
valve gear”, page 111
8 - Bolt
❑ 8 Nm +45°
9 - Bearing plate
for camshaft timing
chain (left-side)
10 - Chain sprocket for balance shaft
❑ With balance weight (gearbox end)
11 - Bolt
❑ 30 Nm +90°
page 97
page 97
14 - Thrust washer

page 97
15 - Seal
17 - Bolt
❑ 9 Nm
18 - Crankshaft
19 - Bolt
Installation position: bearing mounting for drive sprocket for cam‐

shaft timing chain (right-side)
• Dowel pins in bearing mounting -3- for drive sprocket for cam‐
© satelettronica
shaft timing chain (right-side) must engage in drillings in thrust
washer -1- and in cylinder block drillings.
4 - Bolt
2. Chain drive 97
2.3 Exploded view - drive chain for oil pump
1 - Bolt
❑ 30 Nm +90°
❑ For oil pump
gearbox
one position
3 - Chain tensioner
❑ With guide rail
4 - Bolt
❑ 20 Nm
5 - Drive chain
© satelettronica
❑ For oil pump
with a paint marker
stalling drive chain for oil
pump”, page 113
2.4 Removing camshaft timing chain from

camshafts

© satelettronica
♦ Socket -T40297-
Removing
Note

on the engine.

⇒ “1.2 Removing and installing timing chain cover”, page 80 .
– Remove cylinder head cover (left and right)
page 124 .
noise insulation .
2. Chain drive 99

gine.
– Use adapter - T40058- and angled ring spanner to turn crank‐

shaft in direction of engine rotation -arrow- to “TDC”.
© satelettronica
Note
♦ Turn the engine until the small notch -1- on the vibration damp‐
er is in line with the joint -2- between the cylinder block and
the retaining frame on the left side (as seen in direction of
travel). This makes it easier to screw in locking pin - T40069-
in a later step.
♦ The marking on the vibration damper is only a visual aid. The
exact “TDC” position can only be obtained by screwing in the
• Threaded holes -arrows- in all camshafts must face upwards.
Note
If camshafts are not positioned as described, turn crankshaft one

rotation further and return to TDC position.


– Fit camshaft clamp - T40133/1- onto cylinder head -arrows-
and tighten to 25 Nm.

© satelettronica
– Remove plug -arrow- for crankshaft “TDC” marking from cyl‐
inder block.

2. Chain drive 101


T40071- .
Note

Caution

when loosening bolt for camshaft adjuster or camshaft
chain sprocket.
© satelettronica
– Apply socket -T40297- with ring spanner -2- to counterhold at
corresponding camshaft adjuster.
– Loosen bolt -1- for camshaft adjuster (inlet side).
– Loosen bolt -3- for camshaft adjuster (exhaust side) by coun‐
terholding with socket -T40297- as well.
Caution

engine.

tion.


(left-side) inwards as far as the stop using a screwdriver -1-.
Note

Caution

when loosening bolt for camshaft adjuster or camshaft
chain sprocket.
© satelettronica
– Apply socket -T40297- with ring spanner -2- to counterhold at
corresponding camshaft adjuster.
– Loosen bolt -1- for camshaft adjuster (exhaust side).
– Loosen bolt -3- for camshaft adjuster (inlet side) by counter‐
holding with socket -T40297- as well.
Caution

engine.

tion.
Installing
Note
Caution

2. Chain drive 103

• Drive chain for valve gear installed

page 111
T40069- .
© satelettronica
• Camshaft clamp -T40133/1- installed on cylinder bank 1 (right-
side) and tightened to 25 Nm -arrows-.
• Camshaft clamp -T40133/2- installed on cylinder bank 2 (left-
side) and tightened to 25 Nm -arrows-.
Caution


moval.
• Groove -1- or -4- on camshaft adjuster should align with cor‐
responding adjustment window -2- or -3-.


moval.
Caution

© satelettronica
moval.
• Groove -1- or -4- on camshaft adjuster should align with cor‐
responding adjustment window -2- or -3-.

moval.
2. Chain drive 105


– Fit socket -T40297- onto camshaft adjuster of exhaust cam‐
shaft.
der tension:
– Remove camshaft clamp -T40133/1- -arrows-.
© satelettronica
– Fit socket -T40297- onto camshaft adjuster of inlet camshaft.
der tension:
– Remove camshaft clamp -T40133/2- -arrows-.


– Tighten camshaft adjuster bolts on cylinder head (right-side)
as follows:
torque
⇒ “2.1 Exploded view - camshaft tim‐
ing chains”, page 93
torque

– Tighten camshaft adjuster bolts on cylinder head (left-side) as
follows:
torque
© satelettronica
torque
– Using adapter - T40058- and angled ring spanner, turn crank‐

shaft 2 revolutions in normal direction of rotation -arrow- until
crankshaft is at “TDC” again.
Note

2. Chain drive 107


– Fit camshaft clamp -T40133/1- on cylinder head and tighten
-arrows-.

– Fit camshaft clamp -T40133/2- on cylinder head and tighten
-arrows-.
© satelettronica
– Remove locking pin.
note the following:
page 124 .
⇒ “1.2.1 Removing and installing timing chain cover (left-
side)”, page 80 .
Tightening torques

ing chain
Removing
installing gearbox


installing gearbox
page 86 .
98 .
Caution


chain (left-side).
© satelettronica
– Remove bolts -1, 2- and take off chain tensioner (right-side).
2. Chain drive 109

– Press guide rail of chain tensioner for drive chain for valve gear
in direction of -arrow- and lock chain tensioner by inserting
– Remove bolt -1- securing bearing mounting for drive chain
sprocket.
– Pull off drive sprocket with bearing mounting and lift off cam‐
shaft timing chain (right-side).
Installing
Note

Caution
© satelettronica
– Fit camshaft timing chain (left-side) on drive chain sprocket

according to marks made upon removal and guide chain up‐
wards to cylinder head.
T40071- .
– Fit camshaft timing chain (right-side) on drive chain sprocket

according to marks made upon removal and guide chain up‐
wards to cylinder head.
– Install drive sprocket
⇒ Fig. ““Installation position: bearing mounting for drive
sprocket for camshaft timing chain (right-side)”“ , page 97 .
– Tighten bolt -1- securing bearing mounting for drive chain
sprocket.
Note
Disregard -arrow-.

– Fit chain tensioner on cylinder head (right-side).

note the following:
page 86 .
Tightening torques

valve gear
© satelettronica
Removing
installing gearbox
installing gearbox
page 86 .
– Remove timing chains
page 108 .
– Remove bolts -1 and 2- and take off chain tensioner.
2. Chain drive 111


⇒ “2.7 Removing and installing drive chain for oil pump”, page
113 .
Caution

♦ Mark running direction of drive chain with coloured arrows
for re-installation.

Installing
Note
© satelettronica

T40069- .
– Lock balance shaft sprocket in “TDC” position by inserting lo‐

cating pin -T40116- in adjustment window -arrow- of sprocket.


• Locating pin -T40116- must be positioned in approximate cen‐

tre of adjustment window -arrow- in balance shaft sprocket.
© satelettronica
• Locating pin must NOT make contact on left or right side. If
necessary, adjust drive chain by one tooth.
⇒ “2.7 Removing and installing drive chain for oil pump”, page
113 .
– Install camshaft timing chains
page 108 .
page 86 .
Tightening torques

oil pump
Removing
installing gearbox
2. Chain drive 113


installing gearbox
page 86 .
– Use pliers to press down chain tensioner spring -arrows- and
lock in place by inserting locking pin - T40071- .
Caution

– Remove bolt -1- and take off chain tensioner.
– Counterhold chain sprocket with a screwdriver -2- and remove

bolt -1-.
© satelettronica
– Detach drive chain with chain sprocket.
Installing
page 86 .
Tightening torques
♦ ⇒ “2.3 Exploded view - drive chain for oil pump”, page 98

3 Cylinder head
Note
Illustration shows the cylinder head for cylinder bank 2 (left-side) as an example.

❑ Renewing
page 117
© satelettronica
cylinder head
2 - Cylinder head
page 117
⇒ Fig. ““Checking cylin‐
page 117
❑ Machining limit
⇒ Fig. ““Cylinder head
machining limit”“ ,
page 117
3 - Bolt
❑ Note correct sequence
when loosening
⇒ page 119
sequence
⇒ Fig. ““Cylinder head -
tightening torque and
4 - Gasket
❑ Removing and installing ⇒ “3.3 Removing and installing cylinder head cover”, page 124

6 - Filler cap
7 - Seal
8 - Bolt
❑ Renew if seal is damaged
❑ Tightening torque and sequence:
♦ ⇒ Fig. ““Cylinder head cover (left-side) - tightening torque and sequence”“ , page 116
♦ ⇒ Fig. ““Cylinder head cover (right-side) - tightening torque and sequence”“ , page 116
9 - Bolt

© satelettronica
Note

2. -1 … 8- 40 Nm


• Maximum distortion: 0.05 mm

© satelettronica
⇒ “3.2.1 Removing and installing cylinder head, bank 1 (right-
side)”, page 117
⇒ “3.2.2 Removing cylinder head - bank 2 (left-side)”, page 119
⇒ “3.2.3 Installing cylinder head”, page 122
3.2.1 Removing and installing cylinder head,

bank 1 (right-side)
♦ Socket XZN M12 (at least 75 mm), commercially available
Procedure
Note

– Remove coolant pipe (front right)

⇒ “3.2.3 Removing and installing coolant pipe (front right)”,
page 211 .
page 216 .
WARNING


© satelettronica
– Remove camshafts (right-side)
– Unplug electrical connectors -arrows- at injectors.

– Unplug electrical connector -1- at temperature sender for en‐
gine temperature regulation - G694- .
– Remove bolts -1, 2- and take chain tensioner off cylinder head.
Note

© satelettronica
– Unscrew bolts, detach cylinder head and set it down on a soft
surface (foam plastic).
3.2.2 Removing cylinder head - bank 2 (left-

side)
♦ Socket XZN M12 (at least 75 mm), commercially available
Procedure
Note
– Remove fuel line for MPI injection system

⇒ “4.5 Removing and installing fuel line”, page 303 .
– Remove camshafts (left-side)

– Remove coolant pipe (front left)

⇒ “3.2.1 Removing and installing coolant pipe (front left)”, page
208 .
– Unplug electrical connectors -1, 3- at injectors.
G247- .
WARNING

© satelettronica
Note
Electrical connector -5- is unplugged in a later step.
• If connection -arrow- has been unfastened or unbolted, it must

be renewed.
– Remove bolts -1, 2- and take chain tensioner off cylinder head.
Note


© satelettronica
– Remove bolts, detach cylinder head and unplug electrical con‐
nector for injector for cylinder 4.
– Place cylinder head onto soft surface (foam plastic).

3.2.3 Installing cylinder head

Procedure
Caution

cylinder block.
surfaces.
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.
© satelettronica
terial.
gasket.
valve gear.
erated.
Note

♦ Renew self-locking nuts, seals, gaskets and O-rings after re‐
moval.
head bolts ⇒ Electronic parts catalogue .
♦ After renewing the cylinder head or cylinder head gasket,
change the coolant and engine oil.


be renewed.
• Camshafts on cylinder head (right-side) locked in “TDC” posi‐

tion -arrows- with camshaft clamp - T40133/1- (25 Nm)
• The camshaft clamp - T40133/1- is positioned correctly if the
© satelettronica
• Camshafts on cylinder head (left-side) locked in “TDC” posi‐
tion -arrows- with camshaft clamp - T40133/2- (25 Nm)
• The camshaft clamp - T40133/2- is positioned correctly if the

T40069- .

– Fit new seals for coolant pipe (front).

• Installation position: the word “oben” (top) or the Part No.
should be visible.
– Tighten cylinder head bolts
⇒ Fig. ““Cylinder head - tightening torque and sequence”“ ,
page 116 .
Note

after repair work.
© satelettronica
note the following:
– Install coolant pipe (front left)
208 .
– Install fuel line for MPI injection system
page 216 .
– Install coolant pipe (front right)
page 211 .
Tightening torques
♦ ⇒ Fig. ““Cylinder head - tightening torque and sequence”“ ,
page 116
page 158
♦ ⇒ Item 19 (page 206)

cover
Removing


– Move fuel hose clear at cylinder head cover.
– Unscrew bolts in the sequence -12 ... 1- and remove cylinder
head cover.
Note
The crankcase breather hose -arrow- cannot be disconnected

from the cylinder head cover without being damaged irreparably.
– Remove bolts in the sequence -12 ... 1-.
© satelettronica
– Move cylinder head cover to one side with crankcase breather
hose -arrow- connected.

If cylinder head cover is being removed:

page 301 .
– Remove bolt -1-, detach connection with crankcase breather
hose and move clear.
– Detach cylinder head cover.
Note
Disregard -item 2-.
Installing
Note
© satelettronica
♦ Renew cylinder head cover bolts if gasket is damaged.

page 301 .
Tightening torques


Procedure
© satelettronica

– Unplug electrical connectors -4, 5- for injectors at rear of cyl‐

inder head (left and right).
Note
– Unscrew spark plugs using spark plug socket - 3122B- .

– Check compression pressure with compression tester - V.A.G
1763- .
Note

pletely and at the same time operate the starter until the
pressure on the tester display no longer increases.
© satelettronica
When new 11.0 … 14.0
Wear limit 10.0
– Erase any entries in event memory resulting from testing:
♦ Drive train
♦ Functions
♦ Readiness code

4 Valve gear
⇒ “4.5 Removing and installing camshaft control valves”,
page 141
⇒ “4.6 Checking hydraulic compensation elements”, page 142
Note
© satelettronica
cracked.
♦ Illustration shows the cylinder head for cylinder bank 2 (left-side) as an example.
4. Valve gear 129

1 - Exhaust valve
❑ Must not be machined;
only grinding-in is per‐
missible
❑ Checking
⇒ “5.2 Checking
valves”, page 154
⇒ “5.3 Valve dimen‐
sions”, page 154
guides”, page 153
2 - Sealing plug
3 - Cylinder head
© satelettronica
guides”, page 153
seals”, page 144
5 - Valve spring
sition of valve spring”“ ,
page 132
7 - Valve cotters
8 - Hydraulic compensation element
❑ Clipped into roller rocker finger -item 8-
❑ Checking ⇒ “4.6 Checking hydraulic compensation elements”, page 142
9 - Securing clip
11 - Bolt
⇒ Fig. ““Retaining frame for camshafts of cylinder head, bank 2 (left-side) - tightening torque and se‐

13 - Bolt
❑ 5 Nm
15 - O-ring
16 - Bolt
❑ 5 Nm
❑ Cylinder bank 1 (right-side): exhaust camshaft control valve 1 - N318-
18 - O-ring
© satelettronica
20 - Inlet camshaft
❑ One or two installed (depending on version); for allocation refer to ⇒ Electronic parts catalogue
23 - Banjo bolt
❑ With valve
❑ 25 Nm
24 - Oil pipe
25 - Inlet valve
4. Valve gear 131


head.
Retaining frame for camshafts of cylinder head, bank 1 (right-

side) - tightening torque and sequence
Note
© satelettronica
the full surface
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further
Retaining frame for camshafts of cylinder head, bank 2 (left-side)

- tightening torque and sequence
Note

the full surface
2. -1 … 21- 8 Nm
3. -1 … 21- Turn 90° further


© satelettronica
Procedure
clean surface.
– Re-insert camshafts, install retaining frame
⇒ Fig. ““Retaining frame for camshafts of cylinder head, bank
1 (right-side) - tightening torque and sequence”“ , page 132 or
2 (left-side) - tightening torque and sequence”“ , page 132 and
tighten with old bolts to 8 Nm (do not turn further).

♦ Plastigauge
Procedure
Note
4. Valve gear 133

clean surface.
ing.
– Re-insert camshafts, fit retaining frame and secure with old
bolts without rotating camshafts
1 (right-side) - tightening torque and sequence”“ , page 132 or
2 (left-side) - tightening torque and sequence”“ , page 132 .
© satelettronica
Radial clearance:
• 24 mm bearing ∅: 0.024 ... 0.066 mm
• 36 mm bearing ∅: 0.032 ... 0.078 mm

engines - T10133 C-

♦ Safety goggles


Removing
– Remove timing chain from camshafts
98 .
– Remove high-pressure pump
page 322 .
– Remove bolts -arrows- and detach housing -1- for high-pres‐
sure pump.

– Unplug electrical connectors on cylinder head:
© satelettronica
1 - For camshaft control valve 1 - N205- / exhaust camshaft con‐
Note

– Remove vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vac‐
uum system; Removing and installing vacuum pump .
– Unplug electrical connectors on cylinder head:
3 - For camshaft control valve 2 - N208- / exhaust camshaft con‐
Note
Disregard -item 2-.
4. Valve gear 135


– Remove corresponding intake manifold (bottom section)
tion) with fuel rail”, page 297 .
– Remove bolts -arrows- and detach corresponding camshaft
control valves.
Note
For better access, loosen high-pressure pipe at fuel rail and

bracket (leave high-pressure pipe in installation position).
© satelettronica
joint and set it down with camshafts on a soft surface on work‐
bench.
– Remove camshaft clamp - T40133/1- -arrows-.

– Mark camshafts, remove and place on a clean surface.


joint and set it down with camshafts on a soft surface on work‐
bench.
– Remove camshaft clamp - T40133/2- -arrows-.
© satelettronica
Installing
Note
Renew seals and sealing plugs after removing.

T40069- .
stalled.
4. Valve gear 137

Caution

tion.
WARNING
Risk of eye injury.


© satelettronica
Note
One or two rectangular section seals are installed on the exhaust

camshaft -2 and/or 3- (depending on version); for allocation refer
to ⇒ Electronic parts catalogue .
– Turn retaining frame over with camshafts fitted, holding cam‐

shafts firmly in position.




© satelettronica
Note

2 mm).
4. Valve gear 139

Caution
Make sure excess sealant does not contaminate camshaft

bearings.

Note
© satelettronica
plying the sealant.

head.
– Tighten bolts securing retaining frame for camshafts.
Note
sealant to dry.
– Clean bore for outer sealing plug in cylinder head (left and
right); it must be free of oil and grease.
– Drive in sealing plug until flush.


pins -T10133/3- .
note the following:
– Install camshaft control valves
– Install intake manifold (bottom section)
sure pump
page 322 .
page 108 .
© satelettronica
Caution

valve gear.
erated.
Tightening torques

trol valves
Removing
page 43 .
4. Valve gear 141


– Move hose -1- for activated charcoal filter system clear at air
pipe.

– Unplug relevant electrical connector -1-.
– Unscrew bolt -2- and detach valve.
Installing
© satelettronica
Note


page 43 .
Tightening torques
tem”, page 275

ments
Note


♦ Feeler gauge
Procedure
© satelettronica
– Remove cylinder head cover
page 124 .
gine.
– Use adapter - T40058- and angled ring spanner to turn crank‐

shaft in direction of engine rotation -arrow-.
4. Valve gear 143


element
page 124 .

seals
© satelettronica
equipment required


5161/19B-
Procedure
– Unscrew spark plugs using spark plug socket - 3122B- .
© satelettronica
– Fit guide plate -VAS 5161/19C- from removal and installation

device for valve cotters - VAS 5161 A- on cylinder head.
– Screw adapter - T40012/1- with seal hand-tight into the cor‐
responding spark plug thread.
4. Valve gear 145


© satelettronica
If the valve stem seal puller - 3364- cannot be used on some of
the valve stem oil seals due to the confined space, proceed as
follows:

lustration.
-arrow-.

Caution
ling.

– Remove plastic sleeve.

© satelettronica

• The closely spaced spring coils -arrow- face the cylinder head.
4. Valve gear 147


cotters.
tion.
Assembling
Caution
© satelettronica
valve gear.
erated.


equipment required
© satelettronica
5161/19B-
Procedure
4. Valve gear 149


supply.
with valve heads.
© satelettronica


Caution
ling.
© satelettronica
– Remove plastic sleeve.


• The closely spaced spring coils -arrow- face the cylinder head.
4. Valve gear 151


cotters.
tion.
Assembling
© satelettronica



© satelettronica
Procedure
Note



new valves.
Note
5.2 Checking valves

faces.
© satelettronica
Note

is permitted.

∅a mm 33.85 ± 0.10 28.0 ± 0.10
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.00 ± 0.20 101.9 ± 0.20
α ∠° 45 45
WARNING
Care must be taken when disposing of old sodium-cooled ex‐

haust valves - risk of injury.
valves must not come into contact with water.
♦ Then throw a maximum of ten valves into a bucket of water
and step away immediately.
♦ A sudden chemical reaction will occur upon contact with
water in which the sodium filling burns.

17 – Lubrication
1 Sump/oil pump
page 158
er G266 ”, page 164
Note
© satelettronica
♦ Oil capacities, oil specifications and viscosity grades ⇒ Maintenance tables .


sender - G266-
temperature sender
G266 ”, page 164
2 - Seal
3 - Bolt
sequence
⇒ Fig. ““Sump (bottom
section) - tightening tor‐
que and sequence”“ ,
page 157
© satelettronica
5 - Bolt
❑ 9 Nm
7 - Bolt
sequence
⇒ Fig. ““Sump (top sec‐
tion) - tightening torque
page 158
❑ Removing and installing ⇒ “1.4 Removing and installing sump (top section)”, page 160
9 - Dowel sleeve
❑ 2x
11 - Bolt
❑ 3 Nm +90°
12 - Gasket
13 - Oil pump drive shaft
14 - O-ring
15 - Sleeve
❑ 2x

16 - Bearing bracket
17 - Bolt
❑ 9 Nm
18 - Chain sprocket for oil pump
19 - Bolt
❑ 3 Nm +90°
20 - O-ring
21 - Seal
22 - Oil pump
23 - Bolt
© satelettronica
❑ 20 Nm
24 - O-ring
25 - Bolt
❑ 9 Nm
26 - Intake connecting pipe
❑ For oil pump
27 - Seal
28 - Oil drain plug
❑ 30 Nm
29 - Nut
❑ 9 Nm
Note



– Tighten bolts -1 ... 6- in diagonal sequence and in stages to
20 Nm:
© satelettronica
1.2 Engine oil

nance tables .
Caution

dipstick.

section)
♦ Safety goggles
Removing


Caution

♦ There will still be some oil in the sump (bottom section).
– Loosen bolts for sump (bottom section) -2- in diagonal se‐

quence and remove bolts.
– Release sump (bottom section) from bonded joint e.g. with a
spatula, taking care not to bend sump.
Installing
Note

© satelettronica
Caution

tion.
WARNING
Risk of eye injury.

– Remove remaining sealant on bottom section -1- and top sec‐

tion of sump with a rotating plastic brush or similar.
Note

mm).

Caution

– Apply sealant bead -arrow- onto clean sealing surface of sump

(bottom section) as shown in illustration.
Note

– Fit sump (bottom section) -2-, tighten bolts

⇒ Fig. ““Sump (bottom section) - tightening torque and se‐
quence”“ , page 157 and plug in electrical connector -1-.
© satelettronica
note the following:
411 .
Tightening torques

tion)
♦ Safety goggles
Removing
• Engine secured to engine and gearbox support
28 .
page 86 .
– Remove oil pump

Note
Disregard -item 1-.
– Slacken bolts -1 ... 6- for sump (top section) in diagonal se‐

quence and remove.
© satelettronica
Installing
Note
Renew seal and O-ring after removal.

Caution

tion.

from sealing surface.
WARNING
Risk of eye injury.

– Remove remaining sealant from sump (top section) -1- and

cylinder block using rotating plastic brush or similar.
© satelettronica
Note

mm).
Caution


with sealant.
sealing surface.
Note


– Fit seal -1- into retaining frame.
Note
Disregard -item 2-.
tighten bolts
⇒ Fig. ““Sump (top section) - tightening torque and se‐
note the following:
– Install oil pump
© satelettronica
page 86 .
Tightening torques

Removing
– Remove sump (bottom section)
page 158 .
– Remove bolts -arrows- and detach baffle plate.

– Using pliers -2-, press drive shaft -1- back against spring pres‐
sure and detach oil pump -3-.
Note
Oil pump drive shaft remains in position.
Installing
Note
Renew O-rings.
– Install sump (bottom section)

page 158 .
411 .
© satelettronica
Tightening torques

Removing
Installing
Note
Renew seal -4- after removing.
411 .
Tightening torques

2 Engine oil cooler

⇒ “2.1 Exploded view - engine oil cooler”, page 165
2.1 Exploded view - engine oil cooler

❑ With oil cooler bypass
valve
stalling engine oil cool‐
er”, page 165
2 - Bracket
3 - Bolt
❑ 3 Nm +90°
© satelettronica
4 - Coolant hose
6 - Seal
(top)”, page 216
8 - Bolt
9 - Bolt
❑ 3 Nm +90°

er

Removing
– Drain coolant
– Release retainers -arrow-, detach wiring duct -1- towards rear
© satelettronica
and push it upwards.
– Move electrical wiring and hoses to side.

– Lift retaining clip -1-, release hose clip -2- and disconnect
coolant hoses.
– Unscrew bolts -3- and -arrows- and detach engine oil cooler
-4- to left side.
Installing
Note

♦ Renew gasket after removing.

Tightening torques

⇒ “3.3 Removing and installing hose for crankcase breather sys‐
tem”, page 169
⇒ “3.4 Removing and installing crankcase breather shut-off valve
N548 ”, page 170
1 - Gasket
2 - Oil separator with cover
crankcase breather
© satelettronica
page 168
3 - Bolt
❑ 9 Nm
4 - O-ring
❑ 2x on NAR versions
5 - Connection
⇒ Fig. ““Installing con‐
nection for crankcase
breather”“ , page 168
6 - O-ring
❑ 2x on NAR versions
7 - Bolt
❑ 9 Nm
8 - O-ring
⇒ “3.3 Removing and installing hose for crankcase breather system”, page 169
10 - Bolt
❑ 2.5 Nm
11 - O-ring
❑ To air pipe
❑ With crankcase breather shut-off valve - N548-


⇒ “3.4 Removing and installing crankcase breather shut-off valve N548 ”, page 170
13 - Hose clip
❑ Not fitted on all versions; for allocation, refer to ⇒ Electronic parts catalogue
14 - Bolt
❑ 2.5 Nm
15 - Bracket
Installing connection for crankcase breather

– Insert connection -1- for crankcase breather with new O-rings
in cover for oil separator.
• Installation position: lug -2- must engage in guide -arrow-.
© satelettronica
Removing
page 216 .
– Remove fuel pressure sender - G247-
⇒ “6.2 Removing and installing fuel pressure sender G247 ”,
page 318 .
– Unscrew connection -arrow- (left and right).

– Detach connection with crankcase breather hose.
Note
♦ The illustration shows the installation position with the super‐

charger installed.

– Remove bolts -2- and -arrows-.

– Detach bracket -3-.
– Push electrical wiring and vacuum hoses to one side and de‐
tach oil separator with cover.
Note
Disregard -item 1-.
Installing
Note
Renew gasket after removing.
• Renew connection -arrow-.
© satelettronica
– Install fuel pressure sender - G247-
⇒ “6.2 Removing and installing fuel pressure sender G247 ”,
page 318 .
page 216 .
Tightening torques
page 167
3.3 Removing and installing hose for crank‐

case breather system
Removing
Note

♦ Crankcase breather hose cannot be detached from cylinder
head cover (left-side) without being irreparably damaged. Al‐
ways renew hose after removal.

page 301 .

– Release fasteners -arrow- and detach wiring duct -1- towards

rear.
– Detach crankcase breather hose -2- from cylinder head cov‐

ers.
– Move crankcase breather hose clear.
breather hose.
Installing
© satelettronica
Note
Renew O-rings after removing.

page 301 .
Tightening torques
page 167

breather shut-off valve - N548-
Removing
Note
♦ Re-fit all cable ties and heat insulation sleeves in the same
locations when installing.
♦ The crankcase breather shut-off valve - N548- and the con‐
necting hose are combined as one component and cannot be
removed individually.
– Remove supercharger
⇒ “1.4 Removing and installing supercharger”, page 244 .

– If fitted, release clip -1-, pull crankcase breather hose -2- off
oil separator -magnified view- and unclip it from bracket
-arrow-.
– Remove crankcase breather shut-off valve - N548- together
with crankcase breather hose -2-.
Installing
Note
– Install supercharger
© satelettronica


⇒ “4.2 Exploded view - oil pressure switches/oil pressure control”,
page 173
page 173
”, page 176

❑ With oil drain valve
© satelettronica
with timing chain cover
(bottom)
let 411
3 - Seal
4 - Sealing cap
❑ 25 Nm

4.2 Exploded view - oil pressure switches/oil pressure control
1 - Seal
sure 2.5 ... 3.2 bar (high
pressure stage of oil
pump)
❑ Black insulation
agnostic tester
switch F22 ”, page 173
❑ 20 Nm
© satelettronica
sure 0.75 ... 1.05 bar
(low pressure stage of
oil pump)
❑ Light grey insulation
agnostic tester
switch for reduced oil
pressure F378 ”,
page 174
❑ 20 Nm
4 - Seal
5 - Bolt
❑ 9 Nm
7 - O-ring

switch - F22-

Removing
page 301 .
– Release fasteners -arrow- and detach wiring duct -1- towards
rear.
– Move electrical wiring and hoses clear and press to one side.
© satelettronica
Note

– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐
sure switch - F22- .
Installing
Note
♦ Renew seal after removing.

mediately to avoid loss of engine oil.

page 301 .
Tightening torques
♦ ⇒ “4.2 Exploded view - oil pressure switches/oil pressure con‐
trol”, page 173


© satelettronica
Removing
-2-.
Installing
Note
Renew seal after removing.
Tightening torques
trol”, page 173


Procedure
• Oil level OK
– Remove oil pressure switch - F22-
173 .
© satelettronica
sure switch.
– Screw oil pressure switch - F22- into oil pressure tester.
– Start engine.
Assembling
– Install oil pressure switch - F22-
173 .

Removing
noise insulation .

Note
N428- .
Installing
Note
Tightening torques
trol”, page 173
© satelettronica

19 – Cooling

Note
© satelettronica
♦ Green = Coolant circuit for gearbox

1 - Water radiator for charge air

cooling circuit
2 - Radiator
er - G62-
4 - Thermostat
5 - Coolant pump
side)
ing
7 - Bleeder screw
8 - Cylinder head
side)
G694-
© satelettronica
V50-
11 - Bleeder screw
13 - Restrictor
15 - ATF cooler
♦ ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; ATF circuit; Exploded view - ATF circuit
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; ATF circuit; Exploded view - ATF circuit
16 - Coolant valve for gearbox - N488-
17 - Cylinder head
18 - Bleeder screw
19 - Filler cap
❑ Vacuum-controlled by solenoid for coolant circuit - N492-

❑ Depending on vehicle equipment
Note

♦ Green = Coolant circuit for gearbox
© satelettronica
1 - Water radiator for charge air
cooling circuit
2 - Radiator
er - G62-
V55-
ry heater; Removing
5 - Thermostat
6 - Coolant pump
side)
ing
8 - Bleeder screw
9 - Cylinder head
side)
- G694-
valve - N279-

tary heater; Rep. gr. 82 ; Coolant circuit with auxiliary/supplementary heater; Removing and installing
heater coolant shut-off valve
12 - Bleeder screw
16 - ATF cooler
♦ ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; ATF circuit; Exploded view - ATF circuit
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; ATF circuit; Exploded view - ATF circuit
17 - Coolant valve for gearbox - N488-
18 - Cylinder head
19 - Bleeder screw
© satelettronica
20 - Filler cap
❑ Vacuum-controlled by solenoid for coolant circuit - N492-
❑ Depending on vehicle equipment


equipment required
© satelettronica

Procedure
WARNING


© satelettronica
nutes.
inate fault.
Note

engine is cold.

1.4 ... 1.6 bar.
scribed.


equipment required
© satelettronica
Draining
WARNING



noise insulation .

Note
Disregard -item 2-.
© satelettronica
– Release hose clips -2-, disconnect coolant hoses from coolant
pipes (front) and drain off coolant.
Note
Disregard -item 1-.

ant pipe (left-side) on gearbox and drain off coolant.
Filling
Caution


Note

© satelettronica
ical climates.
ses.

to -25 °C
to -36 °C
• Coolant ⇒ Electronic parts catalogue (ETKA)

Procedure
– Fit coolant hoses with hose clips -2- onto coolant pipes (front
left).
© satelettronica
– Connect coolant hose to coolant pipe (left-side) on gearbox
with hose clip -arrow-.

– Fill reservoir of -VAS 6096- with at least 15 litres of premixed

coolant (according to recommended ratio).
V.A.G 1274/8- .
Note

rection of flow).
– Connect ⇒ Vehicle diagnostic tester to vehicle.
© satelettronica
– Select following menu options on ⇒ Vehicle diagnostic tester:
♦ Guided Functions mode
♦ 01 - Simos fuel injection and ignition system
♦ Functions - engine
♦ 01 - Coolant circuit vent routine
– Follow instructions shown on vehicle diagnostic tester .


zone.
in the green zone.
sequent filling.
Note
© satelettronica
ess.
tained.

– Open valve -A-.
is then filled.

cedure.
page 43 .

Note
– Open bleeder screws -1- and -2- on charge air coolers one
after the other until coolant comes out.
chamber cover .

hose.
© satelettronica
– Close filler cap on coolant expansion tank (make sure it en‐
gages).
– Start engine.
– Set temperature to “HI” for all zones and select lowest blower
speed (= 0).
page 43 .

gine is cold.
engine is warm.
Tightening torques
♦ Plenum chamber cover ⇒ General body repairs, exterior; Rep.
gr. 50 ; Bulkhead; Exploded view - plenum chamber partition
panel


page 195
page 195
”, page 201
© satelettronica
Coolant pump/thermostat
1 - Bolt
with -item 3-
2 - Washer
with -item 3-
3 - Idler roller
❑ For poly V-belt
-items 1 and 2-
4 - Connection
5 - Gasket
6 - Seal
7 - Thermostat
page 200
❑ Starts to open at approx.
87℃
❑ Fully open at approx.
102°C
❑ Opening travel at least 8
mm

Note
When removing and installing the

thermostat, make sure that the nee‐
dle is fitted correctly (conical end
fitted in wax expansion element of
thermostat). If necessary, push ther‐
mostat needle as far as possible into
wax expansion element.
8 - Seal
9 - Bolt
❑ 9 Nm
10 - Solenoid for coolant circuit - N492-
❑ Fitting location ⇒ Item 5 (page 288)
11 - Coolant pump
❑ With gasket
© satelettronica
12 - Bolt
❑ 9 Nm
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ 9 Nm
Coolant valve

1 - Nut
2 - Washer
3 - Grommet
4 - Spacer sleeve
5 - Coolant hose
N509-
page 203
7 - Bolt
❑ 9 Nm
8 - Heat shield
9 - Coolant hose
10 - Bolt
❑ 9 Nm
© satelettronica
11 - Bracket
valve - N509-
12 - Subframe

1 - Retaining clip
❑ For charge air cooling
pump - V188-
2 - Charge air cooling pump -
V188-
installing charge air
cooling pump V188 ”,
page 197
3 - Coolant hoses
4 - Bolt
❑ 9 Nm
5 - Bracket
pump - V50- and coolant
valve for gearbox -
© satelettronica
N488-
6 - Bolt
❑ 1.5 Nm
V50-
installing coolant circu‐
lation pump V50 ”, page
195
8 - Coolant hose
9 - Coolant hose
10 - Connection
11 - Bolt
❑ 9 Nm
12 - Gearbox
13 - Bolt
❑ 20 Nm
14 - Longitudinal member (left-side)
15 - Bracket
❑ For charge air cooling pump - V188-
16 - Bolt
❑ 9 Nm
17 - Bolt
❑ 20 Nm

1 - O-ring
2 - Retaining clip
er - G62-
ature sender G62 ”,
page 201
4 - O-ring
G694-
© satelettronica
stalling temperature
sender for engine tem‐
perature regulation
G694 ”, page 202
❑ 3 Nm

pump
page 195
⇒ “2.4.2 Removing and installing charge air cooling pump V188
”, page 197

tion pump - V50-

Removing
page 43 .
– Drain coolant
© satelettronica
Note

Note

– Remove bolts -arrows- and detach coolant circulation pump -
V50- .
Installing
Note
Note
© satelettronica

Tightening torques

ing pump - V188-

Removing
– Remove nut -2- and detach retaining clip.
© satelettronica
Note
– Use hose clamps up to 25 mm - 3094- to clamp off coolant

hoses at charge air cooling pump - V188- .
– Detach charge air cooling pump, then release hose clips -1-
and disconnect coolant hoses.
Installing
Note

Tightening torques


Removing
– Drain coolant
page 47 .
– Remove poly V-belt from coolant pump pulley
© satelettronica
page 48 .
ments .
rier.
Note
Disregard -item 2-.


Note
– Remove bolts -arrows- and detach coolant pump.

Installing
ments .
page 48 .
Note
© satelettronica

Tightening torques

Removing
– Remove coolant pipe (front right)
page 211 .

Note

Installing
Note
When removing and installing the thermostat, make sure that the
needle is fitted correctly (conical end fitted in wax expansion el‐
ement of thermostat). If necessary, push thermostat needle as far
as possible into wax expansion element.
Note
© satelettronica
– Install coolant pipe (front right)

page 211 .
Tightening torques

ature sender - G62-
Removing
• Engine cold.
page 43 .

Note
– Pull off retaining clip -1- and detach coolant temperature send‐
er - G62- .
Installing
Note

♦ To avoid loss of coolant, insert new coolant temperature send‐
er - G62- immediately in coolant pipe (front).
© satelettronica
page 43 .

tion - G694-
♦ Twelve-point socket with jointed extension (15 mm, commer‐
cially available)
Note
To avoid having to remove the fuel rail, use a twelve-point socket

(15 mm) -item 1- with jointed extension -2- to unscrew the sender.

Removing
Installing
Tightening torques
page 195

© satelettronica
Removing
noise insulation .


Installing
Note

Tightening torques
© satelettronica

3 Coolant pipes
Note
1 - Bolt
❑ 9 Nm
2 - Coolant pipes (front left)
© satelettronica
(front left)”, page 209
3 - Bolt
❑ 9 Nm
4 - Bracket
5 - Bolt
❑ 22 Nm
6 - Seal
7 - Bolt
❑ 9 Nm
8 - Coolant pipe (front right)
(front right)”, page 211
9 - Seal
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 5 Nm
13 - Bolt
❑ 5 Nm
14 - Seals
15 - Coolant pipes on supercharger
❑ Removing and installing ⇒ “3.2.6 Removing and installing coolant pipes on supercharger”, page 217

16 - Seals
17 - Seal
19 - Bolt
❑ 9 Nm
20 - Bolt
❑ 9 Nm
❑ Removing and installing ⇒ “3.2.4 Removing and installing coolant pipe (left-side)”, page 213
22 - Bolt
❑ 9 Nm
23 - Seal
© satelettronica
24 - Coolant pipe (front left)
❑ Removing and installing ⇒ “3.2.1 Removing and installing coolant pipe (front left)”, page 208
25 - Bolt
❑ 9 Nm
Coolant pipes on gearbox

1 - Gearbox
2 - Bolt
❑ 9 Nm
gearbox
page 220
4 - Bolt
❑ 9 Nm
5 - Bolt
❑ 9 Nm
gearbox
© satelettronica
(left-side) on gearbox”,
page 219
7 - Nut
❑ 9 Nm


⇒ “3.2.1 Removing and installing coolant pipe (front left)”,
page 208
page 209
⇒ “3.2.3 Removing and installing coolant pipe (front right)”, page
211
page 213
⇒ “3.2.6 Removing and installing coolant pipes on supercharger”,
page 217
box”, page 219
© satelettronica
(front left)
Removing
WARNING

– Drain coolant
– Remove coolant pipes (front left)
page 209 .

– Lift retaining clip -2- and detach connection (top left) from ra‐
diator.
Note
Disregard -item 1-.

– Lift retaining clip -3- and remove coolant hose.
– Remove bolts -arrows-, release hose clips -1, 4- and detach
coolant pipe (front left).
Installing
© satelettronica
Note
♦ Renew gasket after removing.

– Install coolant pipes (front left)

page 209 .
⇒ page 223 .
Note

page 43 .
Tightening torques

(front left)

© satelettronica
Removing
WARNING


page 43 .
noise insulation .

WARNING

hot.
Note
For illustration purposes, the installation position is shown in the

following illustrations with the engine removed.
© satelettronica
from coolant pipes (front left).
– Detach coolant pipes (front left) from below.
Installing
Note

page 43 .
Tightening torques

(front right)

Removing
– Remove coolant pipe (front left)
208 .
© satelettronica
ments .
rier.
Note
Disregard -item 1-.


– Release fasteners -arrows- and detach intake manifold flap
potentiometer - G336- .

– Unscrew bolts -arrows- and remove coolant pipe (front right).
Installing
© satelettronica
Note

– Connect coolant line and coolant hose with plug-in connector

⇒ page 223 .
ments .
– Install coolant pipe (front left)
208 .
Note

Tightening torques

(left-side)

Removing
– Drain coolant
body brace .
© satelettronica



trical wiring.
holder -3-.

-arrow B-.
© satelettronica
Note
Disregard -item 2-.



– Release hose clips -arrows- and detach coolant hoses.
– Remove bolt -1- and nut -2- and detach coolant pipe (left-side)
towards rear.
Installing
Note

Tightening torques
♦ Filler neck for washer fluid reservoir ⇒ Electrical system; Rep.
© satelettronica
gr. 92 ; Windscreen washer system; Exploded view - wind‐
screen washer system
♦ Installing body brace ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Suspension strut, upper links; Exploded view - sus‐
pension strut, upper links

(top)
Removing
Note
– Drain coolant
– Remove high-pressure pipe
page 326 .

Note
– Lift retaining clip -2- and disconnect coolant hose from coolant
pipe.
block -arrow-.
Installing
Note

© satelettronica
page 326 .
Note

Tightening torques

on supercharger

© satelettronica
Removing
page 43 .
WARNING

hot.

noise insulation .

Note
Disregard -item 2-.


– Remove bolts -1 and 2- and detach coolant pipes from super‐
charger.
Installing
Note

Note
© satelettronica
Tightening torques

(left-side) on gearbox

Removing
page 43 .
– Drain coolant
– Remove bolt -2- and nut -3-.
– Detach coolant pipe (left-side) at gearbox.
Note
Disregard -item 4-.
Installing
Note
© satelettronica

Tightening torques

Removing
page 43 .
– Drain coolant


– Detach coolant pipe (right-side) from gearbox.
Installing
Note

Tightening torques
© satelettronica

4 Radiators/radiator fans
⇒ “4.1 Exploded view - radiators/radiator fans”, page 222
⇒ “4.4 Removing and installing water radiator for charge air cool‐
ing circuit”, page 230
4.1 Exploded view - radiators/radiator fans

Radiator
1 - Coolant hose
tach
© satelettronica
❑ Connecting
⇒ page 223
2 - O-ring
3 - Air duct
4 - Coolant hose
tach
❑ Connecting
⇒ page 223
5 - O-ring
6 - Radiator
gether with radiator cowl
stalling radiator”,
page 225
with fresh coolant
7 - O-ring
8 - Coolant hose
tank
tach
❑ Connecting
⇒ page 223
9 - Coolant hose
❑ To coolant expansion tank
❑ Press release ring to detach
❑ Connecting ⇒ page 223

10 - O-ring
11 - Air duct
12 - Coolant hoses
13 - Bolt
❑ 4.5 Nm
14 - Water radiator for charge air cooling circuit
⇒ “4.4 Removing and installing water radiator for charge air cooling circuit”, page 230
15 - Retaining pin
❑ For radiator
17 - Bolt
❑ 5.5 Nm
© satelettronica
19 - Bolt
❑ 5 Nm
20 - Washer
21 - Bolt
❑ 4.5 Nm

– If damaged, renew retaining clip -4-.
– If damaged, renew O-ring. To do so, remove O-ring -2- from
plug-in connector -3- using a suitable tool (do not use a sharp
tool). Take care not to damage the plug-in connector or the
surface on which the O-ring is seated.
– Lightly lubricate new O-ring with coolant and fit O-ring in plug-
in connector.
– Press plug-in connector onto connection -1- until it engages
audibly.
– Press plug-in connector in again and then pull to check that it
is correctly engaged.


unit 2 - J671-
page 236
unit - J293-
page 236
3 - Radiator cowl
stalling radiator cowl”,
page 234
4 - Bolt
© satelettronica
❑ 3.5 Nm
5 - Fan wheel
6 - Bolt
❑ 5 Nm
7 - Fan wheel
8 - Bolt
❑ 5 Nm
9 - Bolt
❑ 3.5 Nm

1 - Front air duct

❑ Clipped onto rear air
duct
❑ Move to side to unclip
and remove
2 - Clip
stalling auxiliary radia‐
tor”, page 236
4 - Clip
5 - Coolant hoses
6 - Bolt
© satelettronica
❑ 20 Nm
7 - Nut
❑ 8 Nm
8 - Bracket
9 - Rubber bush
❑ For radiator
10 - Rubber bush
❑ For radiator
11 - Washer
12 - Bolt
❑ 3.5 Nm
Note
Radiator can only be removed and installed together with radiator

cowl.

© satelettronica
Removing
WARNING


noise insulation .
– Remove impact bar ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing impact bar .
tor.

– Lift retaining clip -arrow-, detach connection from radiator and

drain off coolant.

© satelettronica
rier.
Note
Disregard -item 2-.

– Lift retaining clips -1, 2- and detach connection (top left) from
radiator.
– Unclip air ducts -1, 2- from radiator.
© satelettronica
Note

illustration.
Note
Disregard -arrows-.

– Push catch down -arrow A- and move water radiator for charge
air cooling circuit slightly in direction of -arrow B-.
– Detach water radiator for charge air cooling circuit from radi‐
ator and swivel it to the left with coolant hoses attached,
carefully moving item(s) clear at the air duct (left-side), if nec‐
essary.
Note
Disregard -item 1-.
– Unplug electrical connector -2- on refrigerant pressure and

Caution

hoses.
© satelettronica
– Disengage retaining clip in direction of -arrow B- on both sides.
– First pull condenser -1- out of radiator on right side in direction
of -arrow A-.
– Then carefully guide condenser out on the left, paying atten‐
tion to the refrigerant lines.
– Swivel condenser to left side.



Installing
Note
© satelettronica
If there are slight impressions on the fins, refer to

⇒ page 223 .
Note

Tightening torques
4.4 Removing and installing water radiator

for charge air cooling circuit

© satelettronica
Removing
ments .
– Remove closure plate for bumper cover (front) ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing
and installing attachments .
– Remove air intake grille (left and right) ⇒ General body re‐

rier.
Note
Disregard -item 2-.
© satelettronica
– Unclip air ducts -1, 2- from radiator.
Note

illustration.


– Push catch down -arrow A- and move water radiator (front) for
charge air cooling circuit slightly in direction of -arrow B-.
– Detach water radiator (front) for charge air cooling circuit from
radiator and remove it downwards, carefully moving item(s)
clear at air duct (left-side), if necessary.
Note
© satelettronica
Disregard -item 1-.
Installing
Note
♦ If there are slight impressions on the fins, refer to

– Install air intake grille, closure plate for bumper cover and lock
carrier cover ⇒ General body repairs, exterior; Rep. gr. 63 ;
Note

Tightening torques
♦ Refrigerant line ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; Exploded view - condenser


Removing
WARNING


noise insulation .
– Remove water radiator for charge air cooling circuit
⇒ “4.4 Removing and installing water radiator for charge air
cooling circuit”, page 230 .
© satelettronica
– Lift retaining clip -2- and detach connection from radiator.
Note
Disregard -item 1-.


© satelettronica
– Press bottom of radiator slightly towards front.

– Press and release locking tabs (left and right) for radiator cowl
-arrow- simultaneously.
– Remove radiator cowl downwards.
Installing
Tightening torques

V7-
© satelettronica
Removing
Note
– Remove radiator cowl

Installing
– Note installation position of fan wheel.
– Install radiator cowl
Tightening torques

tor

© satelettronica
Removing
noise insulation .
bumper cover .

– Unclip air duct -1- in direction of -arrow- and remove.

– Lift radiator -1- off bracket.
Installing
© satelettronica
Note
♦ The coolant in the entire system must be changed if the radi‐
ator is renewed.

cover .
Tightening torques
♦ ⇒ “4.2 Exploded view - auxiliary radiator”, page 225

1 Supercharger
⇒ “1.1 Exploded view - supercharger”, page 239
⇒ “1.2 Exploded view - magnetic clutch”, page 242
⇒ “1.3 Exploded view - rotor assembly”, page 243
⇒ “1.4 Removing and installing supercharger”, page 244
⇒ “1.5 Checking supercharger for leaks”, page 250
⇒ “1.6 Removing and installing magnetic clutch”, page 252
⇒ “1.7 Removing and installing pulley for supercharger”,
page 259
⇒ “1.8 Removing and installing drive unit”, page 260
⇒ “1.9 Removing and installing rotor assembly”, page 263
⇒ “1.10 Renewing drive shaft oil seal”, page 267
© satelettronica
⇒ “1.11 Securing supercharger to engine and gearbox support”,
page 269
⇒ “1.12 Removing and installing sender 1 for turbocharger speed
G688 ”, page 272
1.1 Exploded view - supercharger
1. Supercharger 239
1 - Supercharger
❑ With charge air coolers
supercharger
stalling supercharger”,
page 244
❑ Exploded view - charge
air coolers
charge air system”,
page 274
6095- when performing
assembly work
⇒ “1.11.1 Securing su‐
percharger to engine
and gearbox support for
assembly work”,
page 269
© satelettronica
6095- when checking
for leaks
⇒ “1.11.2 Securing su‐
percharger to engine
and gearbox support for
leak test”, page 270
2 - Ball stud
❑ 5 Nm
3 - Insulating plate
4 - Bolt
❑ 5 Nm
5 - O-rings
6 - Bolt
❑ Tightening torque ⇒ Fig. ““ Throttle valve module -J338- - tightening torque”“ , page 297
9 - O-rings
10 - Bolt
⇒ Fig. ““ Regulating flap control unit -J808- - tightening torque and sequence”“ , page 297
13 - Bolt
❑ 9 Nm
14 - Bracket
❑ For change-over valves

15 - Connection
16 - Bolt
⇒ Fig. ““ Regulating flap control unit -J808- - tightening torque and sequence”“ , page 297
17 - O-ring
18 - Bolt
❑ 10 Nm
⇒ “6.1 Removing and installing intake air temperature sender G42 / intake manifold pressure sender G71
”, page 318
20 - O-ring
21 - Bleeder screw
❑ For charge air cooler
❑ 1.5 … 3.0 Nm
© satelettronica
22 - Seal
23 - Nut
❑ 20 Nm
24 - Charge pressure sender
❑ Cylinder bank 1 (right-side): charge pressure sender - G31-
❑ Cylinder bank 2 (left-side): charge pressure sender 2 - G447-
⇒ “2.4 Removing and installing charge pressure sender G31 / G447 ”, page 280
25 - Bolt
❑ 10 Nm
26 - O-ring
27 - Stud
❑ 17 Nm
28 - Connection
❑ Installation position ⇒ Fig. ““Installing connection for crankcase breather”“ , page 168
29 - Seals
30 - O-rings
32 - Bolt
❑ 27 Nm
33 - O-ring
1. Supercharger 241
34 - Sender 1 for turbocharger speed - G688-

⇒ “1.12 Removing and installing sender 1 for turbocharger speed G688 ”, page 272
❑ Do not use opening to check oil level
35 - Bolt
❑ 10 Nm
1.2 Exploded view - magnetic clutch
1 - Pulley
stalling pulley for super‐
2 - Bolt
❑ 20 Nm +90°
© satelettronica
3 - Magnetic clutch
stalling magnetic
clutch”, page 252
4 - Bolt
❑ 20 Nm
5 - Carrier
❑ Only renew together
with -item 3-
❑ Do not loosen bolts on
armature
❑ Renew armature if nuts
are loose
stalling magnetic
clutch”, page 252
❑ Clean friction lining and
friction surface with
brake cleaner before in‐
stalling
clamping bolt
⇒ Fig. ““Tightening tor‐
que for clamping bolt”“ , page 243
6 - Bolt
❑ 3.6 Nm
7 - Woodruff key
8 - Supercharger
9 - O-ring
10 - Trim

Tightening torque for clamping bolt

– Tighten clamping bolt -arrow- to 20 Nm.
1.3 Exploded view - rotor assembly
1 - Bolt
❑ 27 Nm
❑ Remove old sealant/
locking fluid from
threads (using a thread
© satelettronica
tap or similar)
❑ Before installing, lubri‐
cate a few threads of the
cleaned bolts with seal‐
ant ⇒ Electronic parts
catalogue
2 - Drive unit
❑ Always renew oil seal
-item 3- after removing
stalling drive unit”,
page 260
3 - Oil seal
❑ For drive shaft
❑ Renewing
⇒ “1.10 Renewing drive
shaft oil seal”,
page 267
4 - Dowel sleeve
5 - Rotor assembly
stalling rotor assembly”,
page 263
❑ After every removal and
installation
⇒ “1.5 Checking super‐
charger for leaks”,
page 250
❑ Remove old sealant/locking fluid from threads (using a thread tap or similar)
6 - Needle bearing
❑ For rotor assembly
❑ Renew together with rotor assembly ⇒ “1.9 Removing and installing rotor assembly”, page 263
1. Supercharger 243
8 - Needle bearing
❑ For rotor assembly
❑ Renew together with rotor assembly ⇒ “1.9 Removing and installing rotor assembly”, page 263
9 - Dowel sleeve
1.4 Removing and installing supercharger

© satelettronica

© satelettronica
Removing
Note
♦ Observe rules for cleanliness

⇒ “3.1 Rules for cleanliness”, page 5 .
♦ 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.

page 47 .
1. Supercharger 245

– Clamp off coolant hoses -2- with hose clamps, up to 25 mm -
3094- .

– Remove bolt -2- and press coolant pipes to the side.
© satelettronica
Note
Disregard -item 3-.
pipe.


release tabs).
Note
Disregard -item 1-.
– Unplug electrical connector -arrow- at throttle valve module -

J338- .
© satelettronica
– Unplug electrical connector -arrow- at regulating flap control
unit - J808- .
Note
Mark installation position of vacuum hoses for re-installation.
– Disconnect vacuum hoses -4- and vacuum line -3-.

– Disconnect vacuum hose -2-, move it clear and place it to left
side.
1. Supercharger 247
– Release fasteners -arrow- and press wiring duct -1- towards

rear.

– Detach valve -3- for crankcase breather system from bracket.
– Unplug electrical connector -2- at intake air temperature send‐
er - G42- / intake manifold pressure sender - G71- .
© satelettronica
– Remove nuts -arrows- and lift off supercharger with charge air
coolers.
– Seal openings on supercharger and all relevant ducts and ho‐
ses of the charge air system using plugs from engine bung set
- VAS 6122- or clean cloths.
– Detach noise insulation panels.
Installing
Note
♦ Renew seals and O-rings after removal.

– Fit noise insulation panels.

– Ensure that crankcase breather connection -1- is positioned

correctly when fitting supercharger
⇒ Fig. ““Installing connection for crankcase breather”“ ,
page 168 .
– Install coolant pipes (front left)
page 209 .

page 47 .
– Check coolant level and top up if necessary.
Note
– Open filler cap on coolant expansion tank.
© satelettronica
Note
– Open bleeder screws -1- and -2- on charge air coolers one
after the other until coolant comes out.
• If necessary, correct the pressure during the bleeding proce‐
dure using the hand pump on the cooling system tester.
1. Supercharger 249
– Check coolant level and top up if necessary.

gine is cold.
engine is warm.
Tightening torques
tem”, page 275
1.5 Checking supercharger for leaks

1687/4- , -V.A.G 1687/10- , -V.A.G 1687/13-1- and -V.A.G
1687/13-2-
© satelettronica
Procedure
6095- for leak test
⇒ “1.11.1 Securing supercharger to engine and gearbox sup‐
port for assembly work”, page 269 .
• Regulating flap control unit - J808- installed
⇒ “4.4 Removing and installing regulating flap control unit J808
”, page 303 .
– Secure adapter -V.A.G 1687/13-1- to bottom of supercharger
housing.
Note
For illustration purposes the supercharger is shown without the

gearbox support.

– Secure adapter -V.A.G 1687/4- to top of supercharger hous‐

ing.
– Secure adapter -V.A.G 1687/13-2- to supercharger housing

with adapter - V.A.G 1687/10- .
© satelettronica
valves -3- and -4-.
valve.
– Connect charge air system tester - V.A.G 1687- as shown in

illustration, and connect to compressed air line using a com‐
mercially available connection piece -1-.
1. Supercharger 251
– If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution


– Close valve -3-.
• Pressure must not drop by more than 0.1 bar for 30 seconds.
felt with the hand; apply commercially available leak detecting
© satelettronica
Note

1.6 Removing and installing magnetic clutch

♦ Puller -T40301-
♦ Centring pin -T40302-

♦ External power supply unit for clutch for supercharger - VAS

6909-
Removing
• Supercharger secured to engine and gearbox support for as‐
sembly work
percharger.
© satelettronica
– Lift magnetic clutch -1- slightly and turn it until one of the three
bolts for trim is accessible.
– Remove first bolt -arrow-.
– Remove remaining bolts; to do so, turn magnetic clutch 1/3 of
a rotation each time.
– Detach magnetic clutch -1- -arrow-.
1. Supercharger 253
– Loosen clamping bolt -arrow- for armature by two turns (turn

armature to corresponding position).
– Apply puller -T40301- to armature.
© satelettronica
• Claws -arrows- of puller must engage on armature as shown
in illustration.
– Detach armature -2- and remove.

– Detach trim -1-.

– Remove O-ring -arrow-.

Checking for wear on inner and outer friction linings
Note
Before re-installing a used magnetic clutch, the degree of wear

on the inner and outer friction linings must be checked. This step
is not necessary when fitting a new magnetic clutch.
– Position caliper gauge -1- on highest point of inner friction lin‐

ing -2- (as shown in illustration) and measure distance -X- to
friction surface -3-.
• Specification: at least 0.2 mm.
– Perform measurement in at least three different positions
around circumference.
– If specification is not met, renew magnetic clutch.
© satelettronica
– Fit armature -2- onto magnetic clutch -1- and tighten centring
pin -T40302- hand-tight.
– Use feeler gauge -3- to check distance between outer friction
lining and outer friction surface.
• Specification: minimum 0.2 mm.
– If specification is not met, renew magnetic clutch.
1. Supercharger 255
• Armature -2- must still be on magnetic clutch -1- and centring

pin -T40302- must be tightened hand-tight.
– Connect external power supply unit for clutch for supercharger
- VAS 6909- to a 12 Volt battery or to jump-start terminal of
another vehicle.
– Connect electrical connector of adapter cable -VAS 6909- to
magnetic clutch and switch on power supply to magnetic
clutch.
Caution
Risk of irreparable damage to magnetic clutch

♦ The magnetic clutch must not be connected to the power
supply for longer than 15 minutes.
♦ The magnetic clutch heats up when current is applied.
– With current applied, use feeler gauge -3- to check distance

between clamping hub (shown in -blue-) and outer friction sur‐
face at point shown in illustration.
© satelettronica
– Perform this measurement in all three positions of clamping
hub.
• Specification: maximum 1.3 mm.
– If specification is exceeded, renew magnetic clutch.
– Switch off external power supply unit for clutch for supercharg‐
er - VAS 6909- .
Installing
Note
– Insert O-ring -arrow- into groove on supercharger housing.

– Fit armature -2- onto magnetic clutch -1-.

– Fit trim -3- onto magnetic clutch and secure with three bolts
-4-.
– Fit centring pin -T40302- into armature and magnetic clutch.
© satelettronica
• Armature will be centred relative to magnetic clutch.
– Connect external power supply unit for clutch for supercharger
- VAS 6909- to a 12 Volt battery or to jump-start terminal of
another vehicle.
– Connect electrical connector of adapter cable -VAS 6909- to
magnetic clutch and switch on power supply to magnetic
clutch.
• Armature is fixed to magnetic clutch when power supply is
switched on.
Note
♦ It is important to ensure that the current to the magnetic clutch

generated by the external power supply unit for clutch for su‐
percharger - VAS 6909- is not interrupted during installation.
♦ The current to the magnetic clutch generated by the external
power supply unit for clutch for supercharger - VAS 6909- may
be disconnected only after the clamping bolt of the clamping
hub is tightened on the shaft.
Caution
Risk of irreparable damage to magnetic clutch

♦ The magnetic clutch must not be connected to the power
supply for longer than 15 minutes.
♦ The magnetic clutch heats up when current is applied.
– Remove centring pin -T40302- with power supply switched on.
1. Supercharger 257
– Check that Woodruff key -1- is seated correctly in drive shaft

-2--
• Drive shaft must be free of oil and grease
The following markings assist in aligning the armature of the mag‐

netic clutch with the shaft of the supercharger:
• Position armature of magnetic clutch so that groove -4- for
Woodruff key is opposite arrow marking -3- on trim.
• Position shaft of supercharger so that Woodruff key -2- faces
“KEY” marking -1-.
© satelettronica
– Fit armature -1- of magnetic clutch onto shaft -2- of super‐
charger -arrow-.
– Fit magnetic clutch onto supercharger and tighten bolts

-arrows- (keep power supply switched on).

– Press pulley downwards by hand towards supercharger

-arrow A- and at the same time tighten clamping bolt
-arrow B- (keep power supply switched on).
– Switch off power supply and disconnect external power supply
unit for clutch for supercharger - VAS 6909- from magnetic
clutch and from power source.
– Install coolant pipes on supercharger
⇒ “3.2.6 Removing and installing coolant pipes on supercharg‐
er”, page 217 .
– Perform adaption for magnetic clutch after removing and in‐
stalling/renewing:
♦ 01 - Engine, self-diagnosis compatible systems
♦ Functions
♦ 01 - Compressor clutch adaption
© satelettronica
Tightening torques
♦ ⇒ “1.2 Exploded view - magnetic clutch”, page 242
1.7 Removing and installing pulley for su‐

percharger
♦ Counterhold tool - T10172 A- with adapters -T10172/5-
1. Supercharger 259
Removing
page 43 .
page 47 .
– Loosen two bolts for pulley by one turn; when doing so, coun‐
terhold the other two bolts with counterhold tool - T10172 A-
and adapters -T10172/5- .
– Apply counterhold tool to loosened bolts and remove both oth‐
er bolts.
– Remove remaining bolts and remove pulley.
Installing
page 47 .
© satelettronica
page 43 .
Tightening torques
♦ ⇒ “1.2 Exploded view - magnetic clutch”, page 242
1.8 Removing and installing drive unit


♦ Oil for supercharger drive ⇒ Electronic parts catalogue
♦ Spreader tool (commercially available)
Removing
sembly work
– Remove magnetic clutch
⇒ “1.6 Removing and installing magnetic clutch”, page 252 .
port.
• Drive unit faces upwards.

– Detach Woodruff key -1- from drive shaft -2-.
© satelettronica
Caution
♦ To make sure bearing cover -1- for rotor assembly does

not come loose and remains properly sealed, always use
spreader tool -arrows- to press off drive unit -2- as shown
in illustration (do not use a hammer).
– Using a spreader tool, carefully press off drive unit from bear‐
ing cover and detach.
1. Supercharger 261
– With the aid of used oil collection and extraction unit - VAS
6622A- , extract all oil for supercharger drive from bearing
cover (including oil chambers -arrows- between ribs).
Installing
Note
♦ Renew seal for drive unit after removal.

♦ Fit self-locking bolts or bolts with sealant ⇒ Electronic parts
catalogue .

– Before assembly, always remove residues from threaded
holes using a thread tap.
– Fill bearing cover with oil for supercharger drive.
Note
The container is filled with the required amount of oil. It is not
© satelettronica
possible to check the oil level at a later stage.
– Apply a thin layer of sealant to sealing surface -arrow- for drive

unit on rotor assembly and fit assembly sleeve - T40318- onto
drive shaft, as shown in illustration.
– Fit drive unit with new seal onto rotor assembly (note position
of dowel sleeves -1, 2-).

– Fit Woodruff key -1- into drive shaft -2-.

– Install magnetic clutch
note the following:
– Check supercharger for leaks
⇒ “1.5 Checking supercharger for leaks”, page 250 .
er”, page 217 .
Tightening torques
♦ ⇒ “1.3 Exploded view - rotor assembly”, page 243
1.9 Removing and installing rotor assembly

♦ Internal puller - VAS 501 001- (not illustrated)
♦ Assembly tool -T40303-
© satelettronica
Removing
sembly work
– Remove magnetic clutch
– Remove drive unit
⇒ “1.8 Removing and installing drive unit”, page 260 .
port.
• Spur gears of rotor assembly face upwards.
1. Supercharger 263
– Carefully detach rotor assembly upwards -arrow-, ensuring

that rotors do not damage inner surfaces of supercharger
housing.
– Set rotor module down carefully and ensure that it is kept free
of dust.
– Block off air ducts with clean cloths to prevent dirt or small
objects from dropping into supercharger housing.
Caution
Risk of damage to surfaces of supercharger housing.

♦ If necessary, use cloths to protect the surfaces of the su‐
percharger housing during the following steps.
– Using a screwdriver, bend seals -arrows- of both rotor needle

bearings inwards.
© satelettronica
– Remove seals -arrows- of both rotor needle bearings with
long-nose pliers.
– Break open needle bearing cages -arrows- of both bearings

with a screwdriver.

– Use long-nose pliers to remove needle bearing cages

-arrows- of both bearings.
– Remove loose roller bearings completely using a magnet.
– Insert threaded bush -VAS 501 001/4- into sleeve of needle

bearing; ensure that collar -1- faces upwards.
– Place thrust washer -VAS 501 001/5- on threaded bush -VAS
501 001/4- with writing on tool facing upwards.
© satelettronica
– Screw spindle -VAS 501 001/1- hand-tight into threaded bush
-VAS 501 001/4- -item 1- as far as it will go.
– Attach support sleeve -VAS 501 001/3- ; end with flat face
must point downwards.
1. Supercharger 265
– Screw forcing nut -VAS 501 001/2- onto spindle.

– Position socket -VAS 501 001/6- on forcing nut.
– Pull out sleeve of needle bearing by turning socket -VAS 501

001/6- ; counterhold with suitable tool at spindle -VAS 501
© satelettronica
001/1- .
– Pull out sleeve of second needle bearing in the same way.
Installing
– Thoroughly clean bearing seats and contact surfaces for rotor
assembly.
– Fit new needle bearing onto tool -T40303- .
• Groove -arrow- faces supercharger housing.
• Seal in needle bearing faces tool.
Caution
Risk of diluting grease filling in needle bearing if too much en‐

gine oil is applied.
♦ Apply only a very thin layer of engine oil.
– Lightly lubricate outer circumference (sleeve) of needle bear‐

ing with engine oil.

– Using assembly tool -T40303- , position needle bearing at hole

in supercharger housing (ensure it is straight) and drive it in
as far as stop with a large plastic hammer.
– Check seating of needle bearing -1- in supercharger housing

-2- after driving needle bearing in:
• Dimension -a- = 1.5 mm
– If necessary, drive needle bearing in further.
© satelettronica
– Apply a thin layer of sealant -arrow- to sealing surface for rotor
module on supercharger housing.
– Carefully fit rotor assembly in supercharger housing.
– Ensure that rotors do not damage inner surfaces of super‐
charger housing, and that rotor shafts are inserted into needle
bearings.
– Install drive unit
– Install magnetic clutch
1.10 Renewing drive shaft oil seal

♦ Pin - VW 295-
1. Supercharger 267
♦ Sleeve - 3144-
♦ Plate - T40285-
© satelettronica
Procedure
– Remove drive unit
– Place drive unit on plate - T40285- with front side facing up‐
wards, as shown in illustration.
– Use drift - VW 295- to drive oil seal out of drive unit.
– Place drive unit on workbench with front side facing down‐

wards.
– Drive in oil seal with sleeve - 3144- .
• Installation position: Open side of oil seal faces tool.
– Install drive unit

1.11 Securing supercharger to engine and

gearbox support
for assembly work”, page 269
for leak test”, page 270

gearbox support for assembly work
Note
When performing assembly work, the openings in the bottom of

the supercharger housing make it possible for you to see and ac‐
cess the charge air coolers.

© satelettronica
♦ Gearbox support - T40206- with -T40206/1-
♦ Mounting -T40304-
1. Supercharger 269
Procedure
• Supercharger removed
– Insert gearbox support - T40206- with -T40206/1- into engine
– Secure mounting -T40304- to -T40206/1- (only screw in bolts
lightly at first), observing alignment of holes -1, 3, 10, 12- on
mountings and gearbox support - T40206- .
– Place supercharger onto mounting -T40304- , as shown in il‐

lustration.
© satelettronica
• Bottom openings in supercharger housing make it possible for
you to see and access charge air coolers.
– Hand-tighten bolts -1- evenly in a diagonal sequence on both
sides.
– Tighten bolts securing mounting -T40304- to -T40206/1- to 21
Nm.
– Tighten bolts -1- on both sides in diagonal sequence to 21 Nm.

gearbox support for leak test
Note
When checking for leaks, the seals on the mountings -T40304-

should seal off the openings in the supercharger housing.

♦ Gearbox support - T40206- with -T40206/1-
© satelettronica
♦ Mounting -T40304-
Procedure
• Supercharger removed
– Insert gearbox support - T40206- with -T40206/1- into engine
– Secure mounting -T40304- to -T40206/1- (only screw in bolts
lightly at first), observing alignment of holes -2, 5, 8, 14- on
mountings and gearbox support - T40206- .
1. Supercharger 271
– Place supercharger onto mounting -T40304- , as shown in il‐

lustration.
• Seals of mountings should seal off openings in supercharger
housing.
– Lightly hand-tighten bolts -1- evenly in a diagonal sequence
on both sides.
– Tighten bolts securing mounting -T40304- to -T40206/1- to 21
Nm.
– Use a feeler gauge -2- to check that bolts are tightened evenly
and adjust if necessary.
© satelettronica
• There must be an even gap all around between supercharger
-1- and mounting -T40304- .
• Maximum permissible deviation in gap dimension: 0.2 mm.
1.12 Removing and installing sender 1 for tur‐

bocharger speed - G688-
Removing
page 43 .


– Remove bolt -3- and detach sender 1 for turbocharger speed
- G688- .
Note
Disregard -item 1-.
Installing
Note
Renew seals.

page 43 .
Tightening torques
© satelettronica
1. Supercharger 273
2 Charge air system

page 275
G447 ”, page 280
1 - Gasket
2 - O-ring
air cooler
© satelettronica
3 - O-ring
air cooler
4 - Gasket
side)
stalling charge air cool‐
er”, page 275
6 - Bolt
❑ Self-locking
❑ 10 Nm
7 - Gasket
❑ Must not be detached
from charge air cooler
air cooler
9 - Bolt
❑ Self-locking
❑ 10 Nm
10 - Gasket
❑ Must not be detached from charge air cooler
❑ Coat with engine oil when installing charge air cooler


❑ Removing and installing ⇒ “2.3 Removing and installing charge air cooler”, page 275

charge air system
Note


© satelettronica

er
♦ Fitting sleeve - 2033-

♦ Assembly device for valves - 2036-
♦ Tyre lever for aluminium rims - V.A.G 1942-

Removing
6095- for assembly work
– Unscrew bolts -arrows- and detach bracket -1- with change‐
© satelettronica
over valves.
Charge air cooler (left-side):
– Remove charge pressure sender 2 - G447-
G447 ”, page 280 .
Charge air cooler (right-side):
page 301 .
– Remove charge pressure sender - G31-
G447 ”, page 280 .

percharger.

– Remove bolts -1, 2- for charge air cooler (left-side) and bolts
-3, 4- for charge air cooler (right-side).
– Attach valve assembly device - 2036- with -2036/1- to super‐

charger, as shown in illustration.
– Apply fitting sleeve - 2033- at front of charge air cooler.
– Using tyre lever - V.A.G 1942- , apply moderate pressure and
slowly press charge air cooler out of supercharger housing.
© satelettronica
Installing
Note
♦ Renew gaskets, O-rings and self-locking bolts after removal.

holes in supercharger housing using a thread tap.
– Check gasket -5- on charge air cooler -4-.

• The gasket must not be cracked or damaged.
– Slide gasket -1- onto charge air cooler.
– Insert O-ring -2- into opening in supercharger housing -3-.

– Coat sealing surface -arrow A- and gasket -arrow B- of charge

air cooler -1- with engine oil.
– Also coat sealing surface inside supercharger housing with
engine oil.
– When fitting charge air cooler, make sure that seals align with
recesses in supercharger housing -arrows-.
© satelettronica
Note
To make it easier to insert and press in the charge air cooler,

position the supercharger housing vertically in engine and gear‐
box support - VAS 6095- .
Caution

♦ Only insert charge air cooler by hand.
– Insert charge air cooler in supercharger housing -arrow A- by

hand as far as stop, letting charge air cooler slide into hole
-arrow B- in front of supercharger housing.

– If necessary, guide charge air cooler by hand via openings

-arrows- in supercharger housing when inserting cooler.
– As soon as possible (due to length of bolts), screw in 2 bolts
loosely by hand to guide charge air cooler additionally.
Caution

♦ The charge air cooler must not be pulled in by screwing in
the securing bolts.
♦ Insert charge air cooler by hand (without using tools) until
sealing flange with gasket makes contact with super‐
charger housing (maximum: 1 mm distance). Only then
tighten bolts, as described in the following.
– Tighten bolts -1, 2- for charge air cooler (left-side) and bolts
-3, 4- for charge air cooler (right-side) in diagonal sequence
and in small steps.
© satelettronica
note the following:
er”, page 217 .
page 301 .
– Install charge pressure sender
G447 ”, page 280 .
Tightening torques


sure sender -G31- / -G447-
Removing
– Unscrew bolt -2- and detach charge pressure sender -G31- or
-G447- -item 1-.
Installing
Note
♦ Renew self-locking bolts and O-ring after removal.

holes for charge pressure senders in supercharger housing
using a thread tap.
© satelettronica
Tightening torques


1 Injection system
page 281

Fitting locations in engine compartment

tiometer - G336-
❑ Exploded view
section) with fuel rail”,
page 295
© satelettronica
- V101-
❑ Exploded view
page 354
3 - Activated charcoal filter sol‐
enoid valve 1 - N80-
4 - Crankcase breather shut-
off valve - N548-
❑ Exploded view
crankcase breather sys‐
tem”, page 167
V50-
of coolant circulation
pump -V50- ”“ ,
page 283
❑ Exploded view
electric coolant pump”,
page 194
6 - Brake servo pressure sen‐
sor - G294-
⇒ Brake system; Rep. gr. 47 ; Vacuum system; Removing and installing brake servo pressure sensor
page 282
❑ Fitting location ⇒ Fig. ““Fitting location of brake light switch -F- ”“ , page 282


❑ Fitting location ⇒ Fig. ““Fitting location of charge air cooling pump -V188- ”“ , page 283
❑ Exploded view ⇒ “2.2 Exploded view - electric coolant pump”, page 194
11 - Intake manifold flap potentiometer 2 - G512-

Note

Removing and installing ⇒ Fuel supply system; Rep. gr. 20 ;

Accelerator mechanism; Removing and installing accelerator
pedal module with accelerator position sender -G79- / -G185-
© satelettronica

regulation - G694-
♦ -Item 1- below intake manifold (bottom section) on cylinder
bank 1 (right-side)

Fitting location of coolant circulation pump - V50-

♦ On top of gearbox housing
1- Electrical connector for coolant circulation pump - V50-
page 195
Fitting location of charge air cooling pump - V188-

♦ Beneath longitudinal member (front left)
3 - Electrical connector for charge air cooling pump - V188-
⇒ “2.4.2 Removing and installing charge air cooling pump V188
”, page 197
© satelettronica
Fitting locations on engine (from above)

1 - Ignition coils with output

stages for cylinder bank 1
♦ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
❑ Exploded view
ignition system”,
page 375
valve 1 - N318-
❑ Exploded view
N205-
❑ Exploded view
© satelettronica
4 - FSI injectors
❑ Exploded view
page 305
❑ Exploded view
❑ Exploded view ⇒ “1.1 Exploded view - ignition system”, page 375
❑ Exploded view ⇒ “4.1 Exploded view - oil filter”, page 172
❑ Exploded view ⇒ “4.1 Exploded view - oil filter”, page 172
9 - FSI injectors
❑ Exploded view ⇒ “4.1 Exploded view - valve gear”, page 129
❑ Exploded view ⇒ “4.1 Exploded view - valve gear”, page 129
12 - Ignition coils with output stages for cylinder bank 2
♦ Ignition coil 4 with output stage - N292-


13 - MPI injectors
♦ Injector 2, cylinder 4 - N535-
♦ Exploded view ⇒ “4.1 Exploded view - intake manifold (bottom section) with fuel rail”, page 295
⇒ Fig. ““Fitting location of temperature sender for engine temperature regulation -G694- ”“ , page 282
© satelettronica
❑ Exploded view ⇒ “2.3 Exploded view - coolant temperature senders”, page 195
20 - MPI injectors
♦ Exploded view ⇒ “4.1 Exploded view - intake manifold (bottom section) with fuel rail”, page 295
Fitting locations on engine (from left side)


❑ Exploded view
ignition system”,
page 375
converter - Z30-
❑ Exploded view
Lambda probe”,
page 329
heater 2 - Z28-
❑ Exploded view
Lambda probe”,
page 329
© satelettronica
4 - Left electrohydraulic engine
mounting solenoid valve -
N144-
trol - N428-
❑ Exploded view
oil pressure switches/oil
pressure control”,
page 173
Fitting locations on engine (from right side)


G28-
❑ Exploded view
ignition system”,
page 375
converter - Z29-
❑ Exploded view
Lambda probe”,
page 329
heater - Z19-
❑ Exploded view
Lambda probe”,
© satelettronica
page 329
❑ Exploded view
ignition system”,
page 375
❑ Exploded view
high-pressure pump”,
page 321
sender - G266-
❑ Exploded view
7 - Right electrohydraulic engine mounting solenoid valve - N145-
Fitting locations on supercharger

1 - Magnetic clutch for super‐

charger - N421-
⇒ “1.1 Exploded view - super‐

G31-
⇒ “1.1 Exploded view - super‐

J338-
❑ Including throttle valve
drive for electric throttle
- G186- , throttle valve
drive angle sender 1 for
electric throttle - G187-
and throttle valve drive
angle sender 2 for elec‐
tric throttle - G188-
❑ Exploded view
supercharger”,
© satelettronica
page 239
head - N489-
- N492-
N316-
N112-
8 - Intake air temperature
sender - G42- / intake manifold
❑ Exploded view ⇒ “1.1 Exploded view - supercharger”, page 239
❑ With regulating flap position control motor - V380- and regulating flap potentiometer - G584-
❑ Exploded view ⇒ “1.1 Exploded view - supercharger”, page 239
11 - Sender 1 for turbocharger speed - G688-

renewed.

2 Vacuum system
Caution

Note
♦ Dark grey = Vacuum supply line

♦ Red = Control pipe to vacuum units for actuating intake mani‐
fold flaps
© satelettronica
♦ Pink = Control pipe to the secondary air combination valves
♦ Green = Control pipe to coolant shut-off valve
♦ Light grey = Control pipe to coolant pump

1 - Coolant pump
2 - Vacuum unit
on cylinder bank 1
(right-side)
N112-
N316-
- N492-
head - N489-
9 - Vacuum unit
© satelettronica
side)
11 - Vacuum pump

Procedure
♦ Cracks


leading to the corresponding component and also check the
remaining vacuum lines in the system.
hoses for leaks.
© satelettronica

3 Air cleaner
1 - Air duct
2 - Sealing element
3 - Mounting
© satelettronica
ing”, page 292
parts catalogue
Maintenance tables
let 411
6 - Air pipe
screw-type clips
charge air system”,
page 275
7 - Cover
its or dirt
8 - Air duct
9 - Bolt
❑ 1.5 Nm

housing
Removing
ments .

Note
Disregard -item 1-.
© satelettronica
pipe.
3. Air cleaner 293


-arrow-.
Installing
Note

♦ To prevent malfunctions, cover all critical parts of the engine
air intake tract (intake pipes, etc.) with a clean cloth before

note the following:
ments .
© satelettronica
Tightening torques
tem”, page 275

4 Intake manifold
rail”, page 295
⇒ “4.2 Removing and installing intake manifold (bottom section)
with fuel rail”, page 297
301
⇒ “4.4 Removing and installing regulating flap control unit J808 ”,
page 303
MPI low-pressure injection system
Note
Illustration shows components for cylinder bank 2 (left-side).
© satelettronica
1 - Vacuum hose
❑ To intake manifold flap
valve - N316-
2 - O-ring
tiometer 2 - G512-
side): intake manifold
flap potentiometer -
G336-
4 - O-ring
5 - Retaining clip
6 - Injector
❑ For MPI low-pressure
injection system
installing injectors - ve‐
hicles with MPI engine”,
page 310
7 - O-ring
8 - Fuel rail
❑ For MPI low-pressure
injection system
installing fuel rail, MPI
injection”, page 308
⇒ “6.3 Removing and installing fuel pressure sender for low pressure G410 ”, page 319

❑ 15 Nm
10 - Bolt
❑ 9 Nm
11 - Fuel supply line
❑ For MPI low-pressure injection system
12 - Bolt
❑ 9 Nm
13 - Fuel hose
14 - Bolt
❑ 5 Nm
15 - Gaskets
16 - Bolt
⇒ Fig. ““Intake manifold (bottom section) for cylinder bank 1 (right-side) - tightening torque”“ ,
page 296 ,
⇒ Fig. ““Intake manifold (bottom section) for cylinder bank 2 (left-side) - tightening torque”“ , page 296
© satelettronica
⇒ “4.2 Removing and installing intake manifold (bottom section) with fuel rail”, page 297
18 - Gaskets
Intake manifold (bottom section) for cylinder bank 1 (right-side) -

tightening torque
– Tighten bolts and nuts -arrows- in stages (final torque 9 Nm).
Intake manifold (bottom section) for cylinder bank 2 (left-side) -

tightening torque
– Tighten bolts and nuts -arrows- in stages (final torque 9 Nm).

Throttle valve module - J338- - tightening torque

– Tighten bolts -arrows- in diagonal sequence to 10 Nm.
Regulating flap control unit - J808- - tightening torque and se‐

quence
2. -6- 10 Nm
© satelettronica
3. -5- 10 Nm

(bottom section) with fuel rail
♦ Tool inserts - V.A.G 1331/2-
Removing

Intake manifold (bottom section) for cylinder bank 1 (right-side):

– Move fuel hose -1- clear at MPI fuel rail.
– Unplug electrical connectors -4- and move electrical wiring
clear.
Note
Place a cloth underneath to catch escaping fuel.
WARNING

© satelettronica
– Release hose clip -2- and detach fuel hose.
– Remove bolts -3- and -arrow-.

– Unscrew bolts -arrows- and detach bottom section of intake
manifold (right-side), paying attention to MPI fuel line -3-.

Intake manifold (bottom section) for cylinder bank 2 (left-side):
Note
Place a cloth underneath to catch escaping fuel.
WARNING


– Unplug electrical connectors -3- and move electrical wiring
© satelettronica
clear.
– Remove bolts -1- and -arrows-.
– Unplug electrical connector -2- and disconnect vacuum hose

-1-.
– Unscrew bolts -arrows- and detach bottom section of intake
manifold (left-side), paying attention to MPI fuel line.
Caution

♦ Block off the intake ports with clean cloths to prevent small
objects from dropping into the engine through the intake
ports in the cylinder heads.
Installing
Note


Caution
Risk of damage to intake manifold flaps.

♦ To prevent the intake manifold flaps from catching on the
guide plates in the cylinder head, the flaps must be in the
power mode position -arrows- (intake passage fully open)
when the intake manifold (bottom section) is installed.
Intake manifold (bottom section) for cylinder bank 1 (right-side):

– Connect hand vacuum pump - VAS 6213- to vacuum unit
(right-side), as shown in illustration.
© satelettronica
Intake manifold (bottom section) for cylinder bank 2 (left-side):
– Connect hand vacuum pump - VAS 6213- to vacuum hose
-1- for vacuum unit (left-side), as shown in illustration.
– Tighten bolts and nuts for intake manifold (bottom section).
to injectors.
– Disconnect hand vacuum pump from vacuum unit/vacuum
hose.
Tightening torques
♦ ⇒ Fig. ““Intake manifold (bottom section) for cylinder bank 2
(left-side) - tightening torque”“ , page 296
♦ ⇒ Fig. ““Intake manifold (bottom section) for cylinder bank 1
(right-side) - tightening torque”“ , page 296


module - J338-
Removing
page 43 .
pipe.

– Unscrew bolts -arrows- and detach throttle valve module -
J338- .
– Disconnect intermediate flange from crankcase breather shut-
off valve - N548- and detach.
© satelettronica
Caution

♦ Block off the intake port with a clean cloth to prevent small
items from dropping into the supercharger.
Installing
Note


– Insert intermediate flange -2- with O-rings into supercharger

-1- -left arrows-.
– Fit throttle valve module - J338- -item 3- on intermediate flange
-right arrows-.
– Tighten bolts -4-.
– Engage crankcase breather shut-off valve - N548- .
page 43 .
– Adapt throttle valve module after renewal:
♦ Drive train
© satelettronica
♦ Functions
♦ Adapt throttle valve control module
Tightening torques
♦ ⇒ Fig. ““ Throttle valve module -J338- - tightening torque”“ ,
page 297
tem”, page 275

4.4 Removing and installing regulating flap

Removing
page 43 .
– Detach bypass elbow -1- with intermediate flange -2- and reg‐
ulating flap control unit - J808- -item 4-.
Installing
Note
© satelettronica
page 43 .
– Adapt regulating flap control unit after renewal:
♦ Drive train
♦ Functions
♦ Adapt regulating flap control unit
Tightening torques
♦ ⇒ Fig. ““ Regulating flap control unit -J808- - tightening torque
4.5 Removing and installing fuel line

Removing
– Remove intake manifold (bottom section) for cylinder bank 1
(right-side)
ments .

– Remove bolts -arrows- and detach air duct -2- from air cleaner
housing.
Note
Disregard -item 1-.
© satelettronica
– Unscrew bolts -2, 3- and detach connection -1-.

– Remove bolts -arrows-, detach fuel line and unplug electrical
connector -1-.
Installing
ments .
– Install intake manifold (bottom section) for cylinder bank 1
(right-side)
Tightening torques

5 Injectors
⇒ “5.4 Cleaning FSI injectors - vehicles with FSI engine”,
page 316

⇒ “5.1.1 Exploded view - fuel rail with injectors, vehicles with MPI
low-pressure injection system”, page 305
⇒ “5.1.2 Exploded view - fuel rail with injectors, vehicles up to
03.2015 with FSI high-pressure injection system”, page 305
⇒ “5.1.3 Exploded view - fuel rail with injectors, vehicles from
04.2015 onwards with FSI high-pressure injection system”, page
307
5.1.1 Exploded view - fuel rail with injectors,

vehicles with MPI low-pressure injection
© satelettronica
system
For exploded view of fuel rail with injectors on vehicles with MPI
low-pressure injection system, refer to
rail”, page 295 .
5.1.2 Exploded view - fuel rail with injectors, vehicles up to 03.2015 with FSI high-
pressure injection system
FSI high-pressure injection system
5. Injectors 305
1 - Injector
installing injectors - ve‐
hicles with FSI engine”,
page 311
2 - Spacer ring
3 - O-ring
❑ Lubricate lightly with
clean engine oil
4 - Support ring
❑ Make sure it is correctly
seated
❑ Via this support ring, the
fuel rail exerts the force
which holds the injector
in the cylinder head
© satelettronica
G247-
stalling fuel pressure
sender G247 ”,
page 318
❑ Lubricate threads lightly
with clean engine oil
❑ 25 Nm
6 - Bolt
❑ 9 Nm
❑ Removing and installing ⇒ “7.3 Removing and installing high-pressure pipe”, page 326
❑ To loosen and tighten high-pressure pipe, counterhold at pipe connection
❑ Lubricate threads of union nuts with fuel
❑ 25 Nm
❑ 40 Nm
9 - Fuel rail
10 - Bolt
❑ Tighten alternately in stages; final torque 9 Nm
11 - Washer
❑ Installation position: conical side faces injector
12 - Retaining ring
❑ Fitting location: side with collar faces injector

13 - Circlip
⇒ “5.3.2 Removing and installing injectors - vehicles with FSI engine”, page 311
❑ Do not apply grease or use any other lubricants
5.1.3 Exploded view - fuel rail with injectors, vehicles from 04.2015 onwards with
1 - Bolt
❑ 9 Nm
© satelettronica
pipe”, page 326
❑ Check for damage be‐
fore re-installing
❑ To loosen and tighten
high-pressure pipe,
counterhold at pipe con‐
nection
❑ Lubricate threads of un‐
ion nuts with fuel
❑ 25 Nm
3 - Connection
❑ 40 Nm
4 - Fuel rail
5 - Bolt
❑ Tighten alternately in
stages; final torque 9
Nm
6 - Support ring
❑ Make sure it is correctly
seated
❑ Via this support ring, the
fuel rail exerts the force
which holds the injector
in the cylinder head
7 - O-ring
8 - Spacer ring
5. Injectors 307
9 - Injector
❑ Cleaning ⇒ “5.4 Cleaning FSI injectors - vehicles with FSI engine”, page 316
❑ Do not apply grease or use any other lubricants
❑ Removing and installing ⇒ “6.2 Removing and installing fuel pressure sender G247 ”, page 318
❑ 25 Nm

⇒ “5.2.1 Removing and installing fuel rail, MPI injection”,
page 308
⇒ “5.2.2 Removing and installing fuel rail, FSI injection”,
© satelettronica
page 309
5.2.1 Removing and installing fuel rail, MPI in‐

jection
Note

der bank 1 (right-side).
Removing

– Move fuel hose -1- clear.
WARNING


– Remove bolts -arrow- and detach fuel rail with injectors from
intake manifold (bottom section).
Note
© satelettronica
Disregard -item 3-.
Installing
Note

Tightening torques
5.2.2 Removing and installing fuel rail, FSI in‐

jection
Note

der bank 2 (left-side).
Removing
5. Injectors 309
WARNING

– Remove union nut -1- and bolts -arrows- and detach fuel rail
-3- from injectors.
Note
Unplug electrical connectors of any injectors that remained

lodged in fuel rail.
© satelettronica
Installing
Note

be renewed.
Tightening torques

⇒ “5.3.1 Removing and installing injectors - vehicles with MPI en‐
gine”, page 310
⇒ “5.3.2 Removing and installing injectors - vehicles with FSI en‐
gine”, page 311

hicles with MPI engine
Note

der bank 1 (right-side).

Removing
– Move fuel hose -1- clear.
WARNING


– Remove bolts -arrow- and detach fuel rail with injectors from
© satelettronica
intake manifold (bottom section).
Note
Disregard -item 3-.
– Remove retaining clip -2- and detach injector -3- from fuel rail
-1-.
Installing
Note

Tightening torques

hicles with FSI engine
5. Injectors 311
Removing
– Remove relevant fuel rail
Removing any injectors lodged in fuel rail:
– Carefully pull injectors out of fuel rail.
Removing any injectors lodged in cylinder head:
© satelettronica
– Cover open inlet ports with a clean cloth.
– Unplug electrical connector on injector that is to be removed.
– Slide sleeve -T10133/18A- over injector.
injector.
Note
♦ Use a torque wrench to pull out injector.

♦ Adjust torque wrench to 5 Nm.
– Apply puller -T10133/20- to groove on injector.

– Attach removal tool -T10133/16A- and pull out injector by turn‐
ing bolt -T10133/21- .

Dismantling injector - vehicles up to 03.2015

– Pull support ring -4-, O-ring -3- and spacer ring -2- off injector
-1-.
Note
Renew retaining ring -6-, washer -5- and circlip -7- only if they are
damaged or when installing a new injector.

so, cut open combustion chamber ring seal using knife or prise
open with small screwdriver and then pull off forwards.
Note

Dismantling injector - vehicles from 04.2015 onwards
© satelettronica
– Pull support ring -5- and spacer ring -3- off injector -2-.
so, cut open seal using knife or prise open with small screw‐
driver and then pull off forwards.
Note
Take care not to damage groove on injector. The injector must be

renewed if the groove is damaged.
Installing
Note
♦ Renew combustion chamber ring seal, spacer ring, O-ring and

support ring after removing.

T10133/4- .
5. Injectors 313


go.
© satelettronica
Note


opposite direction.

opposite direction.

Fully assembling injector - vehicles up to 03.2015

2 - Spacer ring
3 - O-ring
4 - Support ring
5 - Washer
6 - Retaining ring
7 - Circlip
Note
Fully assembling injector - vehicles from 04.2015 onwards
© satelettronica
3 - Spacer ring
4 - O-ring
5 - Support ring
Note

– Use assembly tool -T10133/9- to insert injector as far as it will
go into hole in cylinder head; note correct installation position.
• Electrical connector of injector must engage in recess in cyl‐
inder head.
Note
It should be possible to insert the injector easily. If necessary wait

until the combustion chamber ring seal has contracted sufficient‐
ly.
Perform further installation in reverse order, paying attention to

the following:
– Install fuel rail
5. Injectors 315
5.4 Cleaning FSI injectors - vehicles with

FSI engine
♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid - VAS 6418/2-
Cleaning
– Remove injectors
⇒ “5.3.2 Removing and installing injectors - vehicles with FSI
engine”, page 311 .
– Fill ultrasonic unit with 2,120 ml of water which has been al‐
lowed to settle for a few minutes and cleaning fluid - VAS
6418/2- .
Mixture ratio for cleaning fluid
• 2,100 ml of tap water which has been allowed to settle for a
© satelettronica
few minutes and 20 ml of cleaning fluid - VAS 6418/2-
– Place mounting plate for injection modules - VAS 6418/1- on

top of cleaning unit.
WARNING
It is important to read the safety notes in the operating instruc‐

tions before switching on the ultrasonic cleaning unit - VAS
6418- .
The ideal fluid level is approx. 1-4 mm above the base of the
mounting plate. The ultrasonic cleaning unit - VAS 6418- can
be damaged if the fluid level is too low.
– Insert FSI injectors all the way into guides of mounting plate
for injection modules - VAS 6418/1- .


– Select a cleaning time of 30 minutes with rotary control -A-.
– Set rotary control -B- to a temperature of 50°C.
– Press ► button -D- to start cleaning procedure.
Note
♦ The temperature-controlled cleaning process is now started.

While the fluid is being heated, the ultrasound is activated at
intervals in order to circulate the cleaning solution. The ultra‐
sound is activated continuously when the preselected tem‐
perature is reached.
♦ The actual cleaning process commences when the tempera‐
ture reaches at least 50 ℃ and must last for at least 30
minutes.
– Install injectors with new combustion chamber seal

© satelettronica
5. Injectors 317

⇒ “6.1 Removing and installing intake air temperature sender
G42 / intake manifold pressure sender G71 ”, page 318
318
⇒ “6.3 Removing and installing fuel pressure sender for low pres‐

perature sender - G42- / intake manifold
Removing
page 301 .
– Unscrew bolts -arrows- and detach intake air temperature
© satelettronica
Note
Disregard -item 2-.
Installing
Note

page 301 .
Tightening torques

sender - G247-

♦ Socket (27 mm) - T40218- or commercially available socket

(27 mm)
Removing
WARNING
© satelettronica
– Unscrew fuel pressure sender - G247- -item 2-.

Installing
– Check tightening torque of connection before tightening fuel
pressure sender.
Tightening torques

sender for low pressure - G410-
Removing


– Unscrew fuel pressure sender for low-pressure - G410-
-item 1-.
Installing
Tightening torques
© satelettronica

1 - Bolt
sequence
⇒ Fig. ““High-pressure
pump - tightening torque
page 322
- N290-
© satelettronica
pump”, page 322
3 - Union nut
❑ Lubricate thread of un‐
ion nut with fuel
❑ 27 Nm
4 - O-ring
5 - Bolt
❑ 9 Nm
6 - Fuel supply hose with con‐
nection
❑ Low-pressure side lead‐
ing from fuel tank
pipe”, page 326
8 - Bolt
❑ 9 Nm
9 - Roller tappet
10 - Gasket

11 - Housing
12 - O-ring
14 - Bolt
15 - Threaded pin
❑ 9 Nm
16 - Protective plate
17 - Nut
❑ 9 Nm
18 - Bolt
❑ 9 Nm
19 - Fuel supply hose with connection
© satelettronica
❑ Low-pressure side to MPI injectors
❑ Removing and installing ⇒ “4.5 Removing and installing fuel line”, page 303
20 - Bolt
❑ 9 Nm
21 - O-ring
22 - O-ring

2. -arrows- Tighten in stages; final torque 20 Nm

pump

♦ Socket insert AF 14, flared ring spanner - V.A.G 1331/8-

© satelettronica
♦ Feeler gauge
Removing
Note


page 292 .

WARNING

© satelettronica

– Unscrew bolt -2- and detach connection -1-.
Note
Disregard -item 3-.


Note
Do not attempt to bend high-pressure pipe to a different shape.
Installing
Note
© satelettronica
aged.


gine.
noise insulation .

– Rotate crankshaft in direction of engine rotation -arrow- using

adapter - T40058- and angled ring spanner, and at the same
time press roller tappet into housing until it reaches lowest
point.
onto stop.
– At the same time, tighten securing bolts by hand.
– Tighten bolts; for procedure refer to
⇒ Fig. ““High-pressure pump - tightening torque and se‐
page 326 .
page 292 .
© satelettronica
Tightening torques
♦ ⇒ Fig. ““High-pressure pump - tightening torque and se‐

pipe

Removing
– Remove fuel line for MPI injection system
WARNING

– Remove union nuts -1, 2, 3-. If necessary, counterhold threa‐

ded connection.
© satelettronica
Note
Do not attempt to bend high-pressure pipe to a different shape.
Installing
Note

aged.

be renewed.

– First tighten union nut by hand until it makes contact, making

sure that high-pressure pipe is not under tension.
– Tighten union nut with torque wrench - V.A.G 1331- and tool
insert, AF 17 - V.A.G 1331/6- ; to do so, counterhold at hexa‐
gon flats of threaded connection on fuel rail with an open-end
spanner.
– Do not tighten bolt for retainer until high-pressure pipe has
been tightened.
– Install fuel line for MPI injection system
Tightening torques
© satelettronica

8 Lambda probe
Note

♦ In the case of a used Lambda probe, coat only the thread with high-temperature paste; refer to ⇒ Electronic
parts catalogue for high-temperature paste.
♦ The assembly paste/high-temperature paste must not make contact with the slots on the Lambda probe
body.

© satelettronica
converter - Z30-
G108 / G131 ”,
page 331
❑ 55 Nm
heater 2 - Z28-
G108 / G131 ”,
page 331
❑ 55 Nm
heater - Z19-
G39 / G130 ”,
page 330
❑ 55 Nm
converter - Z29-
⇒ “8.2.1 Removing and installing Lambda probe G39 / G130 ”, page 330
❑ 55 Nm
8. Lambda probe 329


⇒ “8.2.1 Removing and installing Lambda probe G39 / G130 ”,
page 330
⇒ “8.2.2 Removing and installing Lambda probe G108 / G131 ”,
page 331

-G39- / -G130-
© satelettronica
Removing
Note

page 43 .
pipe.

nition coils.
– Press electrical wiring harness -1- up slightly.

– Unplug corresponding electrical connector and move clear:

2- For Lambda probe - G39-
– Unscrew relevant Lambda probes:

1- Lambda probe - G39- using ring spanner -3337/7-
2- Lambda probe after catalytic converter - G130- using ring
spanner -3337/2-
Note
© satelettronica
the engine removed.
Installing
Note

Tightening torques
tem”, page 275

-G108- / -G131-
8. Lambda probe 331

Removing
Note
© satelettronica
page 43 .
– Unplug relevant electrical connector and move electrical wir‐

ing clear:

– Unscrew relevant Lambda probe using ring spanner -3337/7- :

Note

the engine removed.
Installing
Note

© satelettronica

page 43 .
Tightening torques
8. Lambda probe 333


page 334

Removing
chamber cover .
© satelettronica
-item 1-.
Note
Disregard -item 2-.
Installing
chamber cover .
must be performed:
in “Guided Functions” mode, “Replace engine control unit”.
Tightening torques
♦ Filler neck for washer fluid reservoir ⇒ Electrical system; Rep.
gr. 92 ; Windscreen washer system; Exploded view - wind‐
screen washer system

⇒ “1.3 Removing and installing front silencers”, page 339
1 - Bolt
❑ 20 Nm
2 - Mounting
❑ Check preload
© satelettronica
tem”, page 340
3 - Nut
❑ 23 Nm
4 - Clamp (front)
sition of front clamps”“ ,
page 336
❑ Push onto front silencer
as far as stop
free of stress
tem”, page 340
❑ Tighten bolted connec‐
tions evenly
5 - Bolt
❑ 20 Nm
6 - Mounting
❑ Check preload
tem”, page 340
7 - Centre silencer
❑ Combined in one unit with rear silencers as original equipment. Can be renewed separately for repair
purposes
❑ Remove diagonal struts prior to removal if necessary ⇒ Fig. ““Diagonal struts (Audi A7)”“ , page 337
❑ Cutting point ⇒ “1.2 Separating exhaust pipes/silencers”, page 337

8 - Gasket
9 - Nut
❑ 23 Nm
10 - Front silencer
❑ Removing and installing ⇒ “1.3 Removing and installing front silencers”, page 339
11 - Mounting
12 - Nut
❑ 23 Nm
13 - Rear silencer
❑ Centre silencer and rear silencer can be renewed separately
© satelettronica
❑ Remove diagonal struts prior to removal if necessary ⇒ Fig. ““Diagonal struts (Audi A7)”“ , page 337
❑ Cutting point between centre silencer and rear silencer
14 - Nut
❑ 23 Nm
15 - Clamp (rear)

bottom of clamp.


bottom of clamp.

gr. 42 ; Subframe; Exploded view - subframe .
© satelettronica

Procedure
struts -1- and -2-.

© satelettronica

bottom of clamp.
Tightening torques

1.3 Removing and installing front silencers

Removing
noise insulation .
– Unscrew nuts -arrows- for relevant front silencer.
© satelettronica
Caution

than 10°.
front silencer.
Installing
Note

Tightening torques


Removing
– Audi A7: Remove diagonal struts ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Subframe; Exploded view - subframe .
Caution

than 10°.
– Release clamps -1 and 2- and push to rear.
WARNING
Risk of accident caused by weight of silencer.
© satelettronica
♦ A second mechanic is required for removal of the silencer.
– Unscrew bolts -1, 2- and remove silencers.
Note
Disregard -item 3-.
Installing
Note

Tightening torques

Procedure


ers
6 ... 10 mm.
Note

© satelettronica
6 ... 10 mm.

ded by -a- = 11 ... 15 mm.
Aligning tailpipes
Tightening torques



any leaks.
© satelettronica


2.1 Exploded view - emission control system
and impact
stalling catalytic con‐
verter”, page 344
❑ Mounting components
⇒ Fig. ““Components of
mountings for catalytic
converter”“ , page 344
2 - Gasket
© satelettronica
fold”, page 366
4 - Nut
parts catalogue
❑ 23 Nm
5 - Gasket
6 - Nut
7 - Front silencer
bend flexible joint more than 10° – otherwise it can be damaged
❑ Removing and installing ⇒ “1.3 Removing and installing front silencers”, page 339

Components of mountings for catalytic converter

1- Nut, 23 Nm
2- Spacer sleeve
4- Washer
5- Bolt
6- Bolt, 23 Nm
7- Spacer sleeve
8- Buffer
9- Bracket
10 - Bolt, 23 Nm
11 - Bracket
Note
The illustration shows the mountings on the right side as an ex‐
© satelettronica
ample.

verter
⇒ “2.2.1 Removing and installing catalytic converter (left-side)”,
page 344
⇒ “2.2.2 Removing and installing catalytic converter (right-side)”,
page 348

verter (left-side)

Removing
Note
© satelettronica
”, page 331 .
cross brace .
Caution



– Remove bolt -2- and nut -3- and push coolant pipe (left-side)
on gearbox clear to side.
Note
Disregard -items 1, 4-.

gearbox.
© satelettronica
-arrow-.
Note
Disregard -item 1-.


and position underneath gearbox.
WARNING
Risk of accident.
♦ Engine and gearbox jack must remain in position when
work is being carried out and must not be left unattended
under the vehicle.
© satelettronica


and gearbox jack - VAS 6931- .
Installing
Note

”, page 331 .
Tightening torques
© satelettronica
♦ Tunnel cross member ⇒ 7-speed dual clutch gearbox; Rep.
mountings / ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; As‐
sembly mountings; Exploded view - assembly mountings
♦ Cover to gearbox ⇒ 7-speed dual clutch gearbox; Rep. gr.
34 ; ATF circuit; Exploded view - ATF circuit / ⇒ 8-speed au‐
tomatic gearbox; Rep. gr. 37 ; ATF circuit; Exploded view -
ATF circuit

verter (right-side)
♦ Retaining tool - VW 785/1B-

© satelettronica
Removing
Note

cross brace .
Caution


page 301 .
– Remove coolant pipe from right side of gearbox
– Remove Lambda probe after catalytic converter - G130-
”, page 330 .

– Detach electrical connectors -1 ... 5- from bracket and place

to one side.
© satelettronica
system.

– Detach vacuum hose -3- from combination valve for secon‐

dary air system.
air hose -2-.
secondary air system and move valve to left side.
© satelettronica
Note
Disregard -item 1-.
nel (top right).

and position underneath gearbox.
WARNING
Risk of accident.
♦ Engine and gearbox jack must remain in position when
work is being carried out and must not be left unattended
under the vehicle.


and gearbox jack - VAS 6931- .
© satelettronica


Installing
Note
– Install combination valve for secondary air (right-side)

– Install Lambda probe after catalytic converter - G130-
”, page 330 .
© satelettronica
page 301 .
Tightening torques
♦ ⇒ Fig. ““Components of mountings for catalytic converter”“ ,
page 344
♦ Tunnel cross member ⇒ 7-speed dual clutch gearbox; Rep.
mountings / ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; As‐
sembly mountings; Exploded view - assembly mountings


”, page 356
⇒ “3.3 Checking combination valve”, page 357
⇒ “3.4 Removing and installing combination valve”, page 359


- V101-
left of engine compart‐
member
© satelettronica
page 356
agnostic tester
2 - Bolt
❑ 8 Nm
4 - Bracket
motor - V101-
5 - Hose
6 - O-ring
7 - Nut
❑ 9 Nm
8 - Pipe
9 - Bolt
❑ 8 Nm
10 - Nut
❑ 9 Nm
11 - O-ring
12 - Hose
13 - Nut
❑ 9 Nm

14 - Hose
15 - O-ring
16 - O-ring
1 - Gasket
check for leaks
nation valve”,
page 357
© satelettronica
valve (left-side)”,
page 359
3 - Seal
4 - Hose
pump motor - V101-
5 - Bolts
❑ 9 Nm
6 - Gasket
7 - Vacuum hose
check for leaks
nation valve”,
page 357
installing combination valve (right-side)”, page 362
9 - Gasket
10 - Heat shield
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 9 Nm

13 - Bolt
❑ 9 Nm
14 - Heat shield
15 - Bolt
❑ 9 Nm
16 - Vacuum hose
17 - Bolts
❑ 9 Nm

pump motor - V101-
Removing
Note
© satelettronica


V101- .
-2-.
Installing
Note

Tightening torques
© satelettronica
(front)
3.3 Checking combination valve

Procedure
page 301 .

– Release fasteners -arrow- and press wiring duct -1- towards

rear.
– Detach vacuum hose -1- or -2- from combination valve to be

checked.
© satelettronica
– Press release tabs and detach secondary air hose -arrow-
from secondary air pump motor - V101- .
– Extend secondary air hose with a test hose and blow lightly
into secondary air hose with your mouth (do not use com‐
pressed air).
Note


not open
⇒ “3.4 Removing and installing combination valve”,
page 359 .
Assembling
Note

page 301 .


valve
page 359
page 362

valve (left-side)
Removing
Note

© satelettronica
body brace .
– Remove bolts -arrows- and detach heat shield (left-side) -1-.
Caution


battery .

converter - G131- .


© satelettronica
trical wiring.
holder -3-.


-arrow B-.
© satelettronica

– Remove bolts -3- for secondary air system hose.

dary air system.
– Unscrew bolts -1- and detach combination valve for secondary
air system.
Installing
Note

– Install engine control unit - J623-
”, page 334 .
© satelettronica
⇒ “2.2.1 Removing and installing catalytic converter (left-
ing battery .
Tightening torques
♦ ⇒ Electrical system; Rep. gr. 97 ; Relay carriers, fuse carriers,
electronics boxes; Overview of fitting locations - relay carriers,
fuse carriers, electronics boxes
strut, upper links

valve (right-side)
Removing
Note



-1-.

converter - G131- .
page 301 .
© satelettronica
release tabs).
Note
Disregard -item 1-.


dary air system.
air hose -2-.
Installing
Note

page 301 .
© satelettronica
⇒ “2.2.2 Removing and installing catalytic converter (right-
Tightening torques

4 Exhaust manifolds
⇒ “4.2 Removing and installing exhaust manifold”, page 366
1 - Nut
parts catalogue
left-side
fold (left-side) - tighten‐
quence”“ , page 366 ;
© satelettronica
right-side
fold (right-side) - tight‐
2 - Bracket
❑ For heat shield
fold”, page 366
4 - Gasket
5 - Bolt
❑ 9 Nm
6 - Heat shield
7 - Washer
8 - Bolt
❑ 9 Nm
9 - Lambda probe
❑ Before catalytic converter
❑ Removing and installing ⇒ “8.2.1 Removing and installing Lambda probe G39 / G130 ”, page 330
10 - Nut
❑ 23 Nm
11 - Gasket

Note
♦ Renew nuts after removing.

– Tighten nuts in stages in the sequence shown:

2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm
Note
© satelettronica
♦ Renew nuts after removing.
– Tighten nuts in stages in the sequence shown:

2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm

fold
page 366
page 370

fold (left-side)
Removing
Note

noise insulation .
page 48 .


(left-side).
© satelettronica
Caution

than 10°.
side).
Note
Disregard -item 2-.

– Remove bolt -1- and nut -2- and push coolant pipe (left-side)
clear to side.
Note
Disregard -arrows-.

Note
Disregard -item 2-.
© satelettronica
tudinal member.



© satelettronica

Installing
Note
♦ Renew gasket and self-locking nuts after removal.


tighten nuts
⇒ Fig. ““Exhaust manifold (left-side) - tightening torque and
⇒ “2.2.1 Removing and installing catalytic converter (left-
© satelettronica
page 48 .
Tightening torques

fold (right-side)
Removing
Note
– Drain coolant
– Also remove noise insulation (rear) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Removing and instal‐
ling noise insulation .


page 292 .
”, page 330 .
-1-.

© satelettronica
(right-side).

Caution

than 10°.
(right-side).
Note
Disregard -item 1-.

© satelettronica
coolant pipe.
Vehicles with auxiliary heater:

– Loosen nut -1- and remove bolt -2-.
coolant pipe.


Note

the engine removed.
© satelettronica

Installing
Note
♦ Renew gaskets and self-locking nuts after removal.


tighten nuts
⇒ Fig. ““Exhaust manifold (right-side) - tightening torque and
⇒ “2.2.2 Removing and installing catalytic converter (right-
© satelettronica
”, page 330 .
page 292 .
Note

Tightening torques

1 Ignition system
⇒ “1.2 Test data, spark plugs”, page 376
page 376
380
1 - Bolt
❑ 9 Nm
© satelettronica
2 - Hall sender
side)
♦ Inlet side: Hall sender -
G40-
♦ Exhaust side: Hall sender 3
- G300-
page 379
3 - O-ring
4 - Knock sensor
grease
♦ Cylinder bank 1 (right-side):
♦ Cylinder bank 2 (left-side):
page 379
5 - Bolt
❑ 25 Nm
6 - Spark plug
❑ Tightening torque ⇒ Maintenance ; Booklet 411

7 - Ignition coil with output stage

8 - Bolt
❑ 5 Nm
11 - Bolt
❑ 9 Nm
12 - O-ring
© satelettronica
13 - Hall sender
♦ Inlet side: Hall sender 2 - G163-
♦ Exhaust side: Hall sender 4 - G301-
14 - Bolt
❑ 9 Nm
1.2 Test data, spark plugs

3.0 ltr. TFSI engine
bilisation
Tightening torque ⇒ Maintenance ; Booklet 411

with output stages

♦ Puller - T40039-
Removing
page 43 .
pipe.
© satelettronica


nition coils.
– Move electrical wiring harness -1- down slightly.
Note
Illustration shows the installation position for cylinder bank 2 (left-

side) as an example.

Note
♦ To remove ignition coils, fit puller - T40039- onto upper (thick)

rib -arrow- of ignition coil with output stage.
♦ The lower ribs can be damaged if they are used.
– Pull out ignition coil -arrow-.
© satelettronica
Installing
– Apply a thin bead of silicone paste all around end of sealing
hose of ignition coil with output stage -arrow-.
Silicone paste ⇒ Electronic parts catalogue (ETKA) .
onto ignition coils simultaneously.
– Press ignition coils onto spark plugs by hand evenly (do not
knock in with tools).
page 43 .
Tightening torques
tem”, page 275


Removing
Knock sensor 1 - G61- , cylinder bank 1 (right-side):
– Remove FSI injector for cylinder 2
Knock sensor 2 - G66- , cylinder bank 2 (left-side):

– Remove FSI injector for cylinder 5
© satelettronica

– Remove bolt -1- for knock sensor 1 - G61- or bolt -2- for knock
sensor 2 - G66- and detach knock sensor.
Installing
– Install FSI injector
Tightening torques

Removing
page 43 .


Installing
Note

page 43 .
Tightening torques

sender - G28-
© satelettronica
Removing
noise insulation .

side.
Note
Disregard -item 1-.


Installing
– Install ATF cooler ⇒ 7-speed dual clutch gearbox; Rep. gr.
34 ; ATF circuit; Exploded view - ATF circuit / ⇒ 8-speed au‐
tomatic gearbox; Rep. gr. 37 ; ATF circuit; Exploded view -
ATF circuit .
Tightening torques
© satelettronica

Service
Workshop Manual
Audi A6 2011 ➤
8-cylinder direct injection engine (4.0 ltr. 4-valve TFSI)
Engine ID
CEU CRD CEU CWU CTG CWU CWU
C B D B E A C
© satelettronica
Edition 07.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
© satelettronica

Copyright © 2019 Audi AG, Ingolstadt D3E80493CD9

8-cylinder direct injection engine (4.0 ltr. 4-valve TFSI) - Edition 07.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.3 Safety precautions after working in the engine compartment . . . . . . . . . . . . . . . . . . . . . . 3
© satelettronica
3.5 Nuts, bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7 Use of impact wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Removing engine from scissor-type assembly platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.5 Removing and installing power unit mounting senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.6 Removing and installing power unit mounting control unit J931 . . . . . . . . . . . . . . . . . . . . 80
2.7 Calibrating electrohydraulic engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Contents i

3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4 Auxiliary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.1 Exploded view - auxiliary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2 Removing and installing spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3 Renewing oil seal for power steering pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.4 Renewing oil seal for AC compressor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
© satelettronica
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.3 Exploded view - drive chain for auxiliary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.6 Removing and installing chain tensioner for camshaft timing chain . . . . . . . . . . . . . . . . . . 152
2.8 Removing and installing drive chain for auxiliary drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.5 Removing and installing cam actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
ii Contents
4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 230
4.3 Removing and installing oil pressure switches F22 / F378 . . . . . . . . . . . . . . . . . . . . . . . . 231
4.4 Removing and installing stage 3 oil pressure switch F447 . . . . . . . . . . . . . . . . . . . . . . . . 233
4.8 Removing and installing piston cooling jet control valve N522 . . . . . . . . . . . . . . . . . . . . . . 236
5 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5.1 Exploded view - mechanical switching valve, non-return valve, cover in inner V of engine
........................................................................ 237
© satelettronica
5.2 Removing and installing cover in inner V of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
5.3 Removing and installing non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
5.4 Removing and installing mechanical switching valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.8 Removing and installing coolant temperature senders G62 / G694 . . . . . . . . . . . . . . . . . . 273
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
4.3 Exploded view - radiator cowl and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
1 Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Contents iii

1.3 Removing and installing temperature sender for engine cover panel G765 . . . . . . . . . . . . 342
2.3 Removing and installing charge air cooler housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
2.6 Removing and installing charge pressure sender 2 G447 . . . . . . . . . . . . . . . . . . . . . . . . 351
2.7 Removing and installing turbocharger air recirculation valve N249 . . . . . . . . . . . . . . . . . . 352
2.8 Removing and installing turbocharger air recirculation valve, cylinder bank 2 N427 . . . . 353

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
© satelettronica
2.3 Removing and installing vacuum unit for intake manifold flap . . . . . . . . . . . . . . . . . . . . . . 367
2.4 Removing and installing charge pressure control solenoid valve N75 . . . . . . . . . . . . . . . . 371
2.5 Removing and installing secondary air inlet valve N112 / N320 . . . . . . . . . . . . . . . . . . . . 371
2.6 Removing and installing intake manifold flap valve N316 . . . . . . . . . . . . . . . . . . . . . . . . . . 377
2.7 Removing and installing coolant valve for cylinder head N489 . . . . . . . . . . . . . . . . . . . . . . 378
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
4.2 Exploded view - throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
4.5 Removing and installing intake manifold flap potentiometer G336 . . . . . . . . . . . . . . . . . . 393
4.6 Removing and installing intake manifold flap potentiometer 2 G512 . . . . . . . . . . . . . . . . 395
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
6.1 Removing and installing actuator for structure-borne sound R214 . . . . . . . . . . . . . . . . . . 402
6.2 Removing and installing control unit for structure-borne sound J869 . . . . . . . . . . . . . . . . 403
6.4 Removing and installing fuel pressure sender 2 G624 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
6.6 Removing and installing temperature senders for charge air cooler G763 / G764 . . . . . . 406
6.8 Removing and installing intake manifold pressure sender G71 . . . . . . . . . . . . . . . . . . . . 407
7.2 Exploded view - fuel pipes and fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
iv Contents

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

1.4 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
2.2 Removing and installing exhaust flap control unit J883 / exhaust flap control unit 2 J945
........................................................................ 443
© satelettronica
3.3 Checking secondary air inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
1.2 Test data - spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Contents v
© satelettronica
vi Contents
1 Identification
(ARL006510; Edition 07.2019)

Engine number
Note
♦ The engine number -arrow B- is not visible until the charge air
cooler housing has been removed.
♦ The engine cover panel must be pulled off to make the first
three characters of the engine code -arrow A- visible.
© satelettronica
be found on the cylinder block at the front left -arrow B-.
number.
Note

Engine data
⇒ Technical data for engines; Rep. gr. 00 ; Overview of engines
1. Identification 1
tem”, page 2
⇒ “2.3 Safety precautions after working in the engine compart‐
ment”, page 3
page 3
page 3
page 4
page 4
© satelettronica
may spray out.

fuel pump.


2.3 Safety precautions after working in the

engine compartment
WARNING
Danger of fire and damage if the engine cover panel is not fit‐
ted.
♦ The engine cover panel must always be fitted before the
bonnet is closed.
♦ If the engine cover panel is not fitted, it is not permissible
to start or drive the vehicle with the bonnet closed.
a road test
© satelettronica
Or:
seat.

The cooling system is under pressure when the power unit is hot.

incorrectly.
Risk of injury caused by components of the exhaust system

Danger of injury to hands and other parts of the body due to hot
or sharp parts of the exhaust system.
– Allow exhaust system to cool down.

© satelettronica
wiring.
2.8 Safety precautions when working on the subframe

Lowering the vehicle onto its wheels can damage components if
the assembly mountings, steering rack or subframe cross brace
are not properly fitted.
– Never lower vehicle onto its wheels with suspension compo‐
nents unfastened or detached.
– Never support weight of vehicle on subframe or subframe
cross brace with suspension components unfastened or de‐
tached.

6
⇒ “3.5 Nuts, bolts”, page 6
⇒ “3.6 Identification plates”, page 6
⇒ “3.7 Use of impact wrenches”, page 7

© satelettronica
loosening.

Note

⇒ page 336

fitted.
Please note:
ranty.

and wiring
© satelettronica
♦ Because of the limited space in the engine compartment, it is
important to ensure that there is adequate clearance to any
moving or hot components to avoid damage to lines and wir‐
ing.
3.5 Nuts, bolts

♦ Loosen bolts in reverse sequence to specified tightening se‐
quence.
♦ Bolts and nuts used to secure covers and housings must be
tightened in steps according to the specified tightening se‐
quence and method.
♦ Bolts and nuts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Always renew self-locking bolts and nuts.
♦ Unless otherwise specified, use a wire brush to clean the
threads of bolts which are secured with locking fluid. Then in‐
stall bolts with locking fluid; for locking fluid refer to ⇒ Elec‐
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned using a thread tap or similar.
Otherwise there is a danger of the bolts shearing off the next
time they are removed.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
3.6 Identification plates

When renewing vehicle components, the identification plates on
the old parts that have a replacement part number (see ⇒ Elec‐
tronic parts catalogue ) must be attached to the new parts due to
approval regulations.

3.7 Use of impact wrenches

In general, it is permitted to use an impact wrench to unscrew
bolts and nuts. An exception to this is when work is performed
inside an open high-voltage battery. For this work, it is not per‐
mitted to use an impact wrench.
An impact wrench may be used to screw in bolts and nuts when
performing repair work if the following requirements are observed.
In general, electric and compressed-air impact wrenches should
be used.
Requirements:
• Only screw in bolts with locking fluid or self-locking nuts at low
speed.
• Use a suitable impact wrench with variable speed and adjust‐
able torque range.
• Use suitable bits when working in the vicinity of sensitive sur‐
faces, e.g. plastic-coated bits for aluminium rims.
© satelettronica
• When working in the vicinity of natural gas systems, observe
the information in the Workshop Manual “Natural gas engines
- General information”.
Use:
• Fit bolts/nuts by hand.
• Only use an impact wrench to screw in bolts/nuts until the head
of the bolt/nut makes contact and then continue tightening with
a torque wrench.
• Clean threaded pins before unscrewing the bolt/nut.


⇒ “1.3 Removing engine from scissor-type assembly platform”,
page 54
page 56
1.1 Removing engine

⇒ “1.1.1 Removing engine - Audi S6/S7”, page 8
⇒ “1.1.2 Removing engine - Audi RS 6/RS 7”, page 24
1.1.1 Removing engine - Audi S6/S7
© satelettronica


© satelettronica
♦ Stepladder (commercially available)

♦ Safety goggles

Procedure
Note
♦ The engine is removed from below together with the gearbox

and subframe.
♦ All bolts on running gear components with bonded rubber
bushes must be tightened with suspension in unladen position
(vehicle unladen).
♦ Bond

Manuale Officina Audi A6 11-18

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

Manuale Officina Audi A6 11-18

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Audi AG, Ingolstadt D3E802EDBDC

3.36 Horn: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1.1 --- Change history ---

1.2 Overview of engines

1.2.1 Petrol engines

1.2.2 Diesel engines

1.3 Engine number

The engine number consists of the engine code letters (3 or 4

1.3.1 4-cyl. petrol engine 1.8 ltr./2.0 ltr. TFSI/

Risk of fatal injury if high-voltage components are damaged.

1.3.2 6-cyl. petrol engine 2.5 ltr./2.8 ltr. FSI

1.3.3 6-cyl. petrol engine 3.0 ltr. TFSI

1.3.4 8-cyl. petrol engine 4.0 ltr. TFSI

1.3.5 4-cyl. diesel engine 2.0 ltr. TDI

1.3.6 6-cyl. diesel engine 3.0 ltr. TDI

1.4 Vehicle identification number

The vehicle identification number consists of the following:

1.5 Vehicle data sticker

The vehicle data sticker contains the following vehicle data:

1.6 Warnings for high-voltage vehicles

1.6.1 Overview of high-voltage components

10 - High-voltage wiring harness for drive motor - PX2-

1.6.2 Working in the vicinity of high-voltage

ing, soldering, hot air or thermal bonding equipment.

♦ Certain qualifications are required to perform different types of

1.6.3 Handling high-voltage wires

Handling high-voltage wires:

♦ Certain qualifications are required to perform different types of

1.6.4 Work that must be performed with the

When working on a vehicle with the ignition switched on or

♦ Certain qualifications are required to perform different types of

1.6.5 Work that must be performed with the

Safety hazard: the engine can start unexpectedly.

♦ Certain qualifications are required to perform different types of

2.1 Vehicle: raising

Risk of damage to vehicle due to incorrect use of lifting plat‐

– Front: Position support plates of lifting platform under plastic

– Rear: Position support plates of lifting platform under plastic

The location of the lifting points is indicated by markings stamped

2.1.1 Activating jacking mode

Risk of injury as engine of high-voltage vehicle can start un‐

– Use MMI rotary pushbutton to select “Jacking mode” and set

♦ Jacking mode is switched off again automatically once a

2.2 Engine cover panel: removing and in‐

6-cyl. diesel engine 3.0 ltr. TDI (version 2) ⇒ page 21

2.2.1 4-cyl. petrol engine 1.8 ltr. TFSI

2.2.2 4-cyl. petrol engine 2.0 ltr. TFSI (version

2.2.3 4-cyl. petrol engine 2.0 ltr. TFSI/2.0 ltr.

2.2.4 6-cyl. petrol engine 2.5 ltr. FSI/2.8 ltr.

2.2.5 6-cyl. petrol engine 2.5 ltr./2.8 ltr. FSI

2.2.7 8-cyl. petrol engine 4.0 ltr. TFSI

2.2.8 4-cyl. diesel engine 2.0 ltr. TDI

2.2.9 6-cyl. diesel engine 3.0 ltr. TDI (version

2.2.10 6-cyl. diesel engine 3.0 ltr. TDI (version

Procedure for removing:

2.3 Noise insulation: removing and installing

Risk of fatal injury if high-voltage components are damaged.

Noise insulation (front) ⇒ page 21

2.3.1 Noise insulation (front)

Table of tightening torques for installation: