Engine Cabb Caba Cabd Caea Caeb CDHB CDNB CDNC Cdha Cdza Cada Ccua Cfka Cpma Caed CPMB Chja Cpea Repair Manual Eng

Service
Repair Manual
Audi A4 2008 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ ,
Audi A6 China 2012 ➤ , Audi A8 2010 ➤ ,
Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤
Servicing – 4-Cylinder 1.8L; 2.0L 4V TFSI Engine (EA
888 Generation II)
Engine ID
CAB CAB CAB CAE CAE CDH CDN CDN CDH
B A D A B B B C A
CDZ CAD CCU CFK CPM CAE CPM CHJA CPE
A A A A A D B A
Edition 06.2019
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
21 - Turbocharger, Supercharger
24 - Multiport Fuel Injection
26 - Exhaust System, Emission Controls
28 - Ignition/Glow Plug System
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Servicing – 4-Cylinder 1.8L; 2.0L 4V TFSI Engine (EA 888 Generation II) - Edition 06.2019
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number/Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety Precautions when Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety Precautions when Working on Vehicles with Start/Stop System . . . . . . . . . . . . . . 2
2.3 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Safety Precautions when Working on Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Safety Precautions when Working on Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Safety Precautions when Working on Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Safety Precautions when Working on Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Protected
Foreign Objects
by copyright. CopyinginforEngine . . . . . .purposes,
private or commercial . . . . . in. part
. . .or. in. whole,
. . . .is. not
............................ 5
3.3 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . .
with respect to the correctness of information in this document. Copyright by AUDI AG.
. . . . . . ........................... 5
3.4 Line Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Radiator and Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7 Identification Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.8 Impact Wrench, Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Engine, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Engine, Securing to Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Engine Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Overview - Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Vibration Damper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Sub-Assembly Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Overview - Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2 Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Transmission Side Sealing Flange, Removing and Installing, Oil Side Sealing Lip . . . . . . 32
2.4 Needle Bearing in Drive Plate, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Main Bearing Shells Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4 Crankshaft, Measuring Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.5 Crankshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.6 Sensor Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Overview - Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Contents i
4.2 Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.3 Balance Shaft Gasket, Replacing, Intake Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Overview - Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 Pistons, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3 Oil Spray Jets, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.4 Piston and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5 New Connecting Rod, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.6 Connecting Rods, Checking Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1 Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Overview - Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Timing Chain Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Vibration Damper Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.1 Overview - Camshaft Timing Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2 Overview - Balance Shaft Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.3 Bearing Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.4 Camshaft Timing Chain, Removing from Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.5 Camshaft Timing Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.6 Balance Shaft Drive Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.7 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.2 Cylinder Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Check Valve, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
113
3.4 Compression,
permitted unlessChecking . . .AG.
authorised by AUDI . .AUDI
. . . AG
. . does
. . .not
. .guarantee
. . . . . .or.accept
. . . .any
. .liability
........................ 114
4 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2 Camshaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.3 Sliding Bar Ball, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.4 Cam Adjustment Actuator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.5 Camshaft Adjustment Valve 1 N205 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 134
4.6 Valve Stem Seals, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5 Intake and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.1 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.2 Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.3 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1 Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.1 Overview - Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.3 Oil Pan Lower Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.4 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.5 Oil Pan Upper Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.6 Oil Level Thermal Sensor G266 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 160
2 Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.1 Overview - Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.2 Engine Oil Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3 Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
ii Contents
3.1 Overview - Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

3.2 Oil Separator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4 Oil Filter/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.1 Overview - Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.2 Overview - Oil Pressure Switch/Oil Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.3 Oil Pressure Switch F22 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.4 Reduced Oil Pressure Switch F378 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 169
4.5 Oil Pressure Regulation Valve N428 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 170
4.6 Oil Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

1 Coolant System/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.1 Connection Diagram - Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.2 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.3 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2 Coolant Pump/Coolant Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.1 Overview - Coolant Pump/Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.2 Overview - Electric Coolant Pump . .Protected . . . . .by. .copyright.
. . . . .Copying
. . . . .for. private
. . . .or. commercial
. . . . . . .purposes,
. . . . . in. part
. . .or. in. whole,
. 180 is not
2.3 Electric Coolant Pump, Removing andpermitted Installing . . . . . by
unless authorised . .AUDI
. . .AG.. . AUDI
. . . AG
. . does
. . .not
. .guarantee
. . . . . or. .accept
. . . any
180liability
2.4 Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.5 Coolant Pump Toothed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.6 Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.7 Coolant Thermostat, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.8 Engine Coolant Temperature Sensor G62 , Removing and Installing . . . . . . . . . . . . . . . . 183
2.9 Coolant Valves, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3 Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4 Radiator/Radiator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.1 Overview - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.2 Turbocharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.3 Turbocharger Vacuum Diaphragm, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.4 Turbocharger Vacuum Diaphragm, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.5 Turbocharger Vacuum Diaphragm, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.1 Overview - Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.2 Overview - Charge Air Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.3 Charge Air Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.4 Charge Air Pressure Sensor G31 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 203
2.5 Charge Air System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

1 Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.1 Component Location Overview - Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.2 Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.1 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.2 Double Check-Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Contents iii
4.1 Overview - Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

4.2 Intake Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.3 Throttle Valve Control Module J338 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 216
4.4 Throttle Valve Control Module, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.5 Intake Manifold Change-Over, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.1 Overview - Fuel Rail with Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.2 Fuel Rail, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.3 Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5.4 Fuel Injectors, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
5.5 Cold Start Injector N17 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
6.1 Intake Air Temperature Sensor G42 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 229
6.2 Mass Airflow Sensor G70 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
6.3 Fuel Pressure Sensor G247 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
6.4 Fuel Pressure Sensor G247 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
7 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
7.1 Overview - High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
7.2 High Pressure Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
8.1 Overview - Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
8.2 Heated Oxygen Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.1 Engine Control Module J623 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.2 Wiring and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

1 Exhaust Pipes/Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.1 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.2 Exhaust Pipes/Mufflers, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.3 Front Muffler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.4 Muffler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.5 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.6 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2 Emissions Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.1 Overview - Emissions Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.2 Catalytic Converter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3 Secondary Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

1 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.1 Overview - Ignition System . . . . . . . . . . . . .Protected. . . . .by. .copyright.
. . . . .Copying
. . . . .for. private
. . . . or. .commercial
. . . . . .purposes,
. . . . . .in .part253
or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1.2 Ignition Coils with Power Output Stages, Removing andto the
with respect Installing
correctness of . information
. . . . . . in. this
. . document.
. . . . . Copyright
. . . 254 by AUDI AG.
1.3 Knock Sensor 1 G61 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.4 Camshaft Position Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.5 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
iv Contents
00 – General, Technical Data

1 Identification
(Edition 06.2019)
⇒ “1.1 Engine Number/Engine Specifications”, page 1
1.1 Engine Number/Engine Specifications

Engine Number
♦ The engine number (“engine code” and “serial number”) are
located at the front of the engine/transmission joint -arrow-.
♦ There is also a label located on the upper timing chain cover
with the “engine code” and “serial number”.
♦ The engine code is also included on the vehicle data labels.
Engine Specifications
♦ Engine code allocation. Refer to ⇒ Oil Gauge Tester T40178
Service Values; Rep. Gr. 00 ; Engine Overview .
1. Identification 1
2 Safety Precautions
⇒ “2.1 Safety Precautions when Working on Fuel Supply System”,
page 2
⇒ “2.2 Safety Precautions when Working on Vehicles with Start/
Stop System”, page 2
⇒ “2.3 Safety Precautions during Road Test with Testing Equip‐
ment”, page 3
⇒ “2.4 Safety Precautions when Working on Cooling System”,
page 3
⇒ “2.5 Safety Precautions when Working on Exhaust System”,
page 3
⇒ “2.6 Safety Precautions when Working on Ignition System”,
page 4
⇒ “2.7 Safety Precautions when Working on Subframe”,
page 4
2.1 Safety Precautions when Working on

Fuel Supply System
WARNING
There Is a Risk of Injury Due to the Fuel Being under Pressure
The fuel system is under pressure. Injuries are possible from
fuel spraying out.
Before opening the fuel system:
– Wear protective eyewear.

– Wear safety gloves.
– Reduce the pressure: place clean cloths around the connec‐
tion point and carefully open the connection point.
WARNING
Risk of a Fire Due to Leaking Fuel
When the battery is connected, the door contact switch acti‐
vates the fuel pump when opening the driver door. Leaking fuel
can ignite and start a fire.
– Before opening the fuel system, interrupt the power supply to

the fuel pump.

Vehicles with Start/Stop System
WARNING
There Is a Risk of Injury Due to the Engine Starting Unexpect‐
edly
The engine can start unexpectedly on vehicles with an activated
Start/Stop System. A message in the instrument cluster indi‐
cates whether the Start/Stop System is activated.
– Deactivate the Start/Stop System: switch off the ignition.
2 Rep. Gr.00 - General, Technical Data

2.3 Safety Precautions during Road Test

with Testing Equipment
WARNING
There Is a Risk of Injury Caused by Unsecured Testing Equip‐
ment
If the front passenger airbag deploys during an accident, unse‐
cured testing equipment becomes a dangerous projectile.
– Secure the testing equipment on the rear seat.

or
– Have a second technician operate the testing equipment on
the rear seat.

Cooling System
WARNING
Risk of Scalding Due to Hot Coolant
The cooling system is under pressure when the engine is warm.
Risk of scalding due to hot steam and hot coolant.

– Reduce the pressure by covering the coolant expansion tank
cap with a cloth and carefully opening it.

Exhaust System
WARNING
There is a risk of injury due to the exhaust system components
It is possible to injure hands and other parts of the body due to
hot and sharp-edged components in the exhaust system.
– Allow the exhaust system to cool.

CAUTION
There is a risk of damaging the coupling
Improper handling can cause the coupling to become damaged
or to leak.
– Coupling must not be bent more than 10°.

– Do not load theunless
permitted coupling onbythe
authorised cable.
AUDI AG. AUDI AG does not guarantee or accept any liability
2. Safety Precautions 3
2.6 Safety Precautions when Working on Ig‐

nition System
DANGER
Risk of injury due to electrocution
The ignition system is under high voltage when the engine is
running. It is possible to be electrocuted by touching the ignition
system.
– Never touch or remove the ignition wires when the engine is

running or at cranking speed.
CAUTION
There is a risk of damaging the components.
Washing the engine as well as connecting and disconnecting
wires when the engine is running can damage components.
– Switch off the ignition before connecting and disconnecting

wires.
– Switch off the ignition before washing the engine.

Subframe
CAUTION
Risk of Damaging the Components

If the subframe mount, steering gear or subframe crossbrace is
incorrectly installed resting the vehicle on its wheels can dam‐
age components.
– Never place the vehicle with loosened suspension compo‐

nents on its wheels.
– Never support the vehicle with loosened suspension compo‐
nents on the subframe of subframe crossbrace.

3 Repair Information
⇒ “3.1 Guidelines for Clean Working Conditions”, page 5
⇒ “3.2 Foreign Objects in Engine”, page 5
⇒ “3.3 Contact Corrosion”, page 5
⇒ “3.4 Line Routing and Securing”, page 6
⇒ “3.5 Radiator and Condenser Assembly”, page 6
⇒ “3.6 Bolts and Nuts”, page 6
⇒ “3.7 Identification Plates”, page 6
⇒ “3.8 Impact Wrench, Using”, page 7
3.1 Guidelines for Clean Working Condi‐

tions
Even Small Pieces of Debris Can Cause Faults. Observe the Fol‐
lowing Guidelines for Cleanliness When Working on the Fuel
Supply System, Turbocharger System and Injection System:
♦ Before loosening, the connection points and surrounding
areas must be cleaned thoroughly with engine or brake clean‐
er, and then the cleaned area must be thoroughly dried.
♦ Immediately seal off any open lines and connections with
clean plugs taken from the Engine Bung Set - VAS6122- , for
example.
♦ Place removed parts on a clean surface and cover them with
lint-free cloths.
♦ Carefully cover or seal opened components if repairs are not
performed immediately.
♦ Only install clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been stored out of their original packaging (for ex‐
ample, in tool boxes).
♦ If the system is open, do not work with compressed air and do
not move the vehicle.
♦ Make sure no fuel gets onto the fuel hoses. If necessary, the
fuel hoses must be cleaned again immediately.
♦ Protect any disconnected connectors from dirt and moisture,
and only connect them when they are completely dry.
3.2 Foreign Objects in Engine

♦ To prevent foreign objects from entering when working on the
engine, open intake and exhaust tract channels must always
be sealed off with suitable plugs, for example from the Engine
Bung Set - VAS6122- .
♦ If there is mechanical damage to the turbocharger.
permitted unless authorisedRefer
by AUDItoAG. AUDI AG does not guarantee or accept any liability
⇒ “1.2 Turbocharger, Removing andwithInstalling”, page 194
respect to the correctness .
of information in this document. Copyright by AUDI AG.
3.3 Contact Corrosion

Contact corrosion can occur if incorrect fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating are
installed.
Rubber or plastic parts and adhesives are also made of non-con‐
ductive materials.
3. Repair Information 5
If there are doubts about whether parts can be used or not, then
use new parts. Refer to the Parts Catalog.
Note:
♦ Only original replacement parts are recommended. They are
checked and compatible with aluminum.
♦ The use of Audi accessories is recommended.
♦ Contact corrosion damage is not covered under warranty.
3.4 Line Routing and Securing

♦ Mark the individual fuel, hydraulic and vacuum lines, EVAP
system as well as the wires before removing them. This will
prevent interchanging them and will ensure the original instal‐
lation position. Draw sketches or take pictures of them if
required.
♦ Due to the limited space inside the engine compartment, allow
sufficient clearance to all moving or hot parts to avoid damag‐
ing the lines.
3.5 Radiator and Condenser Assembly

When assembled correctly, the radiator, condenser and turbo‐
charger may have slight impressions on their slats. This is not
damage. Do no replace the cooler, condenser or turbocharger
because of impressions like that.
3.6 Bolts and Nuts

♦ Loosen the bolts opposite the tightening sequence.
♦ Tighten the bolts or the nuts in steps to secure the covers and
housings according to the specified tightening sequence and
methods.
♦ Bolts or nuts which secure covers and housings should be
loosened and tightened diagonally and in steps if no tightening
sequence is specified.
♦ Always replace self-locking nuts and bolts.
♦ If not otherwise specified: clean the threads of the bolts which
were installed with locking fluid with a wire brush. Then insert
the bolts with fluid locking compound. Refer to the Parts Cat‐
alog.
♦ If self-locking bolts were installed or if regular bolts were in‐
stalled with locking fluid, then the threaded holes must be
cleaned, for example with a thread tap. If the holes are not
cleaned, then the bolts could break off the next time they are
removed.
♦ Tightening specifications for non-lubricated bolts and nuts are
given.
3.7 Identification Plates

When replacing vehicle components, the existing identification
plates on the old parts that indicate the replacement part number
(refer to Parts Catalog), must be applied to the new part according
to the specifications.

3.8 Impact Wrench, Using

Removing bolts and nuts is generally allowed using an impact
wrench. Procedures within an open high-voltage battery is exclu‐
ded from this. Generally no impact wrench is permitted for these
procedures.
If the following requirements are met, using an impact wrench to
screw in bolts and nuts is permitted during repair procedures.
Electric and compressed air impact wrenches are generally in‐
tended here.
Requirements:
• Bolts with locking fluid or self-locking nuts must only be
screwed in at low speeds.
• Use a suitable impact wrench with an adjustable speed and
torque range.
• Use suitable screwdriver bits near delicate surfaces, for ex‐
ample, use plastic-coated bits on aluminum rims.
• Note the Natural Gas Fuel Systems - General Information re‐
pair manual when working in a natural gas fuel system area.
Application:
• Position the bolts or nuts by hand.
• Only screw in the bolts or nuts with an impact wrench until the
head of the bolt or nut contacts the surface and then continue
to turn using a torque wrench.
• Clean the threaded pins before removing the bolt or nut.
3. Repair Information 7
10 – Engine Assembly
1 Engine, Removing and Installing
⇒ “1.1 Engine, Removing”, page 8
⇒ “1.2 Engine, Securing to Engine and Transmission Holder”,
page 8
⇒ “1.3 Engine, Installing”, page 9
1.1 Engine, Removing

Refer to ⇒ Rep. Gr. 10 ; Engine, Removing and Installing; En‐
gine, Removing .
1.2 Engine, Securing to Engine and Trans‐

mission Holder
Special tools and workshop equipment required
♦ Engine and Transmission Holder - VAS6095A-
♦ Engine Sling - 2024A-
♦ Shop Crane - VAS6100-
Procedure
• Engine engaged with the -2024A- on the -VAS6100-
• To be aligned to the center of gravity of the assembly, the rails
with holes of the lifting hooks must be inserted as shown.
WARNING
There is a risk of injury from the lifted engine falling.
Parts of the body could be crushed.
– Secure the mounting hooks and pins on the lifting tackle with
a securing pin.
– Remove the drive plate. Refer to

⇒ “2.2 Drive Plate, Removing and Installing”, page 31 .
– Fasten the engine to the -VAS6095/1- using the -VAS6095A- .

Tightening Specification
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Assembling
Assemble in the reverse order of removal. Note the following:
– Install the drive plate. Refer to
8 Rep. Gr.10 - Engine Assembly

1.3 Engine, Installing

Refer to ⇒ Rep. Gr. 10 ; Engine, Removing and Installing; En‐
gine, Installing .
1. Engine, Removing and Installing 9

2 Subframe Mount
Refer to ⇒ Rep. Gr. 10 ; Subframe Mount .

3 Engine Cover
⇒ “3.1 Engine Cover, Removing and Installing”, page 11
3.1 Engine Cover, Removing and Installing

Removal, Version 1
– Remove the engine cover in direction of -arrows-.
Removal, Version 2
– Carefully pull the engine cover off the ball pins one after the
other in direction of -arrows-. Do not pull sharply on the engine
Protected bycover orCopying
copyright. pull itfortoprivate
oneorside.
commercial purposes, in part or in whole, is not
Removal, Version 3
– Remove the engine cover in direction of -arrows-.
Installing
– To prevent damage to the engine cover, do not hit it with a fist
or a tool.
– Pay attention to the oil filler tube when positioning the engine
cover.
– Press on the engine cover with both hands first on the ball pin
in the rear, and then with both hands on the ball pin in the front.
3. Engine Cover 11
4 Special Tools
♦ Holding Fixture - VW540-

13 – Crankshaft, Cylinder Block

1 Cylinder Block, Belt Pulley Side
⇒ “1.1 Overview - Cylinder Block, Belt Pulley Side”, page 13
⇒ “1.2 Ribbed Belt, Removing and Installing”, page 19
⇒ “1.3 Ribbed Belt Tensioner, Removing and Installing”,
page 21
⇒ “1.4 Vibration Damper, Removing and Installing”, page 22
⇒ “1.5 Sub-Assembly Bracket, Removing and Installing”,
page 28
1.1 Overview - Cylinder Block, Belt Pulley

Protected by copyright.Side
Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.1.1
with Overview
respect to - Cylinder
the correctness Block,
of information Belt Pulley
in this document. Side,
Copyright Vehicles
by AUDI AG. with
Hydraulic Power Steering”, page 13
⇒ “1.1.2 Overview - Cylinder Block, Belt Pulley Side, Vehicles with
Electro-Mechanical Power Steering”, page 16
⇒ “1.1.3 Overview - Cylinder Block, Belt Pulley Side, Hybrid Ve‐
hicles”, page 18
1.1.1 Overview - Cylinder Block, Belt Pulley Side, Vehicles with Hydraulic Power
Steering
1. Cylinder Block, Belt Pulley Side 13

1 - Ribbed Belt
❑ Check for wear
❑ Do not kink
❑ Before removing, mark
the running direction us‐
ing chalk or a felt-tip
pen.
❑ Removing and instal‐
ling. Refer to
⇒ “1.2.1 Ribbed Belt,
Removing and Instal‐
ling, Vehicles with Hy‐
draulic Power Steering”,
page 19
❑ Ribbed belt routing. Re‐
fer to
⇒ Fig. ““Ribbed Belt
Routing”“ , page 15 .
❑ When installing, make
sure it is seated correct‐
ly on the belt pulleys
2 - Idler Roller
❑ 20 Nm
3 - Bolt
❑ 150 Nm + 90° Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace after re‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
moving with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Use the Counterhold -

Vibration Damper -
T10355- to loosen and
tighten
❑ Coat the O-ring with en‐
gine oil
4 - O-Ring
❑ Not a replacement part; supplied with the bolt -item 3- ⇒ Item 3 (page 14)
5 - Vibration Damper
❑ With the ribbed belt pulley
❑ Removing and installing. Refer to ⇒ “1.4 Vibration Damper, Removing and Installing”, page 22
6 - Bolt
❑ 40 Nm
7 - Ribbed Belt Tensioner
❑ To release tension on ribbed belt, pivot using a wrench.
❑ Secure with the Belt Tensioner Locking Tool - T40098-
❑ Removing and installing. Refer to
⇒ “1.3.1 Ribbed Belt Tensioning Damper, Removing and Installing, Vehicles with Hydraulic Power Steer‐
ing”, page 21
8 - Sub-Assembly Bracket
❑ With oil filter and engine oil cooler
❑ Removing and installing the sub-assembly bracket. Refer to
⇒ “1.5 Sub-Assembly Bracket, Removing and Installing”, page 28 .
❑ Removing and installing the engine oil cooler. Refer to
⇒ “2.2 Engine Oil Cooler, Removing and Installing”, page 162 .
9 - Generator
❑ Removing and installing. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Generator; Generator, Removing
and Installing .
14 Rep. Gr.13 - Crankshaft, Cylinder Block

10 - Bolt
❑ Tightening specification. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Generator; Overview - Gener‐
ator .
11 - Bolt
❑ Tightening sequence. Refer to ⇒ Fig. ““Sub-Assembly Bracket - Tightening Sequence”“ , page 16 .
12 - Bolt
❑ Tightening specification. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Hydraulic Power
Steering; Overview - Power Steering Pump
13 - Sleeve
14 - Power Steering Pump
❑ Removing and installing. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Hydraulic Power
Steering; Power Steering Pump, Removing and Installing .
15 - A/C Compressor
❑ Do not remove or disconnect the refrigerant lines
❑ Removing and installing. Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; A/C Com‐
pressor; A/C Compressor on Bracket, Removing and Installing .
16 - Bolt
❑ Tightening specification. Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; A/C Com‐
pressor; Overview - A/C Compressor Power Unit .
17 - Alignment Sleeve
❑ For the A/C compressor
❑ Quantity: 2
18 - Bolt
❑ Tightening specification. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Hydraulic Power
Steering; Overview - Power Steering Pump
Ribbed Belt Routing

1- Vibration Damper
2- Idler Roller
3- Ribbed Belt Tensioner
4- Generator
5- Power Steering Pump
6- A/C Compressor

Sub-Assembly Bracket - Tightening Sequence

• Replace the bolts that were tightened with an additional turn
after removing them.
– Mount the sub-assembly bracket and then install the bolts
-4- first.
– Tighten the bolts in the steps shown in the sequence:
Step Bolts Tightening Specification/Additional
Turn
1. -1 through 5- Install by hand all the way
2. -1 through 5- 20 Nm
3. -1 through 5- 90° additional turn
1.1.2 Overview - Cylinder Block, Belt Pulley Side, Vehicles with Electro-Mechan‐
ical Power Steering
1 - Ribbed Belt
❑ Check for wear
❑ Do not kink
❑ Before removing, mark
the running direction us‐
ing chalk or a felt-tip
pen.
ling. Refer to
⇒ “1.2.2 Ribbed Belt,
ling, Vehicles with Elec‐
tro-Mechanical Power
Steering”, page 20
❑ Ribbed belt routing. Re‐
fer to
⇒ Fig. ““Ribbed Belt
Routing”“ , page 17 .
❑ When installing, make
sure it is seated correct‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ly on the belt pulleys permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - Ribbed Belt Tensioner
❑ To release tension on
ribbed belt, pivot using a
wrench.
❑ Secure using the Lock‐
ing Pin - T10060A-
ling. Refer to
⇒ “1.3.2 Ribbed Belt
Tensioning Damper,
ling, Vehicles with Elec‐
tro-Mechanical Power
Steering”, page 22
3 - Bolt
❑ 8 Nm + 45°

❑ Always replace after removing

4 - Bolt
❑ 150 Nm + 90°
❑ Use the Counterhold - Vibration Damper - T10355- to loosen and tighten
❑ Coat the O-ring with engine oil
5 - O-Ring
❑ Not a replacement part; supplied with the bolt -item 4- ⇒ Item 4 (page 17)
❑ With the ribbed belt pulley
❑ Removing and installing. Refer to ⇒ “1.4 Vibration Damper, Removing and Installing”, page 22
❑ With oil filter and engine oil cooler
❑ Removing and installing the sub-assembly bracket. Refer to
⇒ “1.5 Sub-Assembly Bracket, Removing and Installing”, page 28 .
❑ Removing and installing the engine oil cooler. Refer to
⇒ “2.2 Engine Oil Cooler, Removing and Installing”, page 162 .
8 - Seal
9 - Bolt
❑ Tightening specification and sequence. Refer to
⇒ Fig. ““Sub-Assembly Bracket - Tightening Specifications and Sequence”“ , page 18 .
10 - Bolt
❑ Tightening specification. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Generator; Overview - Gener‐
ator .
11 - Generator
❑ Removing and installing. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Generator; Generator, Removing
and Installing .
12 - Alignment Sleeves
❑ For the A/C compressor
13 - A/C Compressor
❑ Do not remove or disconnect the refrigerant lines
14 - Bolt
Ribbed Belt Routing

1- Vibration Damper
2- Ribbed Belt Tensioner
3- Generator
4- A/C Compressor

Sub-Assembly Bracket - Tightening Specifications and Sequence

-4- first.
Turn
1.1.3 Overview - Cylinder Block, Belt Pulley Side, Hybrid Vehicles

1 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 150 Nm + 90°
❑ Always replace after re‐
moving
❑ Lubricate the O-ring
2 - O-Ring
❑ Not a replacement part;
supplied with the bolt
❑ With the ribbed belt pul‐
ley
ling. Refer to
⇒ “1.4 Vibration Damp‐
er, Removing and In‐
stalling”, page 22
❑ With oil filter and engine
oil cooler
❑ Removing and installing
the sub-assembly
bracket. Refer to
⇒ “1.5 Sub-Assembly
Bracket, Removing and
Installing”, page 28 .
❑ Removing and installing
the engine oil cooler.
Refer to
⇒ “2.2 Engine Oil Cool‐
stalling”, page 162 .
5 - Bolts
moving
⇒ Fig. ““Sub-Assembly Bracket - Tightening Sequence”“ , page 19 .

6 - Electrical A/C Compressor - V470-

7 - Electrical A/C Compressor - V470- Bolts
❑ There are different bolt lengths.
Sub-Assembly Bracket - Tightening Sequence

-4- first.
Turn
1.2 Ribbed Belt, Removing and Installing

⇒ “1.2.1 Ribbed Belt, Removing and Installing, Vehicles with Hy‐
draulic Power Steering”, page 19
⇒ “1.2.2 Ribbed Belt, Removing and Installing, Vehicles with
Electro-Mechanical Power Steering”, page 20
1.2.1 Ribbed Belt, Removing and Installing,

Vehicles with Hydraulic Power Steering
♦ Belt Tensioner Locking Tool - T40098-
Removing
WARNING
There is a risk of injury if the radiator fan turns on by itself.
– When performing procedures near the radiator maintain a
distance to the radiator.

CAUTION
Risk of destroying a used ribbed belt by reversing the running
direction.
– Mark the running direction before removal.
– Pay attention to the running direction when reinstalling.
– Turn the tensioner in the direction of -arrow- to release the

tension on the ribbed belt.
– Secure the tensioner with the -T40098- .
– Remove the ribbed belt.
Installing
Install in reverse order of removal and note the following:
– Install the ribbed belt. Refer to
⇒ Fig. ““Ribbed Belt Routing”“ , page 15 .
– Turn the tensioner in direction of -arrow- and remove the -

T40098- .
– Release the tension on the tensioner.
– Check whether the ribbed belt is routed correctly.
– Start the engine and check whether the ribbed belt runs cor‐
rectly.
1.2.2 Ribbed Belt, Removing and Installing,

Vehicles with Electro-Mechanical Power
Steering
♦ Locking Pin - T10060A-
Removing
CAUTION
There Is a Risk of Injury If the Radiator Fan Turns on by Itself.
– When performing procedures near the radiator maintain a
distance to the radiator.

CAUTION
Risk of destroying a used ribbed belt by reversing the running
direction.
– Mark the running direction before removal.
– Pay attention to the running direction when reinstalling.
– Turn the tensioner in the direction of -arrow- to release the

tension on the ribbed belt.
– Lock the tensioner using the -T10060A- .
– Remove the ribbed belt.
Installing
⇒ Fig. ““Ribbed Belt Routing”“ , page 17 .
– Pivot the tensioner slightly clockwise in direction of -arrow- and

remove the -T10060A- .
– Release the tension on the tensioner.
– Check whether the ribbed belt is routed correctly.
– Start the engine and check whether the ribbed belt runs cor‐
rectly.
1.3 Ribbed Belt Tensioner, Removing and

Installing
⇒ “1.3.1 Ribbed Belt Tensioning Damper, Removing and Instal‐
ling, Vehicles with Hydraulic Power Steering”, page 21
⇒ “1.3.2 Ribbed Beltunless
permitted Tensioning
authorised byDamper,
AUDI AG. AUDI Removing
AG does not and Instal‐
guarantee or accept any liability
ling, Vehicles with Electro-Mechanical Power Steering”,
page 22
1.3.1 Ribbed Belt Tensioning Damper, Re‐

moving and Installing, Vehicles with Hy‐
draulic Power Steering
Removing
– Remove the ribbed belt from the tensioner. Refer to
Hydraulic Power Steering”, page 19 .

– Remove the bolt -1- and remove the ribbed belt tensioner from
the sub-assembly bracket.
Installing
Install in reverse order of removal while noting the following:
Hydraulic Power Steering”, page 19 .
Tightening Specifications
♦ Refer to
⇒ “1.1.1 Overview - Cylinder Block, Belt Pulley Side, Vehicles
with Hydraulic Power Steering”, page 13
1.3.2 Ribbed Belt Tensioning Damper, Re‐

moving and Installing, Vehicles with
Electro-Mechanical Power Steering
Removing
– Remove the ribbed belt from the tensioner. Refer to
Electro-Mechanical Power Steering”, page 20 .
– Remove the bolts -arrows- and remove the ribbed belt ten‐
sioner -1- from the sub-assembly bracket.
Installing
Electro-Mechanical Power Steering”, page 20 .
♦ Refer to
with Electro-Mechanical Power Steering”, page 16
1.4 Vibration Damper, Removing and Instal‐

ling
♦ Counterhold - Vibration Damper - T10355-
♦ Vibration Damper Assembly Tool - T10531-
♦ Wrench - 21mm - T40263-
♦ Adapter - T40314- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ 24 mm Socket with respect to the correctness of information in this document. Copyright by AUDI AG.

Individual Components of the -T10531- :

♦ Vibration Damper Assembly Tool - Counterhold Tool -
T10531/1-
♦ Vibration Damper Assembly Tool - Tensioning Pins -
T10531/2-
♦ Vibration Damper Assembly Tool - Turning Over Tool -
T10531/3-
♦ Vibration Damper Assembly Tool - Knurled Nut - T10531/4-
• The vibration damper bolt -A- connects the vibration damper
-1-, the timing chain sprocket -2- and the crankshaft -3- with
each other. Before removing the bolt, the chain sprocket must
be secured to the crankshaft as described in the following.
Removing
Depending on the model, preliminary work may be required. Refer
to ⇒ Rep. Gr. 13 ; Cylinder Block, Belt Pulley Side; Vibration
Damper, Removing and Installing .
– Non-hybrid vehicles: remove the ribbed belt. While doing so,

do not lock the tensioner. Refer to by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
⇒ “1.2 Ribbed Belt, Removingpermitted
and Installing”, page
unless authorised 19AG.
by AUDI . AUDI AG does not guarantee or accept any liability
CAUTION
Risk of damaging the engine by the timing mechanism skipping.
– Only let the engine turn in the direction of engine rotation.
– Turn the crankshaft using the -T40263- , -T40314- and the 24

mm socket in the direction of engine rotation -arrow- until the
vibration damper is at “TDC”.
• The notch -1- on the vibration damper must align with the ar‐
row marking -2- on the lower timing chain cover.
• The mark on the lower timing chain cover is located in the
»four-o'clock position«.
• The vibration damper bolt can only be loosened maximum 1/
2 turn.
– Position the -T10355- and loosen the vibration damper bolts

approximately 1/2 turn.
– If the vibration damper is turned, correct it to the TDC point.

– Remove the bolts -arrows- for the lower timing chain cover.
– Place the -T10531/1- as shown on the vibration damper and

tighten it hand-tight using the knurled bolts -arrows-.
• The arrow marking on the - T10531/1- must point upward.
– Remove the vibration damper bolt completely.
– Check if the - T10531/3- -A- can be easily pushed over the

clamping piece -B-. If necessary turn the adjusting bolt
-arrow-.
• Do not turn the tensioning bolt further, otherwise the -
T10531/2- becomes jammed when installing in the crankshaft
– Install the -T10531/2- in the crankshaft and tighten it hand-tight

using a 12 mm open end wrench -A-.

– Tighten the adjusting bolt -A- hand-tight, to secure the chain

sprocket to the crankshaft.
– Remove the knurled bolts -arrows-. Remove the -T10531/1-

and vibration damper -A-.
If the Crankshaft Should Be Turned without the Vibration Damper:

– Place the -T10531/3- -A- on the -T10531/2- and pay attention
to the chain sprocket tooth contour while doing so.
• The flat side of the tool is at the top in “TDC”.
– Tighten the turning over tool using the -T10531/4- -B-.
– The crankshaft permitted
can now beauthorised
unless turnedbyatAUDI
theAG.
hex fitting
AUDI -arrow-.
AG does not guarantee or accept any liability

Installing
• Replace the bolt with the O-ring after removing.
– If necessary, remove the -T10531/4- -B- and -T10531/3- -A-
from the -T10531/2- .
– Attach the vibration damper in TDC. While doing so, pay at‐
tention to the tooth contour of the chain sprocket -arrow-.
– Place the -T10531/3- -A- on the -T10531/2- .
• At the same time the hex fitting points to the vibration damper.
– Install the -T10531/4- -B-. While doing so, move the vibration
damper back and forth slightly to check if the vibration damper
is seated correctly in the tooth contour.
– Tighten the knurled nut until the vibration damper can no lon‐
ger be turned.
– Place the -T10531/1- as shown on the vibration damper and

tighten hand-tight using the knurled bolt -arrows-.
• The arrow marking on the - T10531/1- must point upward.

– Remove the -T10531/4- -A- and loosen the tensioning pin

-B-.
– Unscrew the -T10531/2- and remove it with the -T10531/3- .
– Install a new vibration damper bolt hand-tight with an oiled O-

ring -1-.
– Remove the knurled bolts -arrows- and remove the -

T10531/1- .
– Position the -T10355- and tighten the vibration damper bolts.

Further installation is performed in reverse order of removal, while

noting the following:
• Replace the timing chain cover bolts -arrows- after removing.
– Non-hybrid vehicles: install the ribbed belt. Refer to
⇒ “1.2 Ribbed Belt, Removing and Installing”, page 19 .
There are additional procedures depending on the model. Refer
to ⇒ Rep. Gr. 13 ; Cylinder Block, Belt Pulley Side; Vibration
Damper, Removing and Installing .
♦ Refer to
⇒ “1.1 Overview - Cylinder Block, Belt Pulley Side”, page 13
♦ Refer to
⇒ Fig. ““Lower Timing Chain Cover with 15 Bolts - Tightening
Specification and Sequence”“ , page 67
♦ Refer to
1.5 Sub-Assembly Bracket, Removing and

Installing
Removing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to ⇒ Rep. Gr. 13 ; Cylinder Block, Belt Pulley Side; Sub-Assembly
Bracket, Removing and Installing .
– Remove the oil filter. Refer to ⇒ “1.2 Engine Oil”, page 154 .
– Place a cloth under the sub-assembly bracket to catch any
escaping engine oil.
– Remove the bolt -arrow- for the oil dipstick tube.
– Remove the bolts -1 through 5- and pull off the sub-assembly
bracket from the coolant pump housing.
Note
There are different designs depending on the engine.
Installing
• Replace the O-ring and seals after removing.
• Used coolant cannot be used again.

– Coat the new O-rings -4- with coolant additive.

– Insert the connection -2- into the coolant pump housing -3-.
– Slide the sub-assembly bracket -1- onto the connection and
then install and tighten the bolts.
– Install the oil filter. Refer to ⇒ “1.2 Engine Oil”, page 154 .
to ⇒ Rep. Gr. 13 ; Cylinder Block, Belt Pulley Side; Sub-Assembly
Bracket, Removing and Installing .
♦ Refer to
with Hydraulic Power Steering”, page 13
♦ Refer to
with Electro-Mechanical Power Steering”, page 16
♦ Refer to
⇒ “1.1.3 Overview - Cylinder Block, Belt Pulley Side, Hybrid
Vehicles”, page 18
♦ Oil Dipstick Tube. Refer to
⇒ “1.1 Overview - Timing Chain Cover”, page 66 .

2 Cylinder Block, Transmission Side

⇒ “2.1 Overview - Cylinder Block, Transmission Side”,
page 30
⇒ “2.2 Drive Plate, Removing and Installing”, page 31
⇒ “2.3 Transmission Side Sealing Flange, Removing and Instal‐
ling, Oil Side Sealing Lip”, page 32
⇒ “2.4 Needle Bearing in Drive Plate, Replacing”, page 35
2.1 Overview - Cylinder Block, Transmission Side
1 - Cylinder Block
2 - Alignment Sleeves
3 - Transmission Side Sealing
Flange
❑ With gasket
moving
❑ Do not apply oil to the
seal.
❑ Before installing, re‐
move oil residue from
crankshaft journal with a
clean cloth
❑ Removing and Instal‐
ling. Refer to
⇒ “2.3 Transmission
Side Sealing Flange,
ling, Oil Side Sealing
Lip”, page 32 .
4 - Bolt
❑ Tightening Specifica‐
tions and Sequence
♦ With 6 bolts. Refer to
⇒ Fig. ““Transmission Side Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Sealing Flange with Six permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Bolts - Tightening Specifi‐
cations and Sequence”“ ,
page 31 .
♦ With 8 bolts. Refer to
⇒ Fig. ““Transmission Side
Sealing Flange with Eight
Bolts - Tightening Specifi‐
cations and Sequence”“ ,
page 31 .
5 - Drive Plate
❑ Removing and installing. Refer to ⇒ “2.2 Drive Plate, Removing and Installing”, page 31
❑ Equipment versions with a manual transmission must have a needle bearing inside the drive plate; if
necessary install the needle bearing. Refer to
⇒ “2.4 Needle Bearing in Drive Plate, Replacing”, page 35 .
❑ For equipment version with a dual-clutch transmission/automatic transmission, then do not install a nee‐
dle bearing inside the crankshaft. Remove the needle bearing if necessary. Refer to
6 - Bolt
❑ 60 Nm + 90°


7 - Needle Bearing
❑ Equipment version with manual transmission
❑ Replacing. Refer to ⇒ “2.4 Needle Bearing in Drive Plate, Replacing”, page 35 .
8 - Intermediate Plate
❑ Installing. Refer to ⇒ Fig. ““Intermediate Plate, Installing”“ , page 31 .
Transmission Side Sealing Flange with Six Bolts - Tightening

Specifications and Sequence
after removing
Protected them.for private or commercial purposes, in part or in whole, is not
by copyright. Copying
– Tighten the
with respect bolts
to the in the
correctness steps shown
of information in the Copyright
in this document. sequence:by AUDI AG.
Step Bolts Tightening Specifications

1. -1 to 6- Install by hand all the way
2. -1 to 6- Aluminum bolts: 4 Nm
Steel bolts: 9 Nm
3. -1 to 6- Aluminum bolts: 45° additional turn
TIP:
Only six bolts are installed, two bolt openings remain open.
Transmission Side Sealing Flange with Eight Bolts - Tightening

Specifications and Sequence
Step Bolts Tightening Specifications
2. -1 to 8- 9 Nm
Intermediate Plate, Installing

– Hang the intermediate plate on the sealing flange
-arrow upper- and slide it on the alignment sleeves
-arrows lower-.
2.2 Drive Plate, Removing and Installing

♦ Counterhold - Flywheel - 10-201-
♦ Internal multi-point socket with at least a 40 mm shaft length.
2. Cylinder Block, Transmission Side 31

Removing
• Transmission removed. Refer to ⇒ Transmission; Rep. Gr.
34 ; Transmission, Removing and Installing; Transmission,
Removing or ⇒ Automatic Transmission; Rep. Gr. 37 ; Trans‐
mission, Removing and Installing; Transmission, Removing .
– Insert the -10-201- to loosen the bolts.
NOTICE
Risk of Damaging the Drive Plate by Using an Unsuitable Tool
– When loosening and tightening the bolts, do not damage the
drive plate centering flange.
– Remove the drive plate bolts -1- using an internal multi-point

socket with at least a 40 mm shaft length.
Installing
• Manual transmission vehicles have a needle bearing inside
the drive plate. Check before installing that the needle bearing
is used. Remove needle bearing from drive plate and install.
Refer to
– Pay attention to the alignment pin when installing the drive
plate. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Reposition the -10-201- to tighten the bolts.
♦ Refer to
⇒ “2.1 Overview - Cylinder Block, Transmission Side”,
page 30
2.3 Transmission Side Sealing Flange, Re‐

moving and Installing, Oil Side Sealing
Lip
♦ Crank Shaft Seal Installer - Guide Piece - T10122/6- or Crank
Shaft Seal Installer - Guide Piece - T10122/6A- from the
Crankshaft Seal Installer Kit - T10122B- or Assembly Device
- T10122C-
♦ Guide Piece to Crankshaft Seal Install Kit - Guide Piece -
T10122/1- from the Crankshaft Seal Installer Kit - T10122B-
or Assembly Device - T10122C-
♦ Sealant . Refer to the Parts Catalog.
♦ Hand Drill with Plastic Brush Attachment
♦ Protective Eyewear
Removing
• Non-hybrid vehicles: transmission removed. Refer to ⇒ Trans‐
mission; Rep. Gr. 34 ; Transmission, Removing and Installing;
Transmission, Removing or ⇒ Automatic Transmission; Rep.
Gr. 37 ; Transmission, Removing and Installing; Transmis‐
sion, Removing .
• Hybrid vehicles: engine is removed and is secured on the En‐
gine and Transmission Holder - VAS6095A- . Refer to


page 8 .
– Unhook the intermediate plate from the sealing flange and at
the alignment sleeves -arrows-.
– Remove the bolts -1 through 8-. (There is also equipment with

only six bolts depending on the version).
– Pry out the sealing flange.
Installing
• Replace the sealing flange after removal.
To prevent contamination of the lubricating system with sealant
residue, place a clean cloth over the open part of the oil pan.
CAUTION
Risk of Injuring the Eyes from Sealant Residue
– Remove any remaining sealant from the cylinder block -1- us‐
ing, for example, a rotating plastic brush.
– Clean any oil and grease off of the sealing surfaces and crank‐
shaft journal.
TIP:
Be sure to check the expiration date of the sealant.
– Cut the tube nozzle at the front marking (nozzle diameter: ap‐
proximately 2 mm).

NOTICE
Risk of Engine Damage Due to Excess Sealant in the Lubrica‐
tion System
– Do not apply sealant bead thicker than indicated.
• Sealant bead thickness: 2 to 3 mm.

• The sealing flange must be installed within five minutes of ap‐
plying the sealant.
• The sealing lip must be pointed
with respect to theofengine
to the correctness informationafter
in this installing.
document. Copyright by AUDI AG.
If the sealing lip »folds« outward when installing, leaks will re‐
sult.
– Check the -T10122/6A- -B-; it must not be tilted or contami‐

nated.
– Mount the -T10122/1- -A- on the -T10122/6A- -B- in direction
of -arrow-.
– Slide the Sealing Flange -C- on the Guide Piece -B-, with the
outer side on it in direction of -arrow-.
– Remove Guide Piece -A-.

– Place the Guide Piece -A- with the Sealing Flange -B- on the
crankshaft journal.
TIP:
It is not necessary to tighten the bolts -arrows-
– Slide the Sealing Flange -B- through the Guide Piece -A- on
the crankshaft journal.
– Remove the Guide Piece -A-.
– Tighten the sealing flange.
• After installing the sealing flange, the sealant must harden for
approximately 30 minutes. Only afterward may the engine oil
be replenished.
– Install the intermediate plate. Refer to
⇒ Fig. ““Intermediate Plate, Installing”“ , page 31 .
– Install the drive plate. Refer to
– Check the oil level. Refer to ⇒ “1.2 Engine Oil”, page 154 .
Tightening Specifications permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Refer to
⇒ Fig. ““Transmission Side Sealing Flange with Six Bolts -
Tightening Specifications and Sequence”“ , page 31
♦ Refer to
⇒ Fig. ““Transmission Side Sealing Flange with Eight Bolts -
Tightening Specifications and Sequence”“ , page 31
2.4 Needle Bearing in Drive Plate, Replac‐

ing
♦ Press Piece - 31.5mm - VW418A-
♦ Press Piece - 28x100mm - VW421-
♦ Bearing Installer - Multiple Use - 40-103-
Only available with the manual transmission a needle bearing is
installed in the drive plate.
Procedure
• The transmission is removed. Refer to ⇒ Transmission; Rep.
Gr. 34 ; Transmission, Removing and Installing; Transmis‐
sion, Removing .

– Place the -40-103- under the drive plate to remove and install.
– Press out the needle bearing using the -VW421- and work‐
shop press.
• The smaller diameter of the -VW421- faces the drive plate.
– Carefully press the needle bearing in all the way using the -
VW418A- and workshop press.
• Installed position: the closed side of the needle bearing faces
the engine.
– Install the todrive
with respect plate. Refer
the correctness to in this document. Copyright by AUDI AG.
of information

3 Crankshaft
⇒ “3.1 Overview - Crankshaft”, page 37
⇒ “3.2 Crankshaft Dimensions”, page 39
⇒ “3.3 Main Bearing Shells Allocation”, page 39
⇒ “3.4 Crankshaft, Measuring Axial Clearance”, page 40
⇒ “3.5 Crankshaft, Measuring Radial Clearance”, page 41
⇒ “3.6 Sensor Wheel, Removing and Installing”, page 41
3.1 Overview - Crankshaft
1 - Cylinder Block
2 - Cylinder Block Bearing
Shell
❑ With oil groove
❑ Replace any worn bear‐
ing shells
❑ Crankshaft bearing
shells identification
(classification). Refer to
⇒ “3.3 Main Bearing
Shells Allocation”,
pagepermitted
39 . unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Lubricate with engine oil
3 - Crankshaft
❑ For assembly work, se‐
cure the engine on the
Engine and Transmis‐
sion Holder -
VAS6095A- . Refer to
⇒ “1.2 Engine, Securing
to Engine and Trans‐
mission Holder”,
page 8 .
❑ After removing, set it
aside so that the sensor
wheel -item 8-
⇒ Item 8 (page 38) is
not rested on and be‐
comes damaged
❑ If the crankshaft is being
replaced, then the bear‐
ing shells must be real‐
located to the bearing
cap. Refer to
⇒ “3.3 Main Bearing
Shells Allocation”,
page 39 .
❑ Axial play, measuring. Refer to ⇒ “3.4 Crankshaft, Measuring Axial Clearance”, page 40 .
❑ Radial play, measuring. Refer to ⇒ “3.5 Crankshaft, Measuring Radial Clearance”, page 41 .
❑ Crankshaft dimensions. Refer to ⇒ “3.2 Crankshaft Dimensions”, page 39 .
4 - Bearing Shell for Bearing Cap
❑ Without oil groove
❑ Replace any worn bearing shells
❑ Crankshaft bearing shells identification (classification). Refer to
⇒ “3.3 Main Bearing Shells Allocation”, page 39 .
3. Crankshaft 37

5 - Bolt
❑ Use the old bolts for radial clearance measurement
❑ Tightening Specifications and Sequence. Refer to
⇒ Fig. ““Crankshaft - Tightening Specifications and Sequence”“ , page 38 .
6 - Bearing Cap
❑ Bearing cap 1: belt pulley side
❑ Bearing caps 2, 3 and 4 also installed on the side
❑ Retaining tabs for cylinder block/bearing cap bearing shells must lie above one another
❑ Mark the installation position for reinstallation. Refer to
⇒ Fig. ““Crankshaft Bearing Cap Identification”“ , page 39 .
7 - Bolt
❑ 10 Nm + 90°
❑ Replace the sensor wheel -item 8- ⇒ Item 8 (page 38) every time the bolts are loosened. Refer to
⇒ “3.6 Sensor Wheel, Removing and Installing”, page 41 .
8 - Sensor Wheel
❑ For Engine Speed Sensor - G28- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Only possible to install in one position - holes are offset -
❑ Replace the sensor wheel every time the bolts -item 7- ⇒ Item 7 (page 38) are loosened
❑ Removing and installing. Refer to ⇒ “3.6 Sensor Wheel, Removing and Installing”, page 41
❑ After replacing, perform an “adaptation”. Refer to Vehicle Diagnostic Tester , Guided Functions
9 - Thrust Washers
❑ For bearing 3
10 - Bolt
⇒ Fig. ““Crankshaft - Tightening Specifications and Sequence”“ , page 38 .
Crankshaft - Tightening Specifications and Sequence

Turn
1. -1 to 10- and Install by hand all the way
-A arrows-
2. -1 through 10- 65 Nm
4. -A arrows- 15 Nm
5. -A arrows- 90° additional turn

Crankshaft Bearing Cap Identification

– Mark the installation position of the bearing cap -1 through 5-
for reinstallation.
3.2 Crankshaft Dimensions

Reconditioning Crankshaft Bearing Connecting Rod
Dimension 1) Pin Diameter in mm Bearing
Pin Diameter in mm
Standard dimen‐ 58.00 47.80
sion
1) The preparation of worn crankshafts is not possible at this time.
3.3 Main Bearing Shells Allocation
♦ The bearing shells are allocated to the cylinder block with the
correct thickness at the factory. Colored dots are used to iden‐
tify the bearing shell thickness.
♦ The letters on the lower sealing surface or on the front side of
the cylinder block indicate which bearing shell must be inser‐
ted at which position in the cylinder block (upper bearing shell).
♦ The letters on the crankshaft indicate which bearing shell must
be inserted at which position in the bearing cap (lower bearing
shell).
♦ The first letter is for bearing cap one, the second for bearing
cap two, etc.
Cylinder Block Bearing Shell Identification:
The cylinder block identification may be engraved either on the
oil pan sealing surface or on the front side (transmission side) of
the cylinder block.
3. Crankshaft 39
The identification on the cylinder block is for the upper bearing

shell (cylinder block bearing shell).
– Note the letters and then match them to the color identification
in the table.
G = Yellow
R = Red
S = Black
VI = Purple
WS = White
Color coding depending on the version. Refer to the Parts Catalog
for the allocation.
Bearing Cap Bearing Shell Identification:

The identification on the crankshaft is for the lower bearing shell
(bearing cap bearing shell)
– Note the letters and then match them to the color identification
in the table.
R = Red
G = Yellow
B = Blue
W = White
V = Purple
S = Black
Color coding depending on the version. Refer to the Parts Catalog
for the allocation.
3.4 Crankshaft, Measuring Axial Clearance

♦ Dial Indicator Holder - VW387-
♦ Dial Gauge - 0-10mm - VAS6079-
Procedure
– Attach the -VAS6079- with the -VW387- to the cylinder block
and set indicator against crankshaft counterweight.
– Press the crankshaft against the dial gauge by hand and set
the dial gauge to “0”.
– Press the crankshaft off the dial gauge and read the meas‐
urement.
Axial clearance:
• New: 0.070 to 0.231 mm.
• Wear limit: 0.30 mm.

3.5 Crankshaft, Measuring Radial Clear‐

ance
♦ Plastigauge®
Procedure
• Use the old bolts for radial clearance measurement.
– Remove the crankshaft bearing cap and clean the bearing cap
and pin.
– Place the Plastigauge® over the entire bearing width on the
pin or in the bearing shells.
• Plastigauge® must rest in the center of the bearing shell.
– Mount the crankshaft bearing cap and tighten with the old bolts
-1 to 10- (refer to
⇒ Fig. ““Crankshaft - Tightening Specifications and Se‐
quence”“ , page 38 ). Do not turn the crankshaft while doing
so.
– Remove the crankshaft bearing cap again.
– Compare the width of Plastigauge® with the measuring scale.
Radial clearance:
• New: 0.017 to 0.037 mm.
– Replace the bolts for the final assembly.
3.6 Sensor Wheel, Removing and Installing

Removing
• The engine is secured to the -VAS6095A- . Refer to
page 8 .
– Remove the oil pan upper section. Refer to
⇒ “1.5 Oil Pan Upper Section, Removing and Installing”, page
157 .
– Remove the balance shaft timing chain. Refer to
⇒ “2.5 Camshaft Timing Chain, Removing and Installing”,
page 90 .
– Remove the connecting rod bearing cap.
– Remove the crankshaft bearing cap.
– Remove the crankshaft and the sensor wheel.
Installing
3. Crankshaft 41
– Always replace the sensor wheel -2- each time the bolts -1-
are loosened.
TIP:
After tightening a second time, the attachment point of the coun‐
tersunk bolts in the sensor wheel is so deformed that the bolt
heads are at the crankshaft -3- -arrows- and the sensor wheel is
loose under the bolts.
• Installation of sensor wheel is only possible in one position -
the bores are offset.
– Install the balance shaft timing chain. Refer to
page 90 .
– Install the oil pan upper section. Refer to
157 .
– If the sensor wheel was replaced, perform an “adaptation”.
Refer to Vehicle Diagnostic Tester in Guided Functions .
♦ Refer to ⇒ “3.1 Overview - Crankshaft”, page 37

4 Balance Shaft
⇒ “4.1 Overview - Balance Shaft”, page 43
⇒ “4.2 Balance Shaft, Removing and Installing”, page 44
⇒ “4.3 Balance Shaft Gasket, Replacing, Intake Side”,
page 49
4.1 Overview - Balance Shaft
1 - Bolt
❑ 9 Nm
moving
2 - Balance Shaft
moving
❑ Intake side
❑ Lubricate the bearing
with engine oil
❑ Replacing. Refer to
⇒ “4.2.1 Balance Shaft,
ling, Intake Side”,
page 44 .
3 - Balance Shaft
moving
❑ Exhaust side
with engine oil
⇒ “4.2.2 Balance Shaft,
ling, Exhaust Side”,
page 47 .
4 - Bolt
❑ 9 Nm
moving
5 - Balance Shaft Pipe
❑ Installation position. Re‐
fer to
⇒ Fig. ““Balance Shaft Pipe Installation Position”“ , page 44 .
6 - Exhaust Side Balance Shaft Seal
❑ Replacing. Refer to ⇒ “4.3 Balance Shaft Gasket, Replacing, Intake Side”, page 49 .
4. Balance Shaft 43
Balance Shaft Pipe Installation Position

• The pin from the balance shaft pipe must fit into the groove
-arrow-.
4.2 Balance Shaft, Removing and Installing

⇒ “4.2.1 Balance Shaft, Removing and Installing, Intake Side”,
page 44
⇒ “4.2.2 Balance Shaft, Removing and Installing, Exhaust Side”,
page 47
4.2.1 Balance Shaft, Removing and Installing,

Intake Side
♦ Puller - Unit Injector - T10055-
♦ Puller - Balancer Shaft - T10394-
♦ Puller Jaw - T10394/1-
Removing
– Remove the radiator. Refer to ⇒ Rep. Gr. 19 ; Radiator/Ra‐
diator Fan; Radiator, Removing and Installing .
– Remove the coolant pump toothed belt. Refer to
⇒ “2.5 Coolant Pump Toothed Belt, Removing and Installing”,
page 181 .
– Remove the balance shaft drive chain. Refer to
⇒ “2.6 Balance Shaft Drive Chain, Removing and Installing”,
page 99 .
– Remove the bolt -2-.
– Remove the drive wheel -1- for the coolant pump toothed belt.

– Remove the bolt -1- and the intermediate shaft sprocket.

– Remove the mounting pin.
– Remove the bolt -2- on the intake camshaft balance shaft.
– Insert the - T10394/1- from the -T10394- and turn upward in

the direction of the -arrow-.
– Insert the -T10394- and push the sliding sleeve in the direction
of -arrow-.
4. Balance Shaft 45
– Install the -T10055- into the -T10394- and remove the balance
shaft in the direction of -arrow-.
Installing
• The intake side balance shaft must be replaced after removal.
• Because of the small play between
Protected bythe balance
copyright. shaft
Copying andorcyl‐
for private commercial purposes, in part or in whole, is not
inder block, the balance shaft may unless
permitted needauthorised
to be cooled in AUDI
by AUDI AG. order AG does not guarantee or accept any liability
to install it. Check if the balancewithshaft
respectcan
to the be inserted
correctness into the
cylinder block without forcing it in. If this is not the case, then
the balance shaft must be installed cooled.
– Place the new balance shaft in a freezer for 30 minutes or
spray it with commercially available cooling spray.
– Lubricate the balance shaft bearing with engine oil.
– Install the new intake camshaft balance shaft and tighten the
bolt -2-.
– Coat the new O-ring -1- with engine oil.

– Coat the mounting pin with engine oil and insert.
• The alignment pin -arrow- for the bearing pins must engage in
the hole in the cylinder block.
NOTICE
There Is a Risk of Destroying the Engine When the Intermediate
Sprocket Is Missing Backlash.
The New Intermediate Sprocket Has an Anti-Friction Coating
That Wears off after a Short Period of Use, Which Automatically
Adjusts the Backlash.
– Never reuse the intermediate sprocket.
TIP:
The new intermediate sprocket has an anti-friction coating that
wears off after a short period of use, which automatically adjusts
the backlash.
– Mark the tooth flank on the intermediate sprocket with a color

-arrow-.
– Install the intermediate sprocket; the marking on the balance
shaft must be between the markings on the tooth flanks.

– Tighten the bolt -1- for the intermediate sprocket. Refer to

⇒ Fig. ““Intermediate Sprocket Tightening Sequence”“ ,
page 77 or the tightening sequence.
– Check the markings on the intermediate sprocket/balance
shaft -arrow-.
– Install the balance shaft drive chain. Refer to
page 99 .
– Replace the balance shaft intake side seal. Refer to
⇒ “4.3 Balance Shaft Gasket, Replacing, Intake Side”,
page 49 .
– Install the coolant pump toothed belt. Refer to
page 181 .
– Install the radiator. Refer to ⇒ Rep. Gr. 19 ; Radiator/Radiator
Fan; Radiator, Removing and Installing .
♦ Refer to
⇒ Fig. ““Intermediate Sprocket Tightening Sequence”“ ,
page 77
♦ Refer to
⇒ “2.2 Overview - Balance Shaft Drive Chain”, page 76
♦ Refer tounless
permitted ⇒ “4.1 Overview
authorised - Balance
by AUDI AG. Shaft”,
AUDI AG does page or43
not guarantee accept any liability
4.2.2 Balance Shaft, Removing and Installing,

Exhaust Side
Removing
– Remove the radiator. Refer to ⇒ Rep. Gr. 19 ; Radiator/Ra‐
diator Fan; Radiator, Removing and Installing .
– Remove the balance shaft drive chain. Refer to
page 99 .
– Remove the bolt -1- on the exhaust camshaft balance shaft.
4. Balance Shaft 47
– Insert the -T10394/1- from the -T10394- .
– Insert the -T10394- and push the sliding sleeve in the direction
of -arrow-.
– Install the -T10055- into the -T10394- and remove the balance
shaft.
Installing
• The exhaust side balance shaft must be replaced after remov‐
al.
• Because of the small play between the balance shaft and cyl‐
inder block, the balance shaft may need to be cooled in order
to install it. Check if the balance shaft can be inserted into the
cylinder block without forcing it in. If this is not the case, then
the balance shaft must be installed cooled.
– Check the installation position for the balance shaft pipe.

The pin -arrow- must engage in the groove.
– Place the new balance shaft in a freezer for 30 minutes or
spray it with commercially available cooling spray.
– Lubricate the balance shaft bearing with engine oil.

– Install the new balance shaft for the exhaust side.

– Before tightening the bolt -1- make sure the balance shaft lies
level on the crankcase.
Note
If the balance shaft is not level, then the pipe for the balance shaft
must be installed again.

– Install
with the balance
respect shaft ofdrive
to the correctness chain.
information Refer
in this to Copyright by AUDI AG.
document.
page 99 .
– Install the radiator. Refer to ⇒ Rep. Gr. 19 ; Radiator/Radiator
Fan; Radiator, Removing and Installing .
♦ Refer to
♦ Refer to ⇒ “4.1 Overview - Balance Shaft”, page 43
4.3 Balance Shaft Gasket, Replacing, In‐

take Side
♦ Seal Installer, Intermediate Shaft - T10356/1-
♦ Seal Installer - Intermediate Shaft - T10353-
♦ Seal Installer - Intermediate Shaft - T10353/1-
Procedure
– Remove the small coolant pipe. Refer to ⇒ Rep. Gr. 19 ;
Coolant Pipes; Coolant Pipes, Removing and Installing .
page 181 .
TIP:
The drive wheel bolt has left-hand thread.
– Remove the bolt -2- and then remove the drive wheel -1- for
the coolant pump toothed belt.
4. Balance Shaft 49
– Firmly press a screwdriver -1- on the surface of the sealing

ring -2- in direction of -arrow B-.
– Pry out the sealing ring in direction of -arrow A-.
– Clean the contact and sealing surface.
– Coat the sealing surface of the balance shaft -2- with trans‐
mission fluid.
– Push the sealing ring -1- onto the balance shaft.
• “Luftseite” or (“Outside”) -arrow- must be readable from the
outside.
TIP:
– Mount the -T10353- or -T10353/1- on the seal -1- and then
tighten it all the way into the cylinder block with the bolt -2-. Be
careful not to tilt the seal when doing this.
page 181 .
– Install the small coolant pipe. Refer to ⇒ Rep. Gr. 19 ; Coolant
Pipes; Coolant Pipes, Removing and Installing .

5 Pistons and Connecting Rod

⇒ “5.1 Overview - Pistons and Connecting Rod”, page 51
⇒ “5.2 Pistons, Removing and Installing”, page 54
⇒ “5.3 Oil Spray Jets, Removing and Installing”, page 55
⇒ “5.4 Piston and Cylinder Bore, Checking”, page 57
⇒ “5.5 New Connecting Rod, Separating”, page 59
⇒ “5.6 Connecting Rods, Checking Radial Clearance”,
page 59
5.1 Overview - Pistons and Connecting Rod

1 - Bolts permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ M8 Bolt: 30 Nm +90°
♦ M9 Bolt: 45 Nm +90°
❑ Replace after removing.
❑ Lubricate the threads
and contact surface.
❑ Use the old bolts for ra‐
dial clearance measure‐
ment
2 - Connecting Rod Bearing
Cap
❑ Note the installation po‐
sition
❑ Due to the separation
procedure (cracking) of
the connecting rod, the
connecting rod bearing
cap only fits in one posi‐
tion and only to the cor‐
responding connecting
rod.
❑ Use a color to mark the
cylinder and connecting
rod to which it belongs
-A-
❑ Installation position: the
marks -B- face the belt
pulley side
❑ Separating the new con‐
necting rod. Refer to
⇒ “5.5 New Connecting
Rod, Separating”,
page 59 .
3 - Bearing Shells
❑ Replace any worn bear‐
ing shells
❑ Installation position. Refer to ⇒ Fig. ““Bearing shell installation position”“ , page 54 .
❑ Coat with engine oil before installing
❑ Axial clearance
♦ New: 0.10 to 0.35 mm
♦ Wear limit: 0.40 mm.
❑ Radial play, measuring. Refer to ⇒ “5.6 Connecting Rods, Checking Radial Clearance”, page 59 .
5. Pistons and Connecting Rod 51

4 - Connecting Rod
❑ Always replace as a set
❑ Identify the cylinder and connecting rod bearing cap to which it belongs
❑ Installation position: the marks -B- face the belt pulley side
❑ Separating the new connecting rod. Refer to ⇒ “5.5 New Connecting Rod, Separating”, page 59 .
❑ Radial play, measuring. Refer to ⇒ “5.6 Connecting Rods, Checking Radial Clearance”, page 59 .
5 - Relief Valve
❑ 27 Nm
6 - Oil Spray Jet
❑ For piston cooling
❑ Removing and Installing. Refer to ⇒ “5.3 Oil Spray Jets, Removing and Installing”, page 55 .
7 - Circlip
8 - Piston Pin
❑ Coat with engine oil before installing
9 - Piston
❑ Removing and Installing. Refer to ⇒ “5.2 Pistons, Removing and Installing”, page 54 .
❑ Mark the installation position and cylinder allocation
❑ Arrow on piston crown points toward belt pulley side
❑ Check piston and cylinder bore. Refer to ⇒ “5.4 Piston and Cylinder Bore, Checking”, page 57 .
10 - Compression Rings
❑ Install with Piston Ring Pliers -VAS211 003- . Refer to
⇒ Fig. ““Installing the compression ring”“ , page 53 .
❑ Offset gaps by 120°
❑ Installation position in connection with two-piece oil scraping ring: installation position “TOP” “R” must
point to the piston crown
❑ Allocation and installation position in connection with three part oil scraping ring. Refer to
⇒ Fig. ““Allocation of the piston ring in connection with the three-part oil scraping ring”“ , page 53 .
❑ Checking the piston ring gap. Refer to ⇒ Fig. ““Piston Ring Gap, Checking”“ , page 57 .
❑ Checking the groove clearance. Refer to
⇒ Fig. ““Piston Ring Groove Clearance, Checking”“ , page 58 .
11 - Oil Scraping Ring
❑ Depending on the version two or three part. Refer to the Parts Catalog for the allocation.
❑ Two-Piece Oil Scraping Ring:
♦ Install offset gaps by 120° to the neighboring compression ring
♦ The “TOP” or “R” marking must face toward the piston crown.
♦ Checking the piston ring gap. Refer to ⇒ Fig. ““Piston Ring Gap, Checking”“ , page 57 .
♦ Height clearance cannot be measured
❑ Three Part Oil Scraping Ring:
♦ Remove and install carefully by hand
♦ Installation position. Refer to ⇒ Fig. ““Install the three-part oil scraping ring”“ , page 53 .
♦ Allocation. Refer to Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Fig. ““Allocation of the piston ringto the
with respect in connection with the
correctness of information three-part
in this oil scraping
document. Copyright ring”“ , page 53 .
by AUDI AG.
♦ Piston ring gap is not measurable

♦ Height clearance cannot be measured

Allocation of the piston ring in connection with the three-part oil

scraping ring
1- Compression ring with bevel -arrow A- on the upper side
inside. »TOP« marking or lettering points upward
2- Compression ring offset -arrow B- on the bottom outside.
»TOP« marking or lettering points upward
3- Three Part Oil Scraping Ring
Installing the compression ring

• »TOP« marking or lettering points upward.
• Only open the compression ring -2- using the Piston Ring Pli‐
ers -VAS211 003- only until it can be pushed over the pistons
-1-.
Install the three-part oil scraping ring

– Pay attention to the spring installation position:
• The plunger of the plates -2 and 3- and the spring -1- must be
offset 90° to each other.
– Install by hand.
Installation sequence:
1. Insert the spring -1- in the groove.
2. Insert the lower plate -3- in the groove.
3. Insert the upper plate -2- in the groove.
• Install the upper joint of the 3-part oil scraping ring 120° offset
to the neighboring compression ring

Bearing shell installation position

– Place the bearing shells centrally into connecting rod and con‐
necting rod bearing cap.
• Dimension -a- = dimension -a-.
5.2 Pistons, Removing and Installing

♦ Pilot Drift - VW222A-
♦ Piston Installation Sleeve - T40347-
Removing
• The engine is secured to the -VAS6095A- . Refer to
page 8 .
– Remove the cylinder head. Refer to
⇒ “3.2 Cylinder Head, Removing and Installing”, page 107 .
⇒ “1.5 Oil Pan Upper Section, Removing and Installing”,Protected
page by copyright. Copying for private or commercial purposes, in part or in whole, is not
157 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Label the installation position and the piston allocation to the
cylinder.
– Mark installation position and allocation of the connecting rod
cylinder -item 4- ⇒ Item 4 (page 52) .
– Remove the connecting rod bearing cap and remove the pis‐
ton and connecting rod upward.
– Remove the circlip -2- from the piston pin eye.
– Remove the piston pin -3- using the -VW222A- .
TIP:
If difficult to move, heat the pistons to approximately 60 °C (140
°F).
– Remove the pistons -1- from the connecting rod -4-.
Installing
• Arrow on the piston crown points toward belt pulley side.
– Install the compression ring. Refer to -item 10-
⇒ Item 10 (page 52) .
– Installing the oil scraping ring. Refer to -item 11-
⇒ Item 11 (page 52) .

– Coat the contact surface of the bearing shells and the cylinder
wall with engine oil.
– Push the piston -1- with the -T40347- carefully by hand in the
cylinder -arrow-.
• Arrow on the piston crown points toward belt pulley side.
– Install the connecting rod bearing cap. Pay attention to the in‐
stallation position -item 2- ⇒ Item 2 (page 51) .
– Install the cylinder head. Refer to
157 .
♦ Refer to
5.3 Oil Spray Jets, Removing and Installing

Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Torx Bit - T40 - T10545-
♦ Wrench - 21mm - T40263-
♦ Adapter - T40314-
Cylinder “1 to 3”:
157 .

CAUTION
– Turn the crankshaft with the - T40263- , -T40314- and the 24

mm socket in direction of -arrow- until the corresponding bolt
is accessible.
Removing Cylinder “4”:
• The engine is removed and secured to the engine/transmis‐
sion holder. Refer to
page 8 .
157 .
– Remove the balance shaft timing chain. Refer to
page 90 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the crankshaft bearing cap.
– Remove the crankshaft.
Continued for All Cylinders:

– Remove the pressure relief valve -1- using the -T10545- .
– Remove the oil spray jet -2-.
Installing
CAUTION
There is a risk of damaging the oil spray jets through distortions.
– Never bend the oil spray jets.
– Install the balance shaft timing chain. Refer to

page 90 .
157 .
♦ Refer to
♦ Refer to ⇒ “3.1 Overview - Crankshaft”, page 37

5.4 Piston and Cylinder Bore, Checking

Pistons, Checking
– Measure approximately 15 mm from the lower edge at a 90°
angle to the piston pin axis using a 75 to 100 mm external
micrometer.
♦ Deviation from specified size: maximum 0.04 mm
Piston Diameter
Standard dimension mm 82.42 1)
• 1) Measurement without coating (thickness = 0.02 mm). The
coating wears off.
Piston Ring Gap, Checking

– Push the piston ring squarely to the cylinder wall from above
down in the lower cylinder opening approximately 15 mm from
bottom edge of the cylinder. To push in use a piston without
rings.
Piston Ring Gap in Connec‐ New Wear Limit
tion with the Two-Piece Oil
Scraping Ring
Dimensions in mm
1. Compression ring 0.20 to 0.40 0.80 mm
mm
mm
Oil Scraping Ring 0.25 to 0.50 0.80 mm
mm
PIston Ring Gap in Connec‐ New Wear Limit

tion with the Three-Piece Oil
Scraping Ring
Dimensions in mm
mm
mm
Oil Scraping Ring Cannot be measured

Piston Ring Groove Clearance, Checking

– Clean the piston ring groove before checking.
Piston Ring Gap in Con‐ New Wear Limit
nection with the Two-
Piece Oil Scraping Ring
Dimensions in mm
1. Compression ring 0.06 to 0.09 mm 0.20 mm
2. Compression ring 0.03 to 0.06 mm 0.15 mm
Piston Ring Gap in Connection with the Three-Piece Oil Scrap‐

ing Ring
Dimensions in mm
1. Compression ring Cannot be measured
2. Compression ring Cannot be measured
Cylinder Bore, Checking

♦ Cylinder Dial Bore Gauge - VAS6078-
CAUTION
Risk of damaging the cylinder bore surface through incorrect
handling.
– Never handle the cylinder bore with service equipment (drill‐
ing, honing, grinding).
– Using a -VAS6078- measure in a diagonal sequence at three

positions transversely -A- and longitudinally -B-.
♦ Deviation from specified
Protected by copyright. size:or maximum
Copying for private 0.08 inmm
commercial purposes, part or in whole, is not
Dimension Cylinder Bore Diame‐
ter
Standard dimension 82.51 mm

Note
A shadow or a shiny spot on the wall of the cylinder does not mean
the cylinder bore is damaged as long as the cross-lapping is still
visible.
• The cylinder bore must not be measured when the cylinder

block is mounted on the -VAS6095A- because the measure‐
ments may be incorrect.
5.5 New Connecting Rod, Separating

New connecting rods might not be completely separated at the
predetermined breaking point. If the connecting rod bearing cap
cannot be removed by hand, proceed as follows:
– Mark the cylinder where the connecting rod is allocated to
-item 4- ⇒ Item 4 (page 52) .
– Lightly clamp the connecting rod -1- in a vise equipped with
aluminum protective pads.
• Clamp the connecting rod lightly to prevent damaging it.
• Clamp the connecting rod below the dotted line.
– Loosen both bolts -2- approximately five turns.
– Carefully tap the connecting rod bearing cap -1- with a plastic
hammer in the direction of -arrow- until it comes loose.
5.6 Connecting Rods, Checking Radial

Clearance
♦ Plastigauge®
Procedure
• Use the old bolts for radial clearance measurement.
– Clean the bearing cap and pin.
– Place the Plastigauge® over the entire width of the bearing
journal or into the bearing shells.

– Position the connecting rod bearing cap and fasten with the
old bolts -item 1- ⇒ Item 1 (page 51) . Do not turn the crank‐
shaft at the same time.
– Remove the connecting rod bearing cap again.
– Compare the width of the Plastigauge® with the measuring
scale.
Radial clearance:
• New: 0.02 to 0.06 mm.
– Replace the bolts for the final assembly.

6 Special Tools
♦ Crankshaft Seal Installer Kit - T10122B- or Assembly Device

- T10122C-
♦ Seal Installer, Intermediate Shaft - T10356/1-
♦ Counterhold - Vibration Damper - T10355-
6. Special Tools 61
♦ Vibration Damper Assembly Tool - T10531-
♦ Seal Installer - Sealing Flange Guide Sleeve - T20097-
♦ Belt Tensioner Locking Tool - T40098-

♦ Wrench - 21mm - T40263-
♦ Pilot Drift - VW222A-
6. Special Tools 63
♦ Press Piece - 31.5mm - VW418A-
♦ Press Piece - 28x100mm - VW421-
♦ Counterhold - Flywheel - 10-201-

♦ Bearing Installer - Multiple Use - 40-103-
♦ Not Illustrated:
♦ Torx Bit - T40 - T10545-
♦ Puller Jaw - T10394/1-
♦ Piston Installation Sleeve - T40347-
♦ 24 mm Socket
6. Special Tools 65
15 – Cylinder Head, Valvetrain

1 Timing Chain Cover
⇒ “1.1 Overview - Timing Chain Cover”, page 66
⇒ “1.2 Timing Chain Cover, Removing and Installing”,
page 68
⇒ “1.3 Vibration Damper Seal, Replacing”, page 72
1.1 Overview - Timing Chain Cover
1 - O-Ring
moving
❑ Coat with oil before as‐
sembly
2 - Oil Dipstick Tube
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
5 - Camshaft Adjustment Valve
1 - N205-
ling. Refer to
⇒ “4.5 Camshaft
Protected Adjust‐
by copyright. Copying for private or commercial purposes, in part or in whole, is not
mentpermitted
Valveunless
1 N205 , Re‐by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
movingwithand Installing”,
respect to the correctness of information in this document. Copyright by AUDI AG.
page 134
6 - Seal
❑ Replace if damaged
❑ Coat with oil before as‐
sembly
7 - Bolt
❑ Tightening specification
and sequence. Refer to
⇒ Fig. ““Upper Timing
Chain Cover - Tighten‐
ing Specifications and
Sequence”“ ,
page 67 .
8 - Upper Timing Chain Cover
ling. Refer to
⇒ Fig. ““Upper Timing Chain Cover - Tightening Specifications and Sequence”“ , page 67
9 - Seal
10 - O-Ring
11 - Alignment Pins
❑ Centering the cover
66 Rep. Gr.15 - Cylinder Head, Valvetrain

12 - Lower Timing Chain Cover

❑ Removing and installing. Refer to ⇒ “1.2.2 Lower Timing Chain Cover, Replacing”, page 69
13 - Bolt
❑ Tightening sequence. Refer to
⇒ Fig. ““Lower Timing Chain Cover with 15 Bolts - Tightening Specification and Sequence”“ ,
page 67 .
14 - Seal
❑ For the vibration damper
❑ Replacing. Refer to ⇒ “1.3 Vibration Damper Seal, Replacing”, page 72 .
15 - Plug
❑ Always replace after removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Upper Timing Chain Cover - Tightening Specifications and Se‐

quence
– Tighten the bolts -1 to 5- in the sequence shown to 9 Nm.
Lower Timing Chain Cover with 15 Bolts - Tightening Specifica‐

tion and Sequence
Turn
2. -1 to 15- 8 Nm
3. -1, 2, 4, 5- and 45° additional turn
-7 to 15-
4. -3 and 6- After installation of the vibration
damper a 45° additional turn
1. Timing Chain Cover 67

Lower Timing Chain Cover with 8 Bolts - Tightening Specification

and Sequence
Turn
2. -1 to 8- 8 Nm
3. -2 and 3- and 45° additional turn
-5 to 8-
4. -1 and 4- After installation of the vibration
damper a 45° additional turn
1.2 Timing Chain Cover, Removing and In‐

stalling Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.2.1 Upper Timing Chain Cover, Removing
with respect and Installing”,
to the correctness of information in this document. Copyright by AUDI AG.
page 68
⇒ “1.2.2 Lower Timing Chain Cover, Replacing”, page 69
1.2.1 Upper Timing Chain Cover, Removing

and Installing
Caution
This procedure contains mandatory replaceable parts. Refer

to component overview and parts catalog prior to starting pro‐
cedure.
Removing
– Remove the Camshaft Adjustment Valve 1 - N205- . Refer to
⇒ “4.5 Camshaft Adjustment Valve 1 N205 , Removing and
– If necessary, remove the oil dipstick tube from the lower timing
chain cover.

– Remove the bolts -1 through 5- and the upper timing chain

cover.
Installing
• Replace the gasket and O-ring after removal.
• Seal installation position: smaller inner diameter points out‐
ward.
– Coat the seal and the O-ring with engine oil.
– Install the Camshaft Adjustment Valve 1 - N205- . Refer to
⇒ “4.5 Camshaft Adjustment Valve 1 N205 , Removing and
♦ Refer to
⇒ Fig. ““Upper Timing Chain Cover - Tightening Specifications
and Sequence”“ , page 67
1.2.2 Lower Timing Chain Cover, Replacing

♦ Sealant . Refer to the Parts Catalog.
Caution
This procedure contains mandatory replaceable parts. Refer

to the component overview and parts catalog prior to starting
procedure.
Note
Due to the adhesive strength of the Sealant , the lower timing

chain cover will bend during removal. The lower timing chain cov‐
er must always be replaced for this reason.
Removing
Preliminary work may be required depending on the model. Refer
to ⇒ Rep. Gr. 15 ; Timing Chain Cover; Timing Chain Cover,
Removing with
andrespect
Installing .
• Engine oil drained. Refer to ⇒ “1.2 Engine Oil”, page 154 .

– Remove the vibration damper. Refer to
⇒ “1.4 Vibration Damper, Removing and Installing”, page 22 .
– Non-hybrid vehicles: remove the ribbed belt tensioner. Refer
to
⇒ “1.3.2 Ribbed Belt Tensioning Damper, Removing and In‐
stalling, Vehicles with Electro-Mechanical Power Steering”,
page 22 .

– Remove the bolts -arrows- and remove the oil dipstick tube
from the timing chain cover.
– Remove the bolts -1 through 15-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
There may be only eight bolts installed, depending on the version.
– Loosen the lower timing chain cover from the bonding.

Installing
• Replace the lower timing chain cover and seal after removal.
– Cover any open engine components.
– Remove any sealant residue on the cylinder block using a flat
blade scraper.
– Clean any oil or grease off the sealing surfaces.
– Make sure both alignment bushings for centering the cover

-arrows- are present.
TIP:
Be sure to check the expiration date of the Sealant .
proximately 3 mm).
NOTICE
tion System

Cover with 15 Bolts

– Apply the Sealant as shown on the clean sealing surface
-arrow 1- and on the edges -arrows 2- of the new cover.
• The cover must be installed within five minutes after the Seal‐
ant has been applied.
– Immediately attach the cover and tighten the bolts. Refer to
Specification and Sequence”“ , page 67 .
Cover with Eight Bolts

– Apply the Sealant as shown on the clean sealing surface
-arrow 1- and on the edges -arrows 2- of the new cover.
• The cover must be installed within five minutes after the Seal‐
ant has been applied.
– Immediately attach the cover and tighten the bolts. Refer to
Specification and Sequence”“ , page 68 .

Continuation
• Tighten the bolts -arrows- with an additional turn after installing
the vibration damper. The bolts must be removed again to in‐
stall the vibration damper.
• After installing the cover, allow the sealant to harden for ap‐
proximately 30 minutes. Only afterward may the engine oil be
replenished.
Installation is performed in reverse order of removal, noting the
following:
– Install the vibration damper. Refer to
– Non-hybrid vehicles: install the ribbed belt tensioner. Refer to
⇒ “1.3.2 Ribbed Belt Tensioning Damper, Removing and In‐
stalling, Vehicles with Electro-Mechanical Power Steering”,
page 22 .
– Fill the engine oil and check the oil level. Refer to
⇒ “1.2 Engine Oil”, page 154 .
to ⇒ Rep. Gr. 15 ; Timing Chain Cover; Timing Protected
Chain Cover,
Removing and Installing . with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Refer to
♦ Refer to
♦ Refer to ⇒ “1.1 Overview - Timing Chain Cover”, page 66
1.3 Vibration Damper Seal, Replacing

♦ Seal Installer - Crankshaft - T10354-
♦ Press Piece - Gearbox - T10375-
from the Vibration Damper Assembly Tool - T10531-
Procedure
– Remove the vibration damper. Refer to
• The -T10531/2- is installed.
– Remove the seal -arrow- with the -T40274- .
– Clean the contact and sealing surface.

– Push the seal -arrow- on the -T10354- .

• The closed side of the seal points to the -T10354- .
– Push the seal -arrow- with the -T10354- on the -T10531/2- and
place on the lower timing chain cover.
– Additionally attach the -T10375- and tighten the -T10531/4- .

– Drive the seal in all the way using the -T10354- .
• Replace the bolt with O-ring for the vibration damper after re‐
moval.
– Install the vibration damper. Refer to

2 Chain Drive
⇒ “2.1 Overview - Camshaft Timing Chains”, page 74
⇒ “2.3 Bearing Bracket, Removing and Installing”, page 77
⇒ “2.4 Camshaft Timing Chain, Removing from Camshafts”, page
81
page 90
⇒ “2.6 Balance Shaft Drive
permitted Chain,
unless Removing
authorised by AUDI AG. and Installing”,
AUDI AG pageor accept any liability
does not guarantee
99 with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “2.7 Valve Timing, Checking”, page 101
2.1 Overview - Camshaft Timing Chains
1 - Bolt
❑ 9 Nm
2 - Chain Tensioner
❑ Is under tension
❑ Remove the Locking Pin
- T40011- before remov‐
ing
3 - Timing Chain Tensioning
Rail
4 - Guide Pin
❑ 20 Nm
5 - Bolt
❑ 9 Nm
6 - Control Valve
❑ 35 Nm
❑ Left-hand thread
❑ Depending on the ver‐
sion, remove with either
the Central Valve As‐
sembly Tool - T10352-
or Central Valve Assem‐
bly Tool - T10352/1A-
7 - Bolt
tions and Sequence.
Refer to
⇒ Fig. ““Bearing Bracket
- Tightening Specifica‐
tion and Sequence”“ ,
page 75 .
moving
8 - Washer
9 - Bearing Bracket
❑ Removing and installing. Refer to ⇒ “2.3 Bearing Bracket, Removing and Installing”, page 77

10 - Camshaft Timing Chain Guide Rail

11 - Camshaft Housing
12 - Camshaft Timing Chain
❑ Before removing, mark the running direction with paint
❑ Removing and installing. Refer to ⇒ “2.5 Camshaft Timing Chain, Removing and Installing”, page 90
13 - Camshaft Timing Chain Guide Rail
14 - Guide Pin
❑ 20 Nm
15 - Three Stage Chain Sprocket
❑ Crankshaft
❑ Installation position. Refer to ⇒ Fig. ““Three Stage Chain Sprocket - Installed Position”“ , page 75 .
Bearing Bracket - Tightening Specification and Sequence

Turn
2. -1 to 6- 9 Nm
3. -7- M6: pretension to 8 Nm
M8: pretension to 20 Nm
4. -7- 90° additional turn
Three Stage Chain Sprocket - Installed Position

• Both surfaces -arrows- must align.
2. Chain Drive 75
2.2 Overview - Balance Shaft Drive Chain
1 - Guide Pin
❑ 20 Nm
2 - Guide Rail
❑ For the timing chain
3 - Balance Shaft Drive Chain
ling. Refer to
⇒ “2.6 Balance Shaft
Drive Chain, Removing
and Installing”,
page 99
4 - Guide Pin
❑ 20 Nm
5 - Tensioning Rail
❑ For the drive chain for
the balance shafts
6 - Balance Shaft
❑ Must be replaced after
removing
❑ Exhaust side
with engine oil
⇒ “4.2.2 Balance Shaft, Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing and Instal‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ling, Exhaust Side”, with respect to the correctness of information in this document. Copyright by AUDI AG.
page 47 .
7 - Guide Pin
❑ 20 Nm
8 - Guide Rail
❑ For the timing chain
9 - Chain Tensioner
❑ 85 Nm
❑ Coat the seal with sealant
10 - Three Stage Chain Sprocket
❑ Installation position. Refer to ⇒ Fig. ““Three Stage Chain Sprocket - Installed Position”“ , page 75 .
11 - O-Ring
12 - Mounting Pin
❑ Installation position. Refer to ⇒ Fig. ““Mounting Pins - Installation Position”“ , page 77 .
13 - Intermediate Sprocket
❑ The intermediate sprocket must be replaced if the bolt -item 15- ⇒ Item 15 (page 76) is loosened.
14 - Washer
15 - Bolt
❑ Tightening sequence. Refer to ⇒ Fig. ““Intermediate Sprocket Tightening Sequence”“ , page 77 .

❑ The intermediate sprocket -item 13- ⇒ Item 13 (page 76) must be replaced if the bolt is loosened.
Mounting Pins - Installation Position

• Replace and lubricate the O-ring -1- after removal.
• The alignment pin -arrow- for the bearing pins must engage in
the hole in the cylinder block.
• Lubricate the bearing pins
Intermediate Sprocket Tightening Sequence
NOTICE
There Is a Risk of Destroying the Engine When the Intermediate
Sprocket Is Missing Backlash.
The new intermediate sprocket has an anti-friction coating that
wears off after a short period of use, which automatically adjusts
the backlash.
– Never reuse the intermediate sprocket.

– Tighten the bolt -1- in steps:
Step Tightening Specification/Additional Turn
1. 10 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2. – Turn the intermediate sprocket.
• The intermediate sprocket must not have any

play otherwise loosen and tighten it again.
3. 25 Nm
4. 90° additional turn
2.3 Bearing Bracket, Removing and Instal‐

ling
♦ Assembly Tool - T10352A-
♦ Locking Pin (3 pc.) - T40011-
♦ Chain Tensioner Lever - T40243-
♦ Wrench - 21mm - T40263-
♦ Tensioner Locking Tool - T40267-
♦ 24 mm Socket
Removing
– Preliminary work may be required depending on the model.
Refer to ⇒ Rep. Gr. 15 ; Chain Drive ; Bearing Bracket, Re‐
moving and installing.
2. Chain Drive 77
– Remove the upper timing chain cover. Refer to

⇒ “1.2.1 Upper Timing Chain Cover, Removing and Installing”,
page 68 .
TIP:
The control valves have left-hand thread.
– Depending on the version, remove the control valve in direc‐
tion of -arrow- using either the -T10352A- or -T10352/1A- .
– To do so counterhold on the vibration damper with the -

T40263- , -T40314- and the 24 mm socket.
– Remove the bolts -arrows-.

• Carefully remove the bearing bracket without tilting it.
– Remove the bearing mount.
– Remove the plug -arrow-.

– Remove the bolt -arrow-.
Two Different Chain Tensioners May Be Installed Depending on

the Version:
Version 1:
– Install the -T40243- -arrows-.
– Lift up the locking wedge for the chain tensioner by inserting
a scriber or a suitable screwdriver into the chain tensioner
opening in direction of -arrow 1-. Slowly press and hold the -
T40243- in direction of -arrow 2-.
TIP:
The chain tensioner is lubricated with oil and can only be pushed
back slowly by applying constant pressure.
– Secure the chain tensioner using the -T40011- .

2. Chain Drive 79
Version 2:
– Press the chain tensioner circlip -1- together and hold it.
– Slowly press and hold the -T40243- in direction of -arrow-. This
will push back the chain tensioner.
TIP:
– Secure the chain tensioner with the -T40267- .

All Versions:
– Remove the -T40243- .
Installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install the bolts -arrows- and tighten them. Tightening specifi‐

cations. Refer to -item 4- ⇒ Item 4 (page 104) .
– Lubricate the hole -arrow- with engine oil.

• Carefully mount the bearing bracket without tilting it.

– Attach the bearing mount and install the bolts -arrows- all the
way by hand.
– Depending on the version, remove either the -T40011- or the
-T40267- .
– Tighten the bearing bracket bolts -arrows-. Refer to
⇒ “2.1 Overview - Camshaft Timing Chains”, page 74 .
Installation is performed in reverse order of removal, noting the
following:
– Install the upper timing chain cover. Refer to
page 68 .
– There may be additional procedures depending on the model.
Refer to ⇒ Rep. Gr. 15 ; Chain Drive ; Bearing Bracket, Re‐
moving and installing.
♦ Refer to
♦ Refer to ⇒ “3.1 Overview - Cylinder Head”, page 104
2.4 Camshaft Timing Chain, Removing from

Camshafts
♦ Counterhold - Multiple Use - T10172A-
♦ Wrench - 21mm - T40263-
♦ Camshaft
permitted Locks
unless authorised - T40271-
by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ 24 mm Socket
Procedure
to ⇒ Rep. Gr. 15 ; Chain Drive; Camshaft Timing Chain, Re‐
moving from Camshafts .
page 68 .
2. Chain Drive 81
TIP:
– Depending on the version, remove the control valve in the di‐
rection of -arrow- using either the -T10352A- or -T10352/1A- .


– Turn the vibration damper in the “TDC” position.
CAUTION
• The notch on the vibration damper and the marking on the

lower cover for timing chain must be opposite one another
-arrow-.
• The markings -1- on the camshaft chain sprockets must point
upward.
TIP:
The combination of the -T40263- , - T40314- and 24 mm socket
are better suited than the -T10355- for positioning the vibration
damper.

– Mark the camshaft timing chain and the cylinder head

-arrows- to match the marking on the chain sprockets -1- with
a waterproof marker.
– In addition, mark the camshaft timing chain to the camshaft
timing chain guide rail -2- with a waterproof marker.
– Remove the plug -arrow-.
– Remove the bolt -arrow-.
2. Chain Drive 83

the Version:
Version 1:
Version 2: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Press the chain tensioner circlip -1- together and slowly press
and hold the -T40243- in the direction of -arrow-.

All Versions:
– Bolt the -T40271/2- to the cylinder head and into the splines
on the chain sprocket in the direction of the -arrow 2-. If nec‐
essary, turn the intake camshaft with a wrench in the direction
of the -arrow 1-.
With Wrench Clearance:

– Bolt the -T40271/1- to the cylinder head. Counterhold the
camshaft with a wrench in a clockwise direction -arrow-.
– Remove the bolt -A- and slide the tensioning rail down. At the
same time continue counterholding the camshaft.
– Turn the exhaust camshaft clockwise in the direction of
-arrow- until the -T40271/1- can be slid into the chain sprocket
splines.
2. Chain Drive 85
Without Wrench Clearance:

– Bolt the -T40271/1- to the cylinder head.
The help of a second technician is necessary for the following
steps.
– Hold the exhaust camshaft securely with the -T10172A- in the
direction of the -arrow A-. Remove the bolt -1- and guide the
tensioning rail -2- downward.
– Turn the exhaust camshaft clockwise in the direction of
-arrow A- until the -T40271/1- can be pushed into the chain
sprocket splines -C- in the direction of -arrow B-.
All Versions:
Note
♦ Mark the camshafts for the -T40271/1- and -T40271/2- .

♦ When using new camshafts: transfer the self-made markings
from the old camshafts to the new camshafts.
♦ Not making the marks will result in much more work when re‐
installing.
– Mark the camshaft sprocket to the -T40271/1- and the -

T40271/2- -arrow-.
– Remove the upper guide rail -1- by unlocking the catch with a
screwdriver and pushing the guide rail forward.
– Remove the camshaft timing chain from chain sprockets.
NOTICE permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Risk of Damaging Valves and Piston Crowns
– Never turn the crankshaft when the camshaft timing chain is
removed.
Installing
• The vibration damper is at the “TDC” point.


• Camshaft chain sprockets fixed with -T40271/1- and -

T40271/2- .
• The markings -arrow- previously made on the camshaft chain
sprockets are flush to the camshaft locks.
– Position the markings on the chain links -arrows- at the chain

sprockets -1- to mount the camshaft timing chain.
– Install the upper guide rail -2-.

step.
– Turn the exhaust camshaft in direction of -arrow 1-, slide the -
T40271/1- out of the chain sprocket splines in direction of
-arrow 2-.
2. Chain Drive 87
– Carefully release the camshaft, until the camshaft timing chain

is laying on the upper guide rail. Hold the camshaft in this po‐
sition.
– Bring the camshaft timing chain tensioning rail into the instal‐
lation position, and tighten the bolt -A-.
– Remove the -T40271/1- .

step.
– Turn the exhaust camshaft with the -T10172A- slightly in the
direction of -arrow A- and push the -T40271/1- from the chain
sprocket splines direction of -arrow B-.
– Release the camshaft carefully in direction -C-, until the cam‐
shaft timing chain touches the guide rail -1-. Hold the camshaft
in this position.
– Bring the camshaft timing chain tensioning rail -2- into the in‐
stallation position, and tighten the bolt -3-.
All Versions:
– Turn the intake camshaft in direction of -arrow 1-, slide the -
-arrow 2- and release the camshaft.

– Check the valve timing. The camshaft timing chain and cylin‐
der head -arrows- must align with the markings on the chain
sprockets -1-.
– The markings for the camshaft timing chain and the camshaft
timing chain guide rail -2- must align.
– The notch on the vibration damper must align with the marking
on the lower timing chain cover -3-.

– Mount the bearing bracket and the bolts -arrows- hand-tight.
-T40267- .
– Install the bolt -arrow-.

– Install the control valve -item 6- ⇒ Item 6 (page 74) .
Further installation is performed in reverse order
Protected of removal,
by copyright. Copying while
for private or commercial purposes, in part or in whole, is not
noting the following: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
page 68 .
to ⇒ 4-Cylinder Direct Injection 1.8L; 2.0L 4V TFSI Engine; Rep.
Gr. 15 ; Chain Drive; Camshaft Timing Chain, Removing from
Camshafts .
2. Chain Drive 89
2.5 Camshaft Timing Chain, Removing and

Installing
♦ Wrench - 21mm - T40263-
♦ Camshaft Locks - T40271-
♦ 24 mm Socket
Removing
to ⇒ Rep. Gr. 15 ; Chain Drive; Camshaft Timing Chain, Re‐
moving and Installing .
page 68 .
TIP:
– Depending on the version, remove the control valve in the di‐
rection of -arrow- using either the -T10352A- or -T10352/1A- .



– Turn the vibration damper in the “TDC” position.
CAUTION

permittedlower cover for
unless authorised timing
by AUDI chain
AG. AUDI must
AG does not be opposite
guarantee one
or accept any another
liability
-arrow-.

upward.
TIP:
damper.
– Remove the lower timing chain cover. Refer to
⇒ “1.2.2 Lower Timing Chain Cover, Replacing”, page 69 .
– Check the “TDC point” again.
– Press the oil pump chain tensioner in the direction of -arrow-

and secure it with a -T40011- .
– Remove the guide pin -1- and the chain tensioner.
– Remove the oil pump drive chain.
2. Chain Drive 91

the Version:
Version 1:
TIP:
Version 2:
– Press the chain tensioner circlip -1- together and hold it.
– Slowly press and hold the -T40243- in direction of -arrow-.
TIP:

All Versions:
– unless
permitted Bolt authorised
the -T40271/2-
by AUDI AG. to the
AUDI AGcylinder head orand
does not guarantee into
accept any the splines
liability
on the chain sprocket in the direction of the -arrow 2-. If nec‐
essary, turn the intake camshaft with a wrench in the direction

of the -arrow 1-.

– Install the -T40271/1- on the cylinder head. Counterhold the
camshaft with a wrench in a clockwise direction -arrow-.
steps.
– Remove the bolt -A- and slide the tensioning rail down. At the
same time continue counterholding the camshaft.
– Turn the exhaust camshaft clockwise in direction of -arrow-
until the -T40271/1- can be slid into the chain sprocket splines.
2. Chain Drive 93

– Install the -T40271/1- on the cylinder head.
steps.
– Hold the exhaust camshaft securely with the -T10172A- in di‐
rection of -arrow A-. Remove the bolt -1- and guide the ten‐
sioning rail -2- downward.
– Turn the exhaust camshaft clockwise in direction of
-arrow A- until the -T40271/1- can be pushed into the chain
sprocket splines -C- in direction of -arrow B-.
All Versions:
– Remove the upper guide rail -arrow- by unlocking the latch
with a screwdriver and pushing the guide rail forward.
– Remove the bolts -1- and remove the guide rail -2-.
– Remove the timing chain.

Installing
Note
The painted links of the timing chain must be positioned on the

markings on the chain sprockets.
– Mount the timing chain on the intake camshaft.

– Mount the timing chain on the exhaust camshaft.
– Lay the timing chain on the crankshaft and hold it there.
– Install the guide rail -2- and tighten the bolts -1-.
– Install the upper guide rail -arrow-.
2. Chain Drive 95

step.
– Turn the exhaust camshaft in direction of -arrow 1-, slide the -
-arrow 2-.
– Continue to hold the camshaft and install the camshaft timing

chain tensioning rail. Tighten the bolt -A-.

step.
– Turn the exhaust camshaft with the -T10172A- slightly in di‐
rection of -arrow A- and push the -T40271/1- from the chain
sprocket splines in direction of -arrow B-.
– Release the camshaft in the direction -arrow C-, until the timing
chain touches the guide rail -1-. Hold the camshaft firmly in this
position, install the tensioning rail -2- and tighten the bolt -3-.

All Versions:
– Turn the intake camshaft in direction of -arrow 1-, slide the -
-arrow 2- and release the camshaft.
– Check that the position of the colored chain link is aligned to

the markings.
– Check that the position of the colored chain link is aligned to

the markings.
2. Chain Drive 97
– Install the drive chain for the oil pump and the chain tensioner.
Tighten the bolt -1- and remove the -T40011- .
– Install the bolts -arrows- and tighten them. Tightening specifi‐

cations. Refer to -item 4- ⇒ Item 4 (page 104) .

– Attach the bearing mount and install the bolts -arrows- all the
way by hand.
-T40267- .
– Install the control valve -item 6- ⇒ Item 6 (page 74) .

– Install the -T10531/3- . In the “TDC point” the flat area -1-
points upward. Install the -T10531/4- . Turn the crankshaft
using a 32 mm open end wrench twice in the direction of en‐
gine rotation.
Note
Due to the ratio, the painted chain links no longer match up after
the engine has been turned.
– Remove the turning over tool and install the lower timing chain
cover. Refer to
⇒ “1.2.2 Lower Timing Chain Cover, Replacing”, page 69 .
page 68 .
♦ Refer to
♦ Refer to
2.6 Balance Shaft Drive Chain, Removing

and Installing
Removing
– Remove the camshaft timing chain. Refer to
page 90 .
– Remove the camshaft timing chain tensioner -3-.
2. Chain Drive 99
– Remove the chain tensioner for the balance shaft drive chain
-1-.
– Remove the tensioning rail -2-.
– Remove the guide rail -3-.
– Remove the guide rail -4-.
– Remove the timing chain.
Installing
– Turn the intermediate sprocket and balance shaft to the mark‐
ing -arrow-.
– Mount the timing chain; the painted links of the timing chain
must be positioned on the markings on the chain sprockets.
– Install the timing chain guide rail and tighten the bolts -4-.
– Install the timing chain guide rail and tighten the bolts -3-.
– Install the timing chain tensioning rail and tighten the bolt -2-.
– Coat the chain tensioner seal -1- with sealant. Refer to the
Parts Catalog for the sealant.
– Install the timing chain tensioner -1-.

– Check the setting one more time.
– Check the markings on the intermediate sprocket/balance

shaft -arrow-.
Note
For clarity the marking on the intermediate sprocket/balance shaft

is shown with the chain removed.

– Install the camshaft timing chain. Refer to
page 90 .
♦ Refer to
2.7 Valve Timing, Checking

♦ Spark Plug Removal Tool - 3122B-
♦ Dial Gauge Set
Protected by - VAS6341-
copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Dial Gauge Adapter
with respect - T10170A-
♦ Wrench - 21mm - T40263-

Procedure
page 68 .
– Remove the front noise insulation. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Noise Insulation; Noise Insulation, Removing
and Installing .
2. Chain Drive 101

– Turn the crankshaft with the -T40263- , -T40314- and 24 mm

socket on the vibration damper in the direction of engine ro‐
tation until the marks -arrows- are almost on top.
– Remove the ignition coils with power output stages cylinder

“1”. Refer to
⇒ “1.2 Ignition Coils with Power Output Stages, Removing and
– Removing the spark plug from cylinder 1 with the -3122B- .
– Install the -T10170/A- all the way into the spark plug thread.
– Insert the -VAS6341- with the -T10170A/1- all the way and
secure it with the locking nut -arrow-.
– Turn the crankshaft slowly in the direction of the engine rota‐
tion until the maximum dial reading is reached. When the
maximum dial reading is reached (BDC of the meter) position
the piston at »TDC«.
TIP:
♦ If the crankshaft was turned past “TDC”, turn the crankshaft
two more turns in the direction of engine rotation. Do not turn
the engine in the opposite direction of the engine rotation.
♦ The combination of the following shown -T40263- , -T40314-
and 24 mm socket are better suited than the -T10355- for
positioning the vibration damper.
– Measure the distance from the left outer edge ridge -1- to the
marking -2- on the intake camshaft.
• Specified value: 61 to 64 mm.

– Once the specified value is reached, measure the distance

between the marking on the exhaust camshaft -3- and the
marking on the intake camshaft -4-.
• Specified value: 124 to 126 mm.
Note
If one tooth has an offset, there will be a deviation of approxi‐

mately 6 mm from the specified value. The timing chain must be
installed again if an offset is detected.
page 68 .
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation;
Overview - Noise Insulation .
2. Chain Drive 103

3 Cylinder Head
⇒ “3.1 Overview - Cylinder Head”, page 104
⇒ “3.2 Cylinder Head, Removing and Installing”, page 107
⇒ “3.4 Compression, Checking”, page 114
3.1 Overview - Cylinder Head
1 - Cylinder Head Gasket

⇒ “3.2 Cylinder Head,
ling”, page 107 .
❑ Installed position: the
part number faces the
cylinder head
❑ Change the coolant and
engine oil after replac‐
ing
2 - Bolt
❑ 25 Nm
3 - Engine Lifting Eye
4 - Bolt
❑ Loosening. Refer to
⇒ Fig. ““Loosening the
Cylinder Head”“ ,
page 106 .
❑ Tightening specification
and sequence. Refer to
⇒ Fig. ““Cylinder Head -
and Sequence”“ ,
page 107 .
5 - Cylinder Head
❑ Removing and Instal‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ling. Refer to permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “3.2 Cylinder Head, with respect to the correctness of information in this document. Copyright by AUDI AG.

ling”, page 107 .
❑ Checking for distortion.
Refer to
⇒ Fig. ““Cylinder Head,
Checking for Distortion”“ , page 107 . Volkswagen Technical Site: https://vwts.ru
❑ Change the coolant and engine oil after replacing
❑ Do not rework the upper sealing surface
❑ Only replace together with the cylinder head cover
❑ Check Valve, Removing and Installing. Refer to
⇒ “3.3 Check Valve, Removing and Installing”, page 113 .
6 - Bolt
❑ Loosening. Refer to ⇒ Fig. ““Loosening the Cylinder Head”“ , page 106 .
⇒ Fig. ““Cylinder Head - Tightening Specification and Sequence”“ , page 107 .

7 - O-Ring
❑ Only 2.0L Engine
❑ Check for damage
❑ No replacement part: included in the cam adjustment actuator delivery package
❑ Coat with engine oil
8 - Cam Adjustment Actuator
❑ Removing and Installing. Refer to
⇒ “4.4 Cam Adjustment Actuator, Removing and Installing”, page 133 .
9 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 5 Nm
10 - O-Ring
11 - Plugs
❑ 5 Nm
❑ with ball head for the engine cover
12 - Cap
❑ With seal
13 - O-Ring
14 - Plugs
15 - to Intake Manifold
16 - Heat Shield
17 - Bolt
❑ 20 Nm
18 - Bolt
❑ 20 Nm
19 - To the Intake Manifold/Turbocharger
20 - Bleed Pipe
21 - O-Ring
❑ No replacement part
22 - Seal
23 - Engine Cover
24 - Bolt
⇒ Fig. ““Oil Separator on Cylinder Head Cover - Tightening Specification and Sequence”“ , page 165 .
25 - Oil Separator
❑ On the cylinder head cover
❑ Overview. Refer to ⇒ “3.1 Overview - Crankcase Ventilation”, page 164 .
26 - Seal
3. Cylinder Head 105

27 - Seal
28 - Vacuum Pump
❑ Removing and installing. Refer to ⇒ Brake System; Rep. Gr. 47 ; Vacuum System; Vacuum Pump,
Removing and Installing
29 - Bolt
❑ Tightening specification. Refer to ⇒ Brake System; Rep. Gr. 47 ; Vacuum System; Overview - Vacuum
System .
30 - Connection
31 - Retaining Plate
32 - Bolt
❑ 9 Nm
33 - O-Ring
❑ Coat with coolant
34 - Engine Lifting Eye
35 - Bolt
❑ 25 Nm
36 - Bolt
❑ Tightening specification -item 3- ⇒ Item 3 (page 253)
37 - Camshaft Position Sensor - G40-
❑ Overview. Refer to ⇒ “1.1 Overview - Ignition System”,
Protected pageCopying
by copyright. 253 .for private or commercial purposes, in part or in whole, is not
38 - Partition Plate with respect to the correctness of information in this document. Copyright by AUDI AG.
39 - O-Ring
Loosening the Cylinder Head

– Loosen the cylinder head bolts in the sequence -1 to 10-.

Cylinder Head - Tightening Specification and Sequence

♦ Bolt differences:
♦ Bolt without collar
♦ Bolt with collar -arrow-

Turn
2. -1 through 10- “Without collar” 40 Nm
“with collar” 50 Nm, difference. Refer
to ⇒ page 107 .
5. -arrows- 8 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6. -arrows- 90° additional turn
Cylinder Head, Checking for Distortion

– Check the cylinder head in several places for distortion using
a straight edge and a feeler gauge.
♦ Maximum permissible distortion: 0.05 mm.
3.2 Cylinder Head, Removing and Installing

♦ Engine Bung Set - VAS6122-
♦ Hose Clip Pliers - VAS6362-
♦ Polydrive Bit Drive Socket - T10070-
♦ Wrench - 21mm - T40263-
♦ Socket - Xzn 12 - T40270-

♦ 24 mm Socket
Removing
• During installation, all cable ties must be installed at the same
location.
• Close the open channels from the intake and exhaust tract with
suitable plugs for example from the -VAS6122- .
to ⇒ Rep. Gr. 15 ; Cylinder Head; Cylinder Head, Removing and
Installing .
Coolant Hose Version 1:
– Open the clamps -1 and 2- and remove the coolant hoses.

– Open the clamps -arrows- and remove the rear coolant hoses.

– Lift the clips -arrows-, loosen the clamp -2- and remove the
rear coolant hoses.

Continuation for All Vehicles:
Note
Depending on the engine installed, there are different installation

positions.
– Disconnect the fuel line -2-. Refer to ⇒ Fuel Supply System;

Rep. Gr. 20 ; Couplings; Couplings, Separating .
– Loosen the clamp -1- and disconnect the hose from the EVAP
canister.
Note
♦ Lay a cloth below the coolant pipe to catch escaping coolant.

♦ Depending on the engine installed, there are different instal‐
lation positions.
– Remove the bolts -1 and 2- and move the front coolant pipe
upward.
– Loosen the clamp -arrow left- and remove the coolant hose.
– Remove the nut -1- and bolt -2- and remove the support for
the intake manifold.
– Remove the bolts -3-. (Only one bolt depending on the version)
– Remove the banjo bolts -1 and 2- and move the line to the
side.

– Disconnect the connectors -1 and 2- on the Oil Pressure

Switch - F22- and Reduced Oil Pressure Switch - F378- .
Note

positions.
– Loosen the hose clamp -arrow-, remove the air duct hose and
pivot it to the side.
– Disconnect the connectors -1 and 2- and free up the wire.
– Disconnect the connector from the Oil Level Thermal Sensor

- G266- -arrow- and free up the wire.

– Loosen the bolts -1- from above.

– Remove the bolt -2- from below.
– Remove the bolts -arrows- on the oil return line.
– Remove the spark plugs with the -3122B- .


– Remove the cylinder head bolts using the -T10070- or -
T40270- in the sequence -1 through 10-.
• Make sure all wires and cables are disconnected.
• Pay attention to the tension and glide tracks when lifting the
cylinder head.
– Remove the cylinder head.
– Lay the cylinder head on a soft surface, such as foam.
– Seal the open channels of the intake and exhaust tract with a
clean cloth or with completely clean plugs from the -
VAS6122- .
Installing
NOTICE
There Is a Risk of Damaging the Sealing Surfaces If Handled
Incorrectly.
– Carefully remove the sealant residue from the cylinder head
and cylinder block.

• Replace the self-locking nuts, gaskets, seals and O-rings after
removal.
• Secure all hose connections with hose clamps that match the
ones used in series production. Refer to the Parts Catalog.
• Only unpack the new cylinder head gasket immediately before
installing.
• To prevent the cylinder head gasket silicone layer and re‐
cessed area from being damaged, always handle the gasket
extremely carefully.
• If a replacement cylinder is installed, only remove the plastic
base right before cylinder head is installed to protect open
valves.
• When installing a replacement cylinder head, the contact sur‐
faces between the roller rocker lever and cam running surface
need to be oiled before the cylinder head cover can be instal‐
led.
• When replacing the cylinder head or cylinder head gasket, re‐
place all of the coolant and engine oil.
– Carefully remove the sealant residue from the cylinder head
and cylinder block.
– Make sure that no long grooves or scratches result.
– Carefully remove all lapping and sanding residue.
– Clean oil and coolant
permitted unlessresidue
authorised out of AG.
by AUDI theAUDI
blind AGholes
does notfor the cyl‐
guarantee or accept any liability
inder head bolts in the
with respect cylinder
to the block
correctness of information in this document. Copyright by AUDI AG.

– Position the cylinder head gasket.

♦ Pay attention to centering pins in cylinder block -arrows-.
♦ Pay attention to the cylinder head gasket installation position:
the part number must be readable from the intake side.
– If the crankshaft was turned in the meantime: bring the piston
for cylinder 1 to TDC and then turn the crankshaft back again
slightly.
• When turning the crankshaft pay attention that no components
are not damaged by the timing chain.
– Position the cylinder head.
– Install and tighten the cylinder head bolts.
TIP:
It is not required to retighten the cylinder head bolts after repairs.

mm socket until the vibration damper is at “TDC”.
• The mark on the lower timing chain cover is located in the
»four-o'clock position«.
– Connect the coolant with
hose to to
respect the
the connector coupling.
correctness of information Refer
in this to Copyright by AUDI AG.
document.
⇒ Rep. Gr. 19 ; Radiator/Radiator Fan; Overview - Radiator/
Radiator Fan .
– Install the camshafts. Refer to
⇒ “4.2 Camshaft, Removing and Installing”, page 120 .
– Install the spark plugs. Refer to
⇒ “1.1 Overview - Ignition System”, page 253 .
– Change the engine oil. Refer to
– Change the coolant. Refer to ⇒ Rep. Gr. 19 ; Cooling System/
Coolant; Coolant, Draining and Filling .
to ⇒ Rep. Gr. 15 ; Cylinder Head; Cylinder Head, Removing and
Installing .
♦ Refer to ⇒ Rep. Gr. 19 ; Coolant Pipes; Overview - Coolant
Pipes .
♦ Refer to ⇒ “1.1 Overview - Turbocharger”, page 189
♦ Refer to ⇒ “4.1 Overview - Intake Manifold”, page 212
3.3 Check Valve, Removing and Installing

♦ Elbow Assembly Tool - T10118-
Removing
• Cylinder head removed. Refer to

– Remove the check valve -arrow- with the -T10118- .

Installing
– Clean the oil channel.
– Coat the seal on the new check valve with clean engine oil.
– Insert the check valve by hand all the way into the cylinder
head.
3.4 Compression, Checking

♦ Compression Tester Kit - VAG1763-
♦ Compression Tester Kit - Adapter - VAG1381/1-
Test Sequence
• Engine oil temperature at least 30 ℃ (86 °F).
• Battery voltage at least 12.7 V.
– Remove the ignition coils with power output stages. Refer to
– Remove the spark plugs using the -3122B- .

– Check the compression using the -VAG1763- , -VAG1381/1-

and -VAG1381/5A- . Information on using the tester. Refer to
the Operating Instructions.
• The help of a second technician is necessary for the following
step.
– Have a second technician operate the starter until the tester
no longer shows an increase in pressure.
Compression Pressure Pressure
New 11.0 to 14.0 bar
(159.54 to
203.05 psi)
Wear limit 7.0 bar (101.52
psi)
Maximum difference between cylinders 3.0 bar (43.51
psi)
Assembling
– Install the ignition coils with powerProtected
outputbystages. Refer to
⇒ “1.2 Ignition Coils with Power Output Stages,
permitted Removing
unless authorised and
Installing”, page 254 . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Delete the DTC memory entries in the engine control module

that have occurred during the test. Refer to Vehicle Diagnostic
Tester .

4 Valvetrain
⇒ “4.1 Overview - Valvetrain”, page 116
⇒ “4.2 Camshaft, Removing and Installing”, page 120
⇒ “4.3 Sliding Bar Ball, Installing”, page 132
⇒ “4.4 Cam Adjustment Actuator, Removing and Installing”, page
133
⇒ “4.5 Camshaft Adjustment Valve 1 N205 , Removing and In‐
⇒ “4.6 Valve Stem Seals, Removing and Installing”, page 134
4.1 Overview - Valvetrain

⇒ “4.1.1 Overview
with- respect
Valveto Train, 1.8LofEngine”,
the correctness page
information in 116 Copyright by AUDI AG.
this document.
⇒ “4.1 Overview - Valvetrain”, page 116
4.1.1 Overview - Valve Train, 1.8L Engine
1 - Exhaust Valve
❑ Do not rework, only lap‐
ping is permitted
❑ Valve Dimensions. Re‐
fer to
⇒ “5.1 Valve Guides,
Checking”, page 142 .
❑ Valve Guides, Check‐
ing. Refer to
2 - Cylinder Head
3 - Valve Guide
❑ Checking. Refer to
4 - Valve Stem Seal
⇒ “4.6 Valve Stem
Seals, Removing and
5 - Valve Spring
6 - Valve Spring Retainer
7 - Valve Retainers
8 - Hydraulic Lifter
❑ With roller rocker lever
❑ Do not interchange
❑ Lubricate the contact
surface
9 - Exhaust Camshaft
ling. Refer to
⇒ “4.2.1 Camshaft, Removing and Installing, 1.8L Engine”, page 120
❑ Check the radial clearance using Plastigauge® (roller rocker lever removed)
❑ Radial clearance: 0.024 to 0.066 mm

❑ Run-out: maximum 0.04 mm

10 - Cylinder Head Cover
❑ With integrated camshaft bearings
❑ Clean the sealing surface, reworking is not permitted.
❑ Remove old sealant residue.
❑ Only replace together with the cylinder head
11 - Bolt
⇒ Fig. ““Cylinder Head Cover - Tightening Specifications and Sequence”“ , page 118 .
❑ Loosening. Refer to ⇒ Fig. ““Cylinder Head Cover, Loosening”“ , page 117 .
12 - O-ring
13 - Plug
14 - Intake Camshaft
❑ Run-out: maximum 0.04
Protected mm Copying for private or commercial purposes, in part or in whole, is not
by copyright.
15 - Cap with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Removing: with the cylinder head cover installed, pierce through one side of the cover with an awl and
pry it out
❑ Installing. Refer to ⇒ page 124 .
16 - Intake Valve
❑ Do not rework, only lapping is permitted
❑ Valve Dimensions. Refer to ⇒ “5.1 Valve Guides, Checking”, page 142 .
❑ Valve Guides, Checking. Refer to ⇒ “5.1 Valve Guides, Checking”, page 142 .
Cylinder Head Cover, Loosening

– Loosen the cylinder head cover in the sequence
-1 through 6-.
4. Valvetrain 117
Cylinder Head Cover - Tightening Specifications and Sequence

Turn
1. -1 to 6- Install all the way in multiple steps by
hand
2. -1 to 6- 8 Nm
3. -1 to 6- 90° additional turn
Note
Make sure that the cylinder head cover is not tilted.
4.1.2 Overview - Valve Train, 2.0L Engine
1 - Exhaust Valve
❑ Do not rework, only lap‐
ping is permitted
❑ Valve Dimensions. Re‐
fer to
⇒ “5.3 Valve Dimen‐
sions”, page 142 .
❑ Valve Guides, Check‐
ing. Refer to
2 - Cylinder Head
❑ Overview. Refer to
⇒ “3.1 Overview - Cylin‐
der Head”, page 104 .
3 - Valve Guide
4 - Valve Stem Seal
❑ Replacing. Refer to Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “4.6 Valve Stem permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Seals, Removing and with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Valve Spring
6 - Valve Spring Retainer
7 - Valve Retainers
8 - Hydraulic Lifter
❑ With roller rocker lever
❑ Do not interchange
❑ Lubricate the contact
surface
9 - Exhaust Camshaft


10 - Spring
11 - Ball
❑ For sliding bar
❑ Installing. Refer to ⇒ “4.3 Sliding Bar Ball, Installing”, page 132 .
12 - Cylinder Head Cover
❑ With integrated camshaft bearings
❑ Remove old sealant residue.
❑ Clean the sealing surface, reworking is not
permitted permitted.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Only replace together with the cylinder head
13 - Bolt
⇒ Fig. ““Cylinder Head Cover - Tightening Specifications and Sequence”“ , page 118 .
❑ Loosening. Refer to ⇒ Fig. ““Cylinder Head Cover, Loosening”“ , page 117 .
14 - O-ring
❑ Check for damage
❑ No replacement part: included in the cam adjustment actuator delivery package
15 - Cam Adjustment Actuator
⇒ “4.4 Cam Adjustment Actuator, Removing and Installing”, page 133
16 - Bolt
❑ 5 Nm
17 - O-ring
18 - Plug
19 - Intake Camshaft
20 - Cap
❑ Removing: with the cylinder head cover installed, pierce through one side of the cover with an awl and
pry it out
❑ Installing. Refer to ⇒ page 124 .
21 - Intake Valve
❑ Do not rework, only lapping is permitted
❑ Valve Dimensions. Refer to ⇒ “5.3 Valve Dimensions”, page 142 .
❑ Valve Guides, Checking. Refer to ⇒ “5.1 Valve Guides, Checking”, page 142 .
4. Valvetrain 119
4.2 Camshaft, Removing and Installing

⇒ “4.2.1 Camshaft, Removing and Installing, 1.8L Engine”,
page 120
⇒ “4.2.2 Camshaft, Removing and Installing, 2.0L Engine”,
page 125
4.2.1 Camshaft, Removing and Installing,

1.8L Engine
♦ Seal Installer - Selector Shaft Oil Seal - T10174-
♦ Sealant. Refer to the Parts Catalog.
Removing
• The sealing surfaces of the lower cylinder head cover and on
the upper cylinder head must not be reworked.
• The camshaft bearings are integrated in the cylinder head or
cylinder head cover. Before removing the cylinder head cover
the tension from the camshaft timing chain must be released.
• If the cylinder head cover was removed, the cap -item 15-
⇒ Item 15 (page 117) must be replaced.
location.
• Replace the cylinder head cover
permittedbolt after
unless removing.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to ⇒ Rep. Gr. 15 ; Valvetrain; Camshaft, Removing and Instal‐
ling .
– Remove camshaft timing chain from camshafts. Refer to
⇒ “2.4 Camshaft Timing Chain, Removing from Camshafts”,
page 81 .
– Remove the oil separator on the cylinder head cover. Refer to
⇒ “3.2.2 Oil Separator, Removing and Installing, on Cylinder
Head Cover”, page 166 .
– Disconnect the wire -arrows-.
– Disconnect the connector -1- from the Camshaft Position Sen‐
sor - G40- .

– Turn the intake camshaft with a wrench in the direction of

-arrow 1-, slide the -T40271/2- out of the chain sprocket
splines in the direction of -arrow 2- and bring the camshaft into
the rest position.

– Turn the exhaust camshaft with a wrench in the direction of
the rest position.

– Turn the exhaust camshaft with the -T10172A- slightly in the
direction of -arrow A- and push the -T40271/1- from the chain
sprocket splines direction of -arrow B-.
– Remove the high pressure pump. Refer to
⇒ “7.2 High Pressure Pump, Removing and Installing”,
page 235 .
– Remove the vacuum pump. Refer to ⇒ Brake System; Rep.
Gr. 47 ; Vacuum System; Vacuum Pump, Removing and In‐
stalling .
4. Valvetrain 121
– Remove the cylinder head cover bolts in -1 to 6- sequence.
– Pry up the cylinder head cover -2- using a tool for example a
screwdriver -1- starting at the chain side.
– Remove the cylinder head cover.
– Remove the camshaft and cover the open engine compo‐
nents.
Installing
• The sealing surfaces must be free of oil and grease.
• Pay attention that all roller rocker levers rest on the valve stem
ends.
• The crankshaft must not be at “TDC”.
– If the crankshaft waspermitted
turnedunless
in the meantime:
authorised bring
by AUDI AG. AUDIthe piston
AG does not guarantee or accept any liability
slightly.
– Remove any sealant residue from the groove on the cylinder

head cover as well as on the sealing surfaces.
WARNING
Risk of injuring the eyes from sealant residue.
– Remove any seal out of the groove in the cylinder head cover
-1- as well as from any sealing surface using, for example, a
rotating plastic brush.
TIP:
– Cut the tube nozzle at the front marking (nozzle diameter:
about 2 mm).
For New Camshafts:
– Transfer the self-made markings from the old camshafts to the
new camshafts.

Versions without Notches:

– Lubricate the running surfaces of both camshafts.
– Place the camshafts into the cylinder head; the factory mark‐
ings -arrows- must be located as shown.
Note
Ignore the self-made markings.
Versions with Notches:

– Place the camshaft in the cylinder head; the notches
-arrows- must be perpendicular to each other.
Note
Continued for All Engines:
Different Sealant Bead Contour:

Version 1:
Version 2:
– Apply the silicone sealant on the clean sealing surface of the
cylinder head cover as shown -arrows-.
• Sealant bead thickness: approximately 2 mm.
Note
♦ Pay attention that the cylinder head cover is not tilted.

♦ The cylinder head cover must be installed within five minutes
after application of silicone sealant.
♦ The sealant bead may not be thicker than specified, otherwise
excess sealant could enter the oil pan and clog the oil intake
pipe screen.
– Tighten the bolts in several steps, tightening sequence. Refer

to
⇒ Fig. ““Cylinder Head Cover - Tightening Specifications and
Sequence”“ , page 118 .
4. Valvetrain 123
– Drive the cap -1- in without sealant using the -T10174- .

• Installation depth -a- = 1 to 2 mm.
– Turn the vibration damper to the “TDC” -arrow- position.

• When turning the crankshaft, make sure that no components
• The notch on the vibration damper must align with the arrow
marking on the lower timing chain cover.
– Turn the intake camshaft in direction of -arrow 1- until the

marking -3- aligns with the -T40271/2- .
– Slide the -T40271/2- into the chain sprocket splines in the di‐
rection of -arrow 2-.


– Turn the exhaust camshaft in the direction of -arrow 1- until
the marking -3- aligns with the -T40271/1- .

– Bolt the -T40271/1- to the cylinder head.
steps.
– Turn the exhaust camshaft in the direction of -arrow A- until
rection of -arrow B-.
– Mount the camshaft timing chain. Refer to
page 81 .
– Install the air filter
permitted unless housing.
authorised byRefer
AUDI AG. toAUDI
⇒ Rep.
AG doesGr. 24 ; AirorFilter;
not guarantee accept any liability
Air Filter with
Housing, Removing
respect to the and
correctness of Installing
information .
in this document. Copyright by AUDI AG.

ling .
♦ Refer to
⇒ “4.1.1 Overview - Valve Train, 1.8L Engine”, page 116
♦ Refer to
Sequence”“ , page 118
4.2.2 Camshaft, Removing and Installing,

2.0L Engine
♦ Camshaft Spacer - T40191-
♦ Camshaft Pins - T40196-
♦ Wrench - 21mm - T40263-
♦ 24 mm Socket
4. Valvetrain 125

Removing
• The sealing surfaces of the lower cylinder head cover and on
the upper cylinder head must not be reworked.
• The camshaft bearings are integrated in the cylinder head or
cylinder head cover. Before removing the cylinder head cover
the tension from the camshaft timing chain must be released.
• If the cylinder head cover was removed, the cap -item 20-
⇒ Item 20 (page 119) must be replaced.
location.
• Replace the cylinder head cover bolt after removing.
ling .
– Remove the cam adjustment actuator. Refer to
⇒ “4.4 Cam Adjustment Actuator, Removing and Installing”,
page 133 .
– Remove the oil separator on the cylinder head cover. Refer to
⇒ “3.2.2 Oil Separator, Removing and Installing, on Cylinder
Head Cover”, page 166 .
Wiring Guide Version 1:
– Disconnect the wire -arrows-.
– Disconnect the connector -1- from the Camshaft Position Sen‐
sor - G40- .
Wiring Guide Version 2:

– Remove the bolt -1-. Then press the release buttons and dis‐
connect the line -arrows-.
– Disconnect the connector -2- on the Camshaft Position Sensor
- G40- .


mm socket until the vibration damper is at “TDC”.
CAUTION

lower cover for timing chain must be opposite one another
-arrow-.
upward.
TIP:
damper.
NOTICE
Incorrect Handling of the Tool Increases the Risk of Destroying
the Engine
– Only insert the tools in the positions shown.
– Install the -T40196- as shown.

– Turn the crankshaft two complete turns in the direction of en‐
gine rotation.
• The engine must be back at “TDC”.
– Remove camshaft timing chain from camshafts. Refer to
page 81 .
4. Valvetrain 127
– Turn the intake camshaft with a wrench in the direction of

the rest position.
– Turn the exhaust camshaft with a wrench in the direction of

the rest position.
– Remove the high pressure pump. Refer to
page 235 .
– Remove the vacuum pump. Refer to ⇒ Brake System; Rep.
Gr. 47 ; Vacuum System; Vacuum Pump, Removing and In‐
stalling .
– Remove the cylinder head cover bolts in -1 to 6- sequence.

– Pry up the cylinder head cover -2- using a tool for example a
screwdriver -1- starting at the chain side.
– Remove the cylinder head cover.
– Remove the camshaft and cover the open engine compo‐
nents.
Installing
• The sealing surfaces must be free of oil and grease.
• Pay attention that all roller rocker levers rest on the valve stem
ends.
• The crankshaft must not be at “TDC”.
– If the crankshaft was turned in the meantime: bring the piston
slightly.
– Remove any sealant residue from the groove on the cylinder

head cover as well as on the sealing surfaces.
WARNING
– Remove any seal out of the groove
permittedin theauthorised
unless cylinder by head
AUDI AG. cover
AUDI AG does not guarantee or accept any liability
-1- as well as from any sealing with
surface
respect using, for example,
to the correctness a in this document. Copyright by AUDI AG.
of information
For New Camshafts:
– Transfer the self-made markings from the old camshafts to the
new camshafts.
All
CAUTION
Risk of Injuring the Eyes Due to the Sliding Bar Ball Springing
Out
– Install the camshaft with the -T40191- as shown. Move the

spacers into the correct position if necessary.
Note
If available, use a second set of -T40191- or reposition the -

T40191/1- .
4. Valvetrain 129
– Install the camshafts into the cylinder head; the factory mark‐
ings -arrows- must be located as shown.
Note
– Check the alignment -arrows- of the camshafts.
TIP:
about 2 mm).
– Apply the silicone sealant on the clean sealing surface of the

cylinder head cover as shown -arrows-.
• Sealant bead thickness: 2 mm.
Note
♦ Pay attention that the cylinder head cover is not tilted.

♦ The cylinder head cover must be installed within five minutes
after application of silicone sealant.
♦ The sealant bead may not be thicker than specified, otherwise
pipe screen.
– Mount the cylinder head cover with
on respect
the cylinder head.of information in this document. Copyright by AUDI AG.
to the correctness
– Tighten the bolts in several steps, tightening sequence. Refer

to

– Drive the cap -1- in without sealant using the -T10174- .

• Installation depth -a- = 1 to 2 mm.
– Turn the vibration damper to the “TDC” -arrow- position.

• When turning the crankshaft, make sure that no components
• The notch on the vibration damper must align with the arrow
marking on the lower timing chain cover.
– Turn the intake camshaft in direction of -arrow 1- until the

marking -3- aligns with the -T40271/2- .
4. Valvetrain 131
– Turn the exhaust camshaft in the direction of -arrow 1- until

– Mount the camshaft timing chain. Refer to
page 81 .
– Install the cam adjustment actuator. Refer to
⇒ “4.4 Cam Adjustment Actuator, Removing and Installing”,
page 133 .
ling .
♦ Refer to
♦ Refer to
4.3 Sliding Bar Ball, Installing

Installing
WARNING
Risk of injuring the eyes due to the sliding bar ball springing out.
– Insert the spring -1- in the camshaft.

– Place the ball -2- on the spring in the camshaft.
– Push the ball and spring downward in direction of -arrow A-
using the -T40191/1- and hold.
– Push the sliding bar -3- in the direction of -arrow B-.

4.4 Cam Adjustment Actuator, Removing

and Installing
2.0L Engine Only
Removing
– Remove the engine cover. Refer to
⇒ “3.1 Engine Cover, Removing and Installing”, page 11 .
– If equipped, remove the connector strip bolts -arrow-.
– Disconnect the connectors -arrows- from the cam adjustment

actuators.
– Remove the cam adjustment actuators -arrows-.

Installing
• Check the O-rings for damage
• The cam adjustment actuator pin must be brought into the in‐
stallation position.
– Press down the cam adjustment actuator pin in direction of
-arrow- by hand.
• The adjusting element pin must not be in the outward position.
– Install the engine cover. Refer to
♦ Refer to
4. Valvetrain 133
4.5 Camshaft Adjustment Valve 1 - N205- ,

Removing
– Disconnect the connector from the Camshaft Adjustment
Valve 1 - N205- -1-.
– Remove the bolts -arrows- and then the Camshaft Adjustment
Valve 1 - N205- .
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Replace the gasket and O-ring after removal.

– Oil the O-ring on the sealing surface to the valve for the cam‐
shaft adjustment with engine oil.
4.6 Valve Stem Seals, Removing and In‐

stalling
⇒ “4.6.1 Valve Stem Seals, Removing and Installing, Cylinder
Head Installed”, page 134
⇒ “4.6.2 Valve Stem Seals, Removing and Installing, Cylinder
Head Removed”, page 138
4.6.1 Valve Stem Seals, Removing and In‐

stalling, Cylinder Head Installed
♦ Puller - Valve Seal - 3364-
♦ Seal Installer - Valve Stem - 3365- or (depending on the ver‐
sion/manufacturer of the valve stem seal)
♦ Fitting Tool - T40376/1- , not illustrated
♦ Valve Cotter Tool Kit - Adapter - T40012-
♦ Valve Keeper Tool Kit - VAS5161A-
♦ Valve Cotter Tool Kit - Guide Plate 19C - VAS5161/19C-
♦ Mounting Sleeve . Refer to Parts Catalog
Procedure
– Remove the camshafts. Refer to
– Mark the allocation of the roller rocker lever and the hydraulic
lifter so they can be installed again.
– Remove the roller rocker lever with the hydraulic lifter and
place them on a clean surface.

– Remove the spark plugs using the -3122B- .
– Tighten the -VAS5161/19B- on the cylinder head as shown

using the -VAS5161A/12- .
– Set the piston for the respective cylinder to “bottom dead cen‐
ter (BDC)”.
– Install the -T40012- in the spark plug threads.

– Connect compressed air with at least 6 bar (87.02 psi) pres‐
sure.
– Loosen stuck valve retainers using a -VAS5161/3A- and a
plastic hammer.
Intake Side:
– Install the -VAS5161/6- with the -VAS5161/5- in the center
threads of the -VAS5161A/19B- .
4. Valvetrain 135
Exhaust Side:
– Install the -VAS5161/6- with the -VAS5161/5- in the outer
Continuation:
– Insert the -VAS5161/8A- into the -VAS5161/19B- .
– Engage the -VAS5161/2- on the -VAS5161/6- .
– Press down the -VAS5161/8A- and at the same time turn the
knurled thumb screw on the -VAS5161/8A- to the right until the
points engage in the valve retainers.
– Move the knurled thumb screw back and forth slightly. This
presses the valve retainers apart and captures them in the in‐
stallation cartridge.
– Release the -VAS5161/2- .
– Remove the -VAS5161/8A- .
– Remove the valve stem seals using -3364- .
– If the -3364- cannot be used because there is not enough

space, drive the spring pin -arrow- out using a drift and remove
the impact attachment.

– Position the lower section of the -3364- on the valve stem seal.
– Place the drift -1- in the hole in the lower section of the removal
tool.
– Position the extractor lever on the puller and remove the valve
stem seal in direction of -arrow-.
• In order not to damage the valve stem seal -4- during instal‐
lation, mount the Mounting Sleeve -3- on the valve stem -2-.
– Lightly oil the valve stem seal sealing lip.
• Depending on the version/manufacturer of the valve stem
seal, use the -3365- or -T40376/1-
– Insert the valve stem seal in the Seal Installer - Valve Stem
-5- and carefully press on over the Mounting Sleeve on the
valve guide -1- all the way.
– Remove the Mounting Sleeve .
– Insert the valve spring and valve spring retainer.
– Connect the -VAS5161A- as shown.
Intake Side:
Exhaust Side:
4. Valvetrain 137
Continuation:
• If the valve retainers were removed from the assembly car‐
tridge, they must then be inserted into the -VAS5161/18- .
• Press the -VAS5161/8A- onto the insertion tool from above.
– Press the -VAS5161/8- down with the -VAS5161/2- and rotate
the cartridge knurled thumb screw back and forth while pulling
up.
– Release the -VAS5161/2- with the knurled thumb screw
pulled.
– Remove the -VAS5161A- .
– Repeat the procedure on each valve.
Assembling
– Install the camshafts. Refer to
4.6.2 Valve Stem Seals, Removing and In‐

stalling, Cylinder Head Removed
♦ Fitting Tool - T40376/1-
♦ Cylinder Head Tensioning Device - VAS6419-
♦ Mounting Sleeve . Refer to Parts Catalog.
Procedure
– Mark the allocation of the roller rocker lever and the hydraulic
lifter so they can be installed again.
– Remove the roller rocker lever with the hydraulic lifter and
place them on a clean surface.
– If necessary, Protected
remove the intake manifold with the fuel rail. Re‐
fer to ⇒ Rep. Gr. 24 ; Intake
with respect Manifold;
to the correctness Intakein Manifold,
of information this document. Copyright by AUDI AG.
Removing and Installing .
– If necessary, remove the turbocharger. Refer to
⇒ “1.2 Turbocharger, Removing and Installing”, page 194 .

– Insert the -VAS6419- in the -VAS6095A- .

– Tension the cylinder head on the cylinder head tensioning de‐
vice, as shown.
– Connect the cylinder head tensioning device to compressed
air.
– Slide the air cushion with the lever -arrow- under the combus‐
tion chamber onto the valve stem seal that will be removed.
– Let enough compressed air flow into the air cushion until it
contacts the valve plate.
– Set the -VAS5161/19B- on the cylinder head.

– Secure the guide plate with the -VAS 5161/12- .
– Insert the -VAS5161/3A- into the guide plate and loosen the
stuck valve retainers with a plastic mallet.
– Install the -VAS5161/6- with the -VAS5161/5- in the guide

plate.
– Push the -VAS5161/8- into guide plate.
Intake Side:
– Engage the pressure fork -VAS5161/2- on the engaging de‐
vice as illustrated.
4. Valvetrain 139
Exhaust Side:
– Install the -VAS5161/6- with the -VAS5161/5- in the outer
Continuation:
– Insert the -VAS5161/8A- into the -VAS5161/19B- .
– Engage the -VAS5161/2- on the -VAS5161/6- .
– Press down the -VAS5161/8A- and at the same time turn the
knurled thumb screw on the -VAS5161/8A- to the right until the
points engage in the valve retainers.
– Move the knurled thumb screw back and forth slightly. This
presses the valve retainers apart and captures them in the in‐
stallation cartridge.
– Release the -VAS5161/2- .
– Remove the -VAS5161/8A- .
– Remove the valve stem seals using -3364- .
• In order not to damage the valve stem seal -4- during instal‐
lation, mount the Mounting Sleeve -3- on the valve stem -2-.
– Lightly oil the valve stem seal sealing lip.
• Depending on the version/manufacturer
Protected of the
by copyright. Copying for private valve stem
or commercial purposes, in part or in whole, is not
seal, use the -3365- orunless
permitted -T40376/1-
– Insert the valve stem seal in the Seal Installer - Valve Stem
-5- and carefully press on over the Mounting Sleeve on the
valve guide -1- all the way.
– Remove the Mounting Sleeve .
– Insert the valve spring and valve spring retainer.
– Install the -VAS5161A- as shown.

Intake Side:
Exhaust Side:
Continuation:
• If the valve retainers were removed from the assembly car‐
tridge, they must then be inserted into the -VAS5161/18- .
– Press the -VAS5161/8- down with the -VAS5161/2- and rotate
the cartridge knurled thumb screw back and forth while pulling
up.
– Release the -VAS5161/2- with the knurled thumb screw
pulled.
– Remove the -VAS5161A- .
4. Valvetrain 141
5 Intake and Exhaust Valves

⇒ “5.1 Valve Guides, Checking”, page 142
⇒ “5.2 Valves, Checking”, page 142
⇒ “5.3 Valve Dimensions”, page 142
5.1 Valve Guides, Checking

Test Sequence
– Insert the valve into guide. The valve stem end must be flush
with the guide. Due to differences in valve stem diameter, only
use intake valves in intake valve guides, and exhaust valves
in exhaust valve guides.
– Determine the tilting clearance.

Wear Limit
Intake Valve Guide Exhaust Valve Guide
0.60 mm 0.60 mm
• If the wear limit is exceeded, measure again using new valves.
If the wear limit is still exceeded, replace the cylinder head.
• If the valve is to be replaced as part of a repair, use a new
valve for the measurement.
5.2 Valves, Checking

– Check the valves at stem and seat surface for wear grooves.
– If there are clear wear grooves, replace the valve.
5.3 Valve Dimensions

Valve Dimensions Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Intake and exhaust valves must not
with be to
respect reworked. Only
the correctness lapping
is permitted.
Dimension Intake Valve Exhaust Valve
Diameter mm 33.85 ± 0.10 28.0 ± 0.1
a
Diameter mm 5.98 ± 0.01 5.96 ± 0.01
b
c mm 104.0 ± 0.2 101.9 ± 0.2
α ∠° 45 45

6 Special Tools
♦ Polydrive Bit Drive Socket - T10070-
♦ Dial Gauge Adapter - T10170A-
6. Special Tools 143

♦ Press Piece - Gearbox - T10375-


from the Vibration Damper Assembly Tool - T10531-
♦ Locking Pin (3 pc.) - T40011- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Valve Cotter Tool Kit - Adapter - T40012-

♦ Camshaft Pins - T40196-
♦ Wrench - 21mm - T40263-

♦ Camshaft Locks - T40271-


♦ Compression Tester Kit - VAG1763-


♦ Dial Gauge Set - VAS6341-
♦ Hose Clip Pliers - VAS6362-
♦ Cylinder Head Tensioning Device - VAS6419-



♦ Fitting Tool - T40376/1-

17 – Lubrication
1 Oil Pan/Oil Pump
⇒ “1.1 Overview - Oil Pan/Oil Pump”, page 151
⇒ “1.2 Engine Oil”, page 154
⇒ “1.3 Oil Pan Lower Section, Removing and Installing”,
page 154
⇒ “1.4 Oil Pump, Removing and Installing”, page 156
⇒ “1.5 Oil Pan Upper Section, Removing and Installing”,
page 157
⇒ “1.6 Oil Level Thermal Sensor G266 , Removing and Installing”,
page 160
1.1 Overview - Oil Pan/Oil Pump

• If large quantities of metal shavings or abraded material are
found in the engine oil while servicing the engine, the oil pas‐
sages must be carefully cleaned to prevent subsequent dam‐
age. Replace the additional oil spray jet, engine oil cooler and
oil filter.
• Oil spray jet and pressure relief valve. Refer to
⇒ “5.1 Overview - Pistons and Connecting Rod”, page 51 .
1. Oil Pan/Oil Pump 151

1 - Oil Level Thermal Sensor -

G266-
ling. Refer to
⇒ “1.6 Oil Level Ther‐
mal Sensor G266 , Re‐
moving and Installing”,
page 160
2 - Seal
moving
3 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Tightening sequence.
Refer to
⇒ Fig. ““Oil Pan Lower
Section - Tightening
Specifications and Se‐
quence”“ , page 153 .
moving
4 - Oil Pan Lower Section
ling. Refer to
⇒ “1.3 Oil Pan Lower
Section, Removing and
Installing”, page 154
5 - Oil Baffle
moving
6 - Suction Line
❑ Clean the screen if there
are debris
7 - Bolt
❑ 9 Nm
8 - O-Ring
❑ Lubricate
9 - Oil Pump
❑ Removing and installing. Refer to ⇒ “1.4 Oil Pump, Removing and Installing”, page 156
10 - Centering Bracket
11 - O-Ring
12 - Oil Pressure Regulation Valve - N428-
⇒ “4.5 Oil Pressure Regulation Valve N428 , Removing and Installing”, page 170
13 - Bolt
❑ Tightening specification -item 1- ⇒ Item 1 (page 168)
14 - Chain Tensioner
15 - Oil Pump Drive Chain
❑ Mark the running direction before removal
16 - Bolt
❑ 9 Nm
152 Rep. Gr.17 - Lubrication

17 - Seal
18 - Oil Separator
❑ On cylinder block
❑ Removing and installing. Refer to ⇒ “3.2 Oil Separator, Removing and Installing”, page 165
19 - Bolt
⇒ Fig. ““Oil Separator on Cylinder Block - Tightening Specification and Sequence”“ , page 165 .
20 - Oil Pan Upper Section
❑ Removing and installing. Refer to ⇒ “1.5 Oil Pan Upper Section, Removing and Installing”, page 157
21 - Bolt
⇒ Fig. ““Oil Pan Upper Section - Tightening Specifications and Sequence”“ , page 154 .
22 - Bolt
⇒ Fig. ““Oil Pan Upper Section - Tightening Specifications and Sequence”“ , page 154 .
23 - Bolt
❑ 20 Nm
24 - Seal
25 - Bolt
❑ 9unless
permitted Nm authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
26 - Seal
27 - Check Valve
28 - Oil Drain Plug
❑ 30 Nm
29 - Nut
❑ 9 Nm
Oil Pan Lower Section - Tightening Specifications and Sequence

Turn
2. -1 to 19- 8 Nm
3. -1 to 19- 45° additional turn

Oil Pan Upper Section - Tightening Specifications and Sequence

Turn
2. -1 through 13- 15 Nm
1.2 Engine Oil permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Engine Oil, Draining and Filling; Engine Oil, Checking; Oil Fil‐
ter Element, Removing and installing. Refer to ⇒ Rep. Gr.
17 ; Oil Pan/Oil Pump; Engine Oil .
♦ Oil capacities, oil specifications and viscosity classes. Refer
to the ⇒ Fluid Capacity Tables; Rep. Gr. 03 .
1.3 Oil Pan Lower Section, Removing and

Installing
♦ Flat-Blade Scraper
♦ Sealant Remover
Note
There are plastic ribs on the oil baffle that deform permanently
when tightening the oil pan lower section. The plastic ribs ensure
the oil baffle has no play and does not rattle. Because of this,
always replace the oil baffle.
Removing
to ⇒ Rep. Gr. 17 ; Oil Pan/Oil Pump; Oil Pan Lower Section,
– Disconnect the connector from the Oil Level Thermal Sensor
- G266- -arrow-.

– Remove the bolts -1 through 19-.

– Remove the oil pan, if necessary loosen by applying light
strikes with a rubber hammer.
– If the oil pan lower section is replaced, remove the Oil Level
Thermal Sensor - G266- . Refer to
⇒ “1.6 Oil Level Thermal Sensor G266 , Removing and In‐
stalling”, page 160 .
Installing
after
Protected removing
by copyright. them.
–withSpray the
respect to the sealing
correctnesssurface with
of information sealant
in this remover
document. Copyright byand
AUDIallow
AG. it to
work.
– Remove any sealant residue on the oil pan upper section using
a flat-blade scraper.
CAUTION
Risk of Injuring the Eyes from Sealant Residue
– Remove any remaining sealant on oil pan lower section -1-

using for example, a rotating plastic brush.
TIP:
about 3 mm).

– Apply sealant on the clean sealing surface of the oil pan lower
section as shown -arrow-.
• The sealant bead may not be thicker than specified, otherwise
pipe screen.
• The oil pan must be installed within five minutes of being ap‐
plied with sealant.
• Allow the sealant to dry for approximately 30 minutes after in‐
stalling the oil pan. Only afterward may the engine oil be
replenished.
– Immediately attach the oil pan lower section and tighten the
bolts. Refer to
⇒ Fig. ““Oil Pan Lower Section - Tightening Specifications and
to ⇒ Rep. Gr. 17 ; Oil Pan/Oil Pump; Oil Pan Lower Section,
♦ Refer to
⇒ Fig. ““Oil Pan Lower Section - Tightening Specifications and
♦ Refer to ⇒ “1.1 Overview - Oil Pan/Oil Pump”, page 151
1.4 Oil Pump, Removing and Installing

♦ Elbow Assembly Tool - T10118- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Chain Tensioner Locking Tool - T40265-
Removing
– Remove the oil pan lower section. Refer to
⇒ “1.3 Oil Pan Lower Section, Removing and Installing”, page
154 .
– Remove the bolts -arrows- and then remove the oil baffle.

– Pull the wire clip from the chain tensioner tension spring with
the - T10118- in the direction of -arrow- and lock with the -
T40265- .
– Remove the bolts -arrows- and remove the oil pump.

Installing
• Replace the oil baffle -item 5- ⇒ Item 5 (page 152) after re‐
moval.
– Make sure both alignment bushings for centering the oil pump
are present.
– Guide the oil pump chain sprocket into the drive chain and
install the oil pump.
NOTICE
Risk of Damaging the Engine by Incorrect Oil Pump Drive Chain
Tension
– Ensure the tension spring wire clip is engaged correctly on
the locating tab of the oil pan upper section.
– Pull the wire clip of the chain tensioner tension spring with the
- T10118- in the direction of -arrow- and remove the -T40265- .
– Insert the new oil baffle and secure it.
– Install the oil pan lower section. Refer to
⇒ “1.3 Oil Pan Lower Section, Removing and Installing”, page
154 .
⇒ “1.2 Engine Oil”,
Protected page 154
by copyright. . for private or commercial purposes, in part or in whole, is not
Copying
1.5 Oil Pan Upper Section, Removing and

Installing

Removing
– Remove the transmission side sealing flange. Refer to
⇒ “2.3 Transmission Side Sealing Flange, Removing and In‐
stalling, Oil Side Sealing Lip”, page 32 .
– Remove the oil pump. Refer to
⇒ “1.4 Oil Pump, Removing and Installing”, page 156 .
– Disconnect the connector -1- and free up the wire.
Note
The illustration shows a vehicle with a pump.
– Loosen and remove the bolts in the following sequence:

-13 to 1-.
• First pry the oil pan upper section out on the transmission side.
Proceed carefully when prying out.
– Loosen the oil pan upper section from the adhesive.
Installing
• Replace the O-rings after removing them.
• Replace the oil baffle -item 5- ⇒ Item 5 (page 152)
with respect after
to the re‐ of information in this document. Copyright by AUDI AG.
correctness
moval.
– Remove any sealant residue on the cylinder block using a flat
blade scraper.

WARNING
– Remove the remaining sealant on the oil pan upper section

and on the lower timing chain cover -1-, for example with a
• Check if the timing chain cover is deformed. Then mount the
oil pan upper section without any sealant and check the gap
between the cover and the oil pan upper section. If deforma‐
tion is determined and the cover cannot be aligned, replace
the cover after installing the oil pan upper section.
– Check for dirt in the oil channels in the oil pan upper section
and in the cylinder block.
TIP:
proximately 2 mm).
NOTICE
tion
Protected by System
– Apply sealant to the clean sealing surfaces on the oil pan up‐
per section -arrow- as shown.
♦ Sealant bead thickness: 2 to 3 mm.

– Apply sealant between the cylinder block and the lower timing
chain cover -arrows-.
• On the transmission side, the oil pan upper section and the
crankcase must be flush.
• The oil pan upper section must be installed within five minutes
after the application of sealant.
– Immediately attach the oil pan upper section and tighten the
bolts.
– Install the bolts -arrows-. Tightening specifications. Refer to

-item 13- ⇒ Item 13 (page 67) .
– Install the oil baffle -item 5- ⇒ Item 5 (page 152) to install the
oil pump. Refer to
⇒ “1.4 Oil Pump, Removing and Installing”, page 156 .
– Install the sealing flange on the transmission side. Refer to
⇒ “2.3 Transmission Side Sealing Flange, Removing and In‐
stalling, Oil Side Sealing Lip”, page 32 .
♦ Refer to
⇒ Fig. ““Oil Pan Upper Section - Tightening Specifications and
1.6 Oil Level Thermal Sensor

Protected by - G266-
copyright. Copying for private ,or Re‐
commercial purposes, in part or in whole, is not
moving and Installing
Removing

– Disconnect the connector -2-.

– Remove the nuts -1- and the Oil Level Thermal Sensor - G266-
-3-.
Installing
• Replace the seal -4- after removal.

2 Engine Oil Cooler

⇒ “2.1 Overview - Engine Oil Cooler”, page 162
⇒ “2.2 Engine Oil Cooler, Removing and Installing”, page 162
2.1 Overview - Engine Oil Cooler
ling. Refer to
2 - Bolt
❑ 15 Nm
3 - Connection
4 - Seal
moving
❑ Coat with coolant
5 - Engine Oil Cooler
❑ See note. Refer to
⇒ , page 151 .
ling. Refer to
⇒ “2.2 Engine Oil Cool‐
6 - Seal
moving
2.2 Engine Oil Cooler, Removing and Instal‐

ling
Removing
– Remove the sub-assembly bracket. Refer to
⇒ “1.5 Sub-Assembly Bracket, Removing and Installing”, page
28 .

– Remove the bolts -4 and 5- and remove the engine oil cooler
-3- with the seal -2- from the sub-assembly bracket -1-.
Installing
• Replace the seal after removal.
– Install the engine oil cooler -3- with a new seal -2-.
– Install the sub-assembly bracket. Refer to
⇒ “1.5 Sub-Assembly Bracket, Removing and Installing”, page
28 .
♦ Refer to ⇒ “2.1 Overview - Engine Oil Cooler”, page 162
2. Engine Oil Cooler 163

3 Crankcase Ventilation
⇒ “3.1 Overview - Crankcase Ventilation”, page 164
⇒ “3.2 Oil Separator, Removing and Installing”, page 165
3.1 Overview - Crankcase Ventilation
1 - Bleed Pipe
2 - O-Ring
3 - Seal
4 - Oil Separator
❑ On the cylinder head
cover
ling. Refer to
⇒ “3.2.2 Oil Separator,
ling, on Cylinder Head
Cover”, page 166
5 - Bolt
tions and Sequence.
Refer to
⇒ Fig. ““Oil Separator on
Cylinder Head Cover -
and Sequence”“ ,
page 165 .
6 - Seal
❑ Always replace if dam‐
aged
7 - Seal
moving
8 - Oil Separator
❑ On cylinder block
ling. Refer to
⇒ “3.2 Oil Separator, Removing and Installing”, page 165
9 - Bolt
⇒ Fig. ““Oil Separator on Cylinder Block - Tightening Specification and Sequence”“ , page 165 .

Oil Separator on Cylinder Block - Tightening Specification and

Sequence
– Tighten the bolts to 9 Nm in the sequence -1 to 9-.
Oil Separator on Cylinder Head Cover - Tightening Specification

and Sequence
Note
♦ The bolts are thread-cutting. Only use original bolts when re‐
placing the cylinder head, since the cylinder head is delivered
without a thread for the installing the crankcase ventilation.
♦ It is not permitted to cut the thread with a thread cutter.
– Tighten the bolts in the sequence -1 to 10- to 11 Nm.
3.2 Oil Separator, Removing and Installing

⇒ “3.2.1 Oil Separator, Removing and installing. on unless
permitted Cylinder
Block”, page 165 with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “3.2.2 Oil Separator, Removing and Installing, on Cylinder Head

Cover”, page 166
3.2.1 Oil Separator, Removing and installing.

on Cylinder Block
Removing
to ⇒ Rep. Gr. 17 ; Crankcase Ventilation; Oil Separator, Re‐
– Remove the bolts -1 through 9- and remove the oil separator.
TIP:
To prevent dirt from entering the lubrication system, seal the
opening in the engine with a clean cloth.
Installing
• Replace the seal and gaskets after removal.
to ⇒ Rep. Gr. 17 ; Crankcase Ventilation; Oil Separator, Re‐
♦ Refer to
⇒ Fig. ““Oil Separator on Cylinder Block - Tightening Specifi‐
cation and Sequence”“ , page 165
3. Crankcase Ventilation 165

3.2.2 Oil Separator, Removing and Installing,

on Cylinder Head Cover
Removing
– Remove the Ignition Coil with Cylinder Power Output Stage “3
and 4”. Refer to
– Disconnect the crankcase ventilation hose -1-.
– Remove the bolts -arrows- and then remove the oil separator
from the crankcase ventilation hose -2- in the direction of
-arrow-.
– Cover the open valvetrain with a clean cloth.
Installing
– Install the cylinder ignition coils “3 and 4”. Refer to
♦ Refer to
⇒ Fig. ““Oil Separator on Cylinder Head Cover - Tightening
Specification and Sequence”“ , page 165 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

4 Oil Filter/Oil Pressure Switch

⇒ “4.1 Overview - Oil Filter”, page 167
⇒ “4.2 Overview - Oil Pressure Switch/Oil Pressure Regulation”,
page 168
⇒ “4.3 Oil Pressure Switch F22 , Removing and Installing”, page
168
⇒ “4.4 Reduced Oil Pressure Switch F378 , Removing and In‐
⇒ “4.5 Oil Pressure Regulation Valve N428 , Removing and In‐
⇒ “4.6 Oil Pressure, Checking”, page 171
4.1 Overview - Oil Filter
❑ Removing andpermitted
instal‐unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ling. Refer to with respect to the correctness of information in this document. Copyright by AUDI AG.
2 - O-Ring
❑ No replacement part,
part of the valve insert
delivery package
3 - O-Ring
❑ No replacement part,
part of the valve insert
delivery package
4 - Valve Insert
❑ With O-rings
5 - Oil Filter
ling. Refer to
⇒ “1.2 Engine Oil”, page
154
❑ See note. Refer to
⇒ page 151 .
4. Oil Filter/Oil Pressure Switch 167

4.2 Overview - Oil Pressure Switch/Oil Pressure Regulation
1 - Bolt
❑ 9 Nm
2 - Oil Pressure Regulation
Valve - N428-
ling. Refer to
⇒ “4.5 Oil Pressure
Regulation Valve N428 ,
ling”, page 170
3 - O-Ring
moving
❑ Overview. Refer to
⇒ “1.1 Overview - Cylin‐
der Block, Belt Pulley
Side”, page 13 .
5 - Oil Pressure Switch - F22-
❑ 20 Nm
❑ 2.15 to 2.95 bar (31.18
to 42.78 psi)
❑ Blue insulation
❑ Check in Guided Fault
Finding . Refer to Vehi‐
cle Diagnostic Tester .
ling. Refer to
⇒ “4.3 Oil Pressure
Switch F22 , Removing
and Installing”,
page 168
6 - Reduced Oil Pressure permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Switch - F378- with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 20 Nm
❑ Different installation positions depending on the version.
❑ 0.55 to 0.85 bar (7.97 to 12.32 psi)
❑ Brown insulation
❑ Check in Guided Fault Finding . Refer to Vehicle Diagnostic Tester .
⇒ “4.4 Reduced Oil Pressure Switch F378 , Removing and Installing”, page 169
4.3 Oil Pressure Switch - F22- , Removing

and Installing
Procedure

Vehicles with Hydraulic Power Steering:

– Unscrew the Oil Pressure Switch - F22- -2-.
Vehicles with Electro-Mechanical Power Steering:

– Unscrew theunless
permitted Oil authorised
Pressure Switch
by AUDI - F22-
AG. AUDI -4-.not guarantee or accept any liability
AG does
Hybrid Vehicles:
– Remove the Oil Pressure Switch - F22- .
– To prevent oil loss, install the new oil pressure switch imme‐
diately.
♦ Refer to
⇒ “4.2 Overview - Oil Pressure Switch/Oil Pressure Regula‐
tion”, page 168
4.4 Reduced Oil Pressure Switch - F378- ,

Procedure

Vehicles with Hydraulic Power Steering:

– Remove the Reduced Oil Pressure Switch - F378- -3-.
Vehicles with Electro-Mechanical Power Steering:

– Remove the Reduced Oil Pressure Switch - F378- -1-.
Hybrid Vehicles:
– Remove the Reduced Oil Pressure Switch - F378- .
Continuation for All Vehicles: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Replace the seal after removal. with respect to the correctness of information in this document. Copyright by AUDI AG.
– To prevent oil loss, install the new oil pressure switch imme‐
diately.
♦ Refer to
tion”, page 168
4.5 Oil Pressure Regulation Valve - N428- ,

♦ Used Oil Collection and Extraction Unit - SMN372500-
Removing
and Installing .

Note
The illustration shows a vehicle with a pump.
– Place the -SMN372500- under the engine.

– Remove the bolt -2- and remove the Oil Pressure Regulation
Valve - N428- -3-; to do so, pull the ribbed belt slightly down‐
ward.
Installing
• Replace the O-ring after removing.
♦ Refer to
tion”, page 168
4.6 Oil Pressure, Checking

♦ Oil Pressure Gauge Kit - VAG1342-
Test Requirements
• Check if the oil level is OK. Refer to
• Engine oil temperature at least 80 °C (176 °F) (radiator fan
must start up once).
Test Sequence
– Remove theProtected
Reduced Oil Pressure
by copyright. Copying for Switch - F378- purposes,
private or commercial . Referintopart or in whole, is not
⇒ “4.4 Reduced Oilunless
permitted Pressure
authorisedSwitch F378
by AUDI AG. AUDI, AG
Removing and or accept any liability
does not guarantee
– Install the -VAG1342- into the oil filter bracket in place of the
oil pressure switch.
– Install the Reduced Oil Pressure Switch - F378- in the -
VAG1342- .
– Start the engine.
• Oil pressure when idling: 1.2 to 2.0 bar (17.4 to 29 psi).
• Oil pressure at 2000 RPM: 1.6 to 2.2 bar (23.2 to 31.9 psi).
• Oil pressure at 3700 RPM: 3.0 to 4.0 bar (43.51 to 58.01 psi).
Note
During the break-in phase, the oil pressure may be at 2000/min

at 3.0 to 4.0 bar (43.51 to 58.01 psi).

Assembling
– Install the Reduced Oil Pressure Switch - F378- . Refer to
⇒ “4.4 Reduced Oil Pressure Switch F378 , Removing and

5 Special Tools
♦ Used Oil Collection and Extraction Unit - SMN372500-
♦ Chain Tensioner Locking Tool - T40265-
♦ Oil Pressure Gauge Kit - VAG1342-

19 – Cooling System
1 Coolant System/Coolant
⇒ “1.1 Connection Diagram - Coolant Hoses”, page 174
⇒ “1.2 Cooling System, Checking for Leaks”, page 174
⇒ “1.3 Coolant, Draining and Filling”, page 177
1.1 Connection Diagram - Coolant Hoses

Refer to ⇒ Rep. Gr. 19 ; Cooling System/Coolant; Connection
Diagram - Coolant Hoses .
1.2 Cooling System, Checking for Leaks

♦ Cooling System Tester - VAG1274B-
♦ Cooling System Tester - Adapter - VAG1274/8-
♦ Cooling System Tester - Adapter - VAG1274/9- for Version 1
cap
♦ Adapter - VAG1274B/15- for version 2 cap
♦ Safety Gloves
Procedure
• Engine at operating temperature.
WARNING
The cooling system is under pressure when the engine is warm.
There is a risk of scalding due to hot steam and hot coolant.
Scalding the skin and other parts of the body is possible.
– Reduce the pressure by covering the coolant expansion tank
cap with a cloth and carefully opening it.
– Open the coolant expansion tank cap -1- by releasing the

catch in direction of -arrow- if necessary.
Tip: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Different versions depending on models and version.
174 Rep. Gr.19 - Cooling System

– Position the -VAG1274B- with the -VAG1274/8- on the coolant

expansion tank.
– Generate approximately 1 bar (14.5 psi) pressure using the
cooling system tester hand pump.
• The pressure must not drop more than 0.2 bar (2.9 psi) within
10 minutes.
– If the pressure falls more than 0.2 bar (2.9 psi), search for leaks
and correct the problem.
TIP:
The pressure decrease of 0.2 bar (2.9 psi) within 10 minutes is a
condition of the cooling of the coolant. The colder the engine the
more the pressure decrease. If necessary repeat the test with the
engine cold.
WARNING
There is a risk of scalding due to hot steam and hot coolant.
Scalding the skin and other parts of the body is possible.
– Reducing the pressure: press the pressure release valve on
the cooling system tester until the pressure gauge displays
a value of 0.
Checking the Pressure Relief Valve in the Version 1 Cap
– Position the -VAG1274B- with the -VAG1274B/15- on the cap.

– Generate approximately 2 bar (29 psi) pressure using the
cooling system tester hand pump.
Blue Protected
Cap: by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Thewith
pressure must
respect to the lowerofto
correctness 1.6 to in1.4
information thisbar (23.20
document. to 20.30
Copyright by AUDIpsi)
AG.
and stay there.
– If the pressure relief valve does not react as specified, replace
the cap.
Black Cap:
• The pressure must lower to 1.8 to 1.6 bar (26.1 to 23.2 psi)
and stay there.
the cap.
1. Coolant System/Coolant 175

Checking the Pressure Relief Valve in the Version 2 Cap:
– Position the -VAG1274B- with the -VAG1274/9- on the cap.

– Generate pressure with the cooling system tester hand pump.
Blue Cap:
♦ The pressure release valve must open at 1.4 to 1.6 bar (20.30
to 23.20 psi).
the cap.
Black Cap:
♦ The pressure release valve must open at 1.6 to 1.8 bar (23.2
to 26.1 psi).
the cap.

1.3 Coolant, Draining and Filling

Coolant Specification
Note
♦ The mixture of the water used greatly influences the effective‐

ness of the coolant. The water quality to be used is based on
the contents, which can be specific to a country or even a re‐
gion. Distilled water fulfills all requirements. For this reason,
distilled water must be used when adding coolant or filling
coolant for the first time.
♦ Use only coolant additives listed. Refer to the Parts Catalog.
Other coolant additives may above all reduce the corrosion
protection effect significantly. The damage resulting from this
may lead to loss of coolant and consequently to severe engine
damage.
♦ Coolant with the correct mixture ratio prevents freezing and
corrosion damage and calcium deposits. Additionally, the boil‐
ing temperature will be raised. For this reason the cooling
system must be filled with coolant additive year-round.
♦ Because of its high boiling point, the coolant contributes to
engine reliability under heavy engine loads, particularly in
countries with tropical climates.
♦ The Refractometer - T10007A- MUST be used to determine
the current freeze protection value. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Freeze protection must be assured down to minimum -25 °C
(-13 °F) (in arctic climatic countries down to approximately -36
°C (-32.8 °F)). The freeze protection may only be increased,
when stronger freeze protection is needed due to the climate.
But only down to -48 °C (-54 °F), otherwise the effectiveness
of the coolant decreases.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The frost
protection must be at least -25 °C (-13 °F).
♦ Read the freeze protection value on the scale for the coolant
additive that has been added.
♦ The temperature on the Refractometer - T10007A- corre‐
sponds to the »freezing point«. At this temperature, ice crys‐
tals may begin to form in the coolant.
♦ Used coolant cannot be used again.
♦ Only use water/coolant additive to lubricate the coolant hoses.
Coolant, Draining and Filling

Refer to ⇒ Rep. Gr. 19 ; Cooling System/Coolant; Coolant,
Draining and Filling .
1. Coolant System/Coolant 177

2 Coolant Pump/Coolant Regulation

⇒ “2.1 Overview - Coolant Pump/Coolant Thermostat”,
page 178
⇒ “2.2 Overview - Electric Coolant Pump”, page 180
⇒ “2.3 Electric Coolant Pump, Removing and Installing”,
page 180
⇒ “2.4 Coolant Pump, Removing and Installing”, page 180
page 181
⇒ “2.6 Coolant Thermostat, Removing and Installing”, page 182
⇒ “2.7 Coolant Thermostat, Checking”, page 183
⇒ “2.8 Engine Coolant Temperature Sensor G62 , Removing and
⇒ “2.9 Coolant Valves, Removing and Installing”, page 184
2.1 Overview - Coolant

Protected by copyright. Copying forPump/Coolant Thermostat
private or commercial purposes, in part or in whole, is not
1 - Bolt
tions and Sequence.
Refer to
⇒ Fig. ““Coolant Pump -
Tightening Specifica‐
tions and Sequence”“ ,
page 179 .
2 - O-Rings
moving
3 - Connection
4 - Clip
❑ Only with the attached
version
❑ Check for secure fit
5 - Bolt
❑ 4 Nm
❑ Only with the bolted ver‐
sion
6 - Retaining Plate
❑ Only with the bolted ver‐
sion
7 - Engine Coolant Tempera‐
ture Sensor - G62-
ling. Refer to
⇒ “2.8 Engine Coolant
Temperature Sensor
G62 , Removing and In‐
8 - O-Ring
moving

9 - Coolant Pump
❑ Removing and installing. Refer to ⇒ “2.4 Coolant Pump, Removing and Installing”, page 180
❑ For a new coolant pump, remove the protective cap
10 - Seal
11 - Centering Pin
❑ Quantity: 2
12 - Toothed Belt
❑ For the coolant pump
⇒ “2.5 Coolant Pump Toothed Belt, Removing and Installing”, page 181
13 - Toothed Belt Guard
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 10 Nm + 90°
❑ Left-hand thread
16 - Toothed Belt Sprocket
❑ Note the installation position
17 - Exhaust Side Balance Shaft Seal
❑ Replacing. Refer to ⇒ “4.3 Balance Shaft Gasket, Replacing, Intake Side”, page 49 .
18 - Balance Shaft
19 - Coolant Thermostat
❑ Removing and installing. Refer to ⇒ “2.6 Coolant Thermostat, Removing and Installing”, page 182
❑ Checking. Refer to ⇒ “2.7 Coolant Thermostat, Checking”, page 183 .
20 - Centering Pin
21 - O-Ring
22 - Connection
23 - Bolt
❑ 9 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Coolant Pump - Tightening Specifications and Sequence

– Tighten the coolant pump bolts to 9 Nm in a -1 to 5- sequence.
2. Coolant Pump/Coolant Regulation 179

2.2 Overview - Electric Coolant Pump

Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Coolant Regulation;
Connection Diagram - Electric Coolant Pump .
2.3 Electric Coolant Pump, Removing and

Installing
Electric Coolant Pump, Removing and Installing .
2.4 Coolant Pump, Removing and Installing

Removing
to ⇒ Rep. Gr. 19 ; Coolant Pump/Coolant Regulation; Coolant
Pump, Removing and Installing .
page 181 .
TIP:
– Disconnect the connector -1- on the Engine Coolant Temper‐
ature Sensor - G62- .
– Open the clamps -1 and 2-, remove the coolant hoses and
move them to the side.
– Remove the bolts -1 to 5-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove the coolant pump from the centering pin and discon‐
nect it from the engine oil cooler.
Installing
• Replace the seals and O-ring after removal.

– Coat the O-rings -4- with coolant. Refer to Parts Catalog for
the coolant.
– Make sure that both centering pins are installed in the cylinder
block if necessary insert.
– Install the connection piece -2- into the engine oil cooler -1-.
– Push the coolant pump -3- onto the connection piece and onto
the centering pins in the cylinder block.
– Tighten the coolant pump bolts. Refer to

⇒ Fig. ““Coolant Pump - Tightening Specifications and Se‐
quence”“ , page 179 .
Note
If a new coolant pump was installed, then the protective cap

-arrow- must be removed.

page 181 .
– Connect the coolant hose to the connector coupling. Refer to
⇒ Rep. Gr. 19 ; Radiator/Radiator Fan; Overview - Radiator/
Radiator Fan .
Pump, Removing and Installing
Protected . Copying for private or commercial purposes, in part or in whole, is not
by copyright.
♦ Refer to
page 178
2.5 Coolant Pump Toothed Belt, Removing

and Installing
♦ Torque Wrench 1331 Insert - Ring Wrench - 12mm - T10360-
♦ Torque Wrench 1410 - VAG1410-
Removing
Pump Toothed Belt, Removing and Installing .

– Remove the bolts -arrows- and remove the toothed belt guard.
Tip:
– Loosen the bolt on the coolant pump drive wheel -1- clockwise
in the direction of -arrow- and unscrew it three turns using the
-VAG1410- and the - T10360- .
– Remove the toothed belt -2-.
Installing
• Note the toothed belt sprocket installation location -item 16-
⇒ Item 16 (page 179) .
Pump Toothed Belt, Removing and Installing .
♦ Refer to
page 178
2.6 Coolant Thermostat, Removing and In‐

stalling
Removing
– Remove the coolant pump. Refer to
⇒ “2.4 Coolant Pump, Removing and Installing”, page 180 .
– Remove bolts -arrows- and remove the connection.
– Remove the coolant thermostat.
Installing
Install in reverse
Protected by copyright.order
Copyingof
forremoval while noting
private or commercial purposes,the following:
in part or in whole, is not
• Replace
with respectthe
to theseals andofO-ring
correctness after
information in thisremoval.
document. Copyright by AUDI AG.
– Clean the sealing surface on the O-ring.

– Coat the O-ring with coolant. Refer to the Parts Catalog for the
correct coolant.

– Install the thermostat -4- into the housing -5- for the coolant
pump and move it slightly forward in direction of -arrow-.
– Carefully mount the connector -3-, while doing so, insert the
centering pin -2- into the guide -1-.
– Install the coolant pump. Refer to
⇒ “2.4 Coolant Pump, Removing and Installing”, page 180 .
♦ Refer to
page 178
2.7 Coolant Thermostat, Checking

• Coolant thermostat removed. Refer to
⇒ “2.6 Coolant Thermostat, Removing and Installing”,
page 182 .
– Heat the coolant thermostat in the hot water bath.
Opening Begins Opening Ends Opening Lift
Approximately 95° Approximately 105° Minimum 8 mm
1)
• 1) Cannot be tested
2.8 Engine Coolant Temperature Sensor -

G62- , Removing and Installing
Procedure
• The engine is cold.
to ⇒ Rep. Gr. 19 ; Coolant Pump/Coolant Regulation; Engine
Coolant Temperature Sensor - G62- , Removing and Installing .
– Quickly open the coolant reservoir cap and release any re‐
maining pressure in the cooling system and then close it again.
– Place a cloth underneath to catch any escaping coolant.
TIP:

Attached Version:
– Press the locking mechanisms in direction of -arrows- and re‐
move the clip.
– Remove the Engine Coolant Temperature Sensor - G62- -2-.
Threaded Version:
– Remove the bolts -arrows- and the retaining plate -1-.
– Remove the Engine Coolant Temperature Sensor - G62- .
All: with respect to the correctness of information in this document. Copyright by AUDI AG.
• Replace the O-rings after removing them.

– Insert the new engine coolant temperature sensor immediately
so that as little coolant is lost as possible.
– Check the coolant level. Refer to
⇒ “1.3 Coolant, Draining and Filling”, page 177 .
to ⇒ Rep. Gr. 19 ; Coolant Pump/Coolant Regulation; Engine
Coolant Temperature Sensor - G62- , Removing and Installing .
♦ Refer to
page 178
2.9 Coolant Valves, Removing and Instal‐

ling
Coolant Valve, Removing and Installing .

3 Coolant Pipes
Refer to ⇒ Rep. Gr. 19 ; Coolant Pipes .
3. Coolant Pipes 185

4 Radiator/Radiator Fan
Refer to ⇒ Rep. Gr. 19 ; Radiator/Radiator Fan .

5 Special Tools
♦ Torque Wrench 1331 Insert - Ring Wrench - 12mm - T10360-
♦ Cooling System Tester - VAG1274B-
♦ Adapter - VAG1274B/15- for version 2 cap
♦ Cooling System Tester - Adapter - VAG1274/8-

♦ Cooling System Tester - Adapter - VAG1274/9- for Version 1

cap
♦ Safety Gloves

21 – Turbocharger, Supercharger
1 Turbocharger
⇒ “1.1 Overview - Turbocharger”, page 189
⇒ “1.2 Turbocharger, Removing and Installing”, page 194
⇒ “1.3 Turbocharger Vacuum Diaphragm, Checking”, page 196
1.1 Overview - permitted
Turbocharger
Part I
Part II. Refer to ⇒ page 190 .
Part III. Refer to ⇒ page 191 .
Part IV - 1.8L engine only. Refer to ⇒ page 193 .
1 - Turbocharger
❑ Can only be replaced
with exhaust manifold
and vacuum diaphragm.
ling. Refer to
⇒ “1.2 Turbocharger,
ling”, page 194
2 - Hose
3 - Turbocharger Vacuum Dia‐
phragm
❑ Can be replaced only
with the turbocharger
4 - Hose Clamp
5 - Hose
6 - Hose
7 - Bolt
❑ 3 Nm
8 - Wastegate Bypass Regula‐
tor Valve - N75-
9 - Hose
10 - Turbocharger Recircula‐
tion Valve - N249-
❑ Note the installation po‐
sition. Refer to
⇒ Fig. ““ Turbocharger
Recirculation Valve -
N249- Installation Posi‐
tion”“ , page 190 .
11 - Bolt
❑ 7 Nm
12 - O-Ring
13 - O-Ring
1. Turbocharger 189
14 - Connection
15 - Bolt
❑ 9 Nm
Turbocharger Recirculation Valve - N249- Installation Position

– Note the installation location -arrows-.
Part II
Part I. Refer to ⇒ page 189 .
1 - Turbocharger
ling. Refer to
ling”,Protected
page by194
2 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 9 Nm
3 - Crankcase Ventilation Line
4 - Seal
moving
5 - Seal
moving
6 - Bolt
❑ 30 Nm
7 - Oil Supply Line
8 - Bolt
❑ 9 Nm
9 - Bolt
❑ 9 Nm
10 - O-Ring
moving
190 Rep. Gr.21 - Turbocharger, Supercharger

11 - Seal
12 - Bolt
❑ 35 Nm
13 - Bolt
❑ 9 Nm
14 - Bolt
❑ 35 Nm
15 - Seal
16 - Coolant Supply Line
17 - Bolt
❑ 9 Nm
18 - Bolt
❑ 9 Nm
19 - Seal
20 - Oil Return Line
21 - Seal permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Always replace after removing with respect to the correctness of information in this document. Copyright by AUDI AG.
Part III
1. Turbocharger 191
1 - Gasket
moving
2 - Nut
❑ Tightening sequence.
Refer to
⇒ Fig. ““Turbocharger -
Tightening Specifica‐
tions and Sequence”“ ,
page 193 .
moving
❑ Coat the exhaust mani‐
fold stud bolts with hot
bolt paste. Refer to the
Parts Catalog for the hot
bolt paste.
3 - Bolt
❑ 35 Nm
4 - O-Ring
moving
5 - Coolant Return Line
6 - Bolt
❑ 9 Nm
7 - Turbocharger Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Can only be replaced with respect to the correctness of information in this document. Copyright by AUDI AG.
ling. Refer to
ling”, page 194
8 - Bolt
❑ 30 Nm
9 - Bracket
10 - Support
11 - Bolt
❑ 30 Nm
12 - Bolt
❑ 30 Nm
❑ Coat the bolt with hot bolt paste. Refer to the Parts Catalog for the hot bolt paste.
13 - Nut
❑ 30 Nm
❑ Do not open when removing the turbocharger
❑ Coat the exhaust manifold stud bolts with hot bolt paste. Refer to the Parts Catalog for the hot bolt paste.
14 - Clamping Strip

Turbocharger - Tightening Specifications and Sequence

– Tighten the bolts in steps in the sequence shown:
Step Bolts Tightening Specification
1. -1 to 5- 3 Nm
2. -1 to 5- 12 Nm
3. -1 to 5- 16 Nm
4. -1 to 5- 25 Nm
Part IV - 1.8L Engine Only

1 - Turbocharger
ling. Refer to
ling”, page 194
2 - Turbocharger Vacuum Dia‐
phragm
⇒ “1.3 Turbocharger
Vacuum Diaphragm,
ling. Refer to
Vacuum Diaphragm,
Replacing”, page 197
❑ Adjusting. Refer to
Vacuum Diaphragm,
Adjusting”, page 198 .
3 - Bolt
❑ 10 Nm
4 - Nut
❑ 9 Nm
❑ Secure with sealing
wax. Refer to Parts Cat‐
alog for the correct seal‐
ing wax.
5 - Locking Plate
❑ Always replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Knurled Nut permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1. Turbocharger 193
1.2 Turbocharger, Removing and Installing

If Mechanical Damage Is Found on the Turbocharger (for Exam‐
ple a Destroyed Compressor Wheel), Simply Replacing the Tur‐
bocharger Is Not Enough. To Avoid Subsequent Damage Later,
Perform the Following Steps:
• Check the air filter housing, air filter element and air duct hoses
for contamination.
• Check the entire charge air circuit and charge air cooler for
foreign objects.
• If there are foreign objects in the charge air system, clean the
charge air circuit and replace the charge air cooler if neces‐
sary.
Removing
to ⇒ Rep. Gr. 21 ; Turbocharger; Turbocharger, Removing and
Installing .
pivot it to the side.
– Disconnect the connectors -1 and 2- and free up the wire.
– Loosen the bolts -1- from above.

– Remove the bolt -2- from below.

– Remove the bolts -arrows- on the oil return line.
– Remove the nuts -arrows-.
– Remove the turbocharger upward with the exhaust manifold.
Installing
• Replace seals, gaskets, O-rings and self-locking nuts after
disassembly.
• Coat the turbocharger stud bolts with hot bolt past. Refer to
the Parts Catalog.
• Hose connections and charge air system hoses must be free
of oil and grease before installing.
• Add oil to turbocharger through oil feed line connecting piece.
• Used coolant cannot be used again.
– Install the catalytic converter. Refer to ⇒ Rep. Gr. 26 ; Emis‐
sions Control System; Catalytic Converter, Removing and
Installing .
– Fill with coolant. Refer to ⇒ Rep. Gr. 19 ; Cooling System/
Coolant; Coolant, Draining and Filling .
to ⇒ Rep. Gr. 21 ; Turbocharger; Turbocharger, Removing and
Installing .
• After installing the turbocharger, let the engine idle for approx‐
imately one minute without increasing the engine speed. This
ensures adequate oil supply to the turbocharger.
♦ Refer to
⇒ “2.2 Overview - Charge Air Hose Connections”, page 201
1. Turbocharger 195
1.3 Turbocharger Vacuum Diaphragm,

Checking
♦ Hand Vacuum Pump - VAS6213-
Test Conditions:
♦ The hose from the turbocharger must have flow to the vacuum
diaphragm via the Wastegate Bypass Regulator Valve - N75- .
♦ Wastegate Bypass Regulator Valve - N75- OK
Procedure
to ⇒ Rep. Gr. 21 ; Turbocharger; Turbocharger Vacuum Dia‐
phragm, Removing and Installing .
– Connect the -VAS6213- to the vacuum diaphragm -arrow-.
– Set the slide ring -1- on -VAS6213- to position -B- for “pres‐
sure”.
NOTICE
Risk of Damaging the Components If the Pressure Is Set Too
High
– Never set the test pressure specified.
– Operate the -VAS6213- several times and observe the link‐

age.
The linkage -A- must move approximately 300 mbar (4.35 psi)
and be at approximately 700 mbar (10.15 psi) at end position.

The linkage stroke is approximately 10 mm.
Note
If pressure cannot be raised using the -VAS6213- or pressure

drops immediately, check the -VAS6213- and connecting hoses
for leaks.
If no fault is found with the -VAS6213- and the connecting hoses:

♦ In vehicles with a 1.8L engine, replace the vacuum diaphragm.
Refer to
⇒ “1.4 Turbocharger Vacuum Diaphragm, Replacing”,
page 197 .
♦ On vehicles with a 2.0L engine, replace the turbocharger. Re‐
fer to
1.4 Turbocharger Vacuum Diaphragm, Re‐

placing
Note
This procedure description is only for 1.8L engines.
Removing
– Remove the turbocharger. Refer to
– Remove securing plate -1- over linkage on turbocharger.
– Loosen the lock nut -2-.

– Disconnect linkage from turbocharger -3-.
– Disconnect the vacuum diaphragm -1- and remove -4-.
Installing
Install in reverse order of removal while noting the following:
– Adjust the turbocharger vacuum diaphragm. Refer to
⇒ “1.5 Turbocharger Vacuum Diaphragm, Adjusting”,
page 198 .
– Install the turbocharger. Refer to
1. Turbocharger 197
1.5 Turbocharger Vacuum Diaphragm, Ad‐

justing
♦ Pressure Control Valve - VAS6342-
♦ Digital Pressure Sensor - VAG1397B-
♦ Torque Wrench 1783 - 2-10Nm - VAG1783-
♦ Torque Wrench 1783 - Open Jaw - 10mm - VAG1783/1-
Note
This procedure description is only for 1.8L engines.
Adjusting
• Turbocharger removed.
Note
It is necessary to adjust the diaphragm only if it has been re‐

moved.
– Pre-adjust the bypass door -1- via nut -arrow- so bypass door
can still just be turned by hand.

– Secure the -VW387- onto the turbocharger -arrow-.
Note
♦ The mm specifications apply to the value read out (includes 1

mm pretension).
♦ The -VAS6341/1- with -VAS6341/3- must align with the link‐
age on the vacuum diaphragm.
– Secure the -VAS6341/1- with the -VAS6341/3- and -

VAS6341/4- to the -VW387- .
– Set the -VAS6341/1- to 1 mm pretension.
– Turn the -VAS6341/1- Protected
displaybyto 0. Copying for private or commercial purposes, in part or in whole, is not
copyright.
– Check the dial gauge forwith
ease oftomovement.
respect the correctness of information in this document. Copyright by AUDI AG.
– Turn the nut -1- approximately seven turns in the direction of

-arrow-.
– Turn the nut -2- in the direction of -arrow- until the dial gauge
shows 7 mm.
– Hand-tighten the nut -1-.
– Turn the -VAS6341/1- display to 0.
– Connect the -VAS6213- and the -VAG1397B- to connection II

and the -VAS6342- as shown.
– Switch on the -VAG1397B- and set the sliding switch to posi‐
tion II.
– Close the -VAS6342- on the lever -1-.
1. Turbocharger 199
– Set the slide ring -1- on the -VAS6213- in position -B- for
“pressure”.
Note
The following measurements must be performed in one se‐

quence. In the meantime, the pressure must not dissipate to 0.
– Operate the -VAS6213- until the -VAG1397B- displays 460 +/-

5 mbar (6.67 ± 0.07 psi).
Note
If 460 ± 5 mbar (6.67 ± 0.07 psi) is exceeded, then the measuring

must be started again from the beginning.
– Protected
Read byand note the value on the -VAS6341/1- .
– Operate
with respect the
to the-VAS6213- until the
correctness of information -VAG1397B-
in this displays
document. Copyright 650
by AUDI AG.
mbar to 700 mbar (9.42 psi to 10.15 psi).
– Reduce the pressure to 460 +/- 5 mbar (6.67 ± 0.07 psi) via -
VAS6342- .
Note
If 460 ± 5 mbar (6.67 ± 0.07 psi) is not reached, then the meas‐
uring must be started again from the beginning.
– Read and note the value on the -VAS6341/1- .

– Add value 1 and 2 together and divide by two.
– The result (mean value) must be 5 +/- 0.5 mm.
– If the value is greater, then lower the pressure to 0 bar, loosen

the nut -1- and turn the nut -2- a half a turn and then tighten
the nut -1- hand-tight.
– Turn the -VAS6341/1- display to 0 and repeat the measure‐
ment.
– If the average value is 5 ± 0.5 mm, then tighten the lock nut
and repeat the measurement.
– If the average value is 5 ± 0.5 mm, then secure the nuts with
sealing wax. Refer to Parts Catalog for the correct sealing wax.
– Secure the new securing plate -1- over the vacuum diaphragm
linkage.
♦ Turbocharger vacuum diaphragm. Refer to ⇒ page 193

2 Charge Air System

⇒ “2.1 Overview - Charge Air System”, page 201
⇒ “2.3 Charge Air Cooler, Removing and Installing”, page 203
⇒ “2.4 Charge Air Pressure Sensor G31 , Removing and Instal‐
ling”, page 203
⇒ “2.5 Charge Air System, Checking for Leaks”, page 203
2.1 Overview - Charge Air System

Refer to ⇒ Rep. Gr. 21 ; Charge Air System; Overview - Charge
Air System .
2.2 Overview - Charge Air Hose Connec‐

tions
With Hose Clamps
• The hose connections as well as air duct pipes and hoses must
be free of oil and grease before installing.
• In order to be able to securely mount the air duct hoses on
their connections, spray the bolts on the previously used
screw-type clamps with rust remover before installing.
Hose clamps on the hooks on the pressure side -arrows-.
• To remove the air duct hose, the screw-type clamp must be
loosened enough.
• Loosened screw-type clamps can be reused.
• A screw-type clamp -1- with hooks -arrows- may not be re‐

moved from the air duct hose.
Protected• by Ifcopyright.
a screw-type clamp
Copying for private with hooks
or commercial wasin removed
purposes, from
part or in whole, is notthe air
duct
permitted unless hose,bythe
authorised AUDI airAG.duct
AUDIhose
AG doesmust be replaced.
not guarantee or accept any liability
• A new air duct hose will be delivered with the screw-type clamp
installed.
2. Charge Air System 201

Tightening specification for

1- Hose Clamp -a- = 13 mm wide: 5.5 Nm
2- Hose Clamp -b- = 9 mm wide: 3.4 Nm
With Decoupling Element
NOTICE
There Is a Risk of Damaging the Seal If the Air Duct Pipe Is
Installed Incorrectly
– Follow the installation instructions.
Removing
– Release the connector coupling by pulling clip -arrow-. Dis‐
connect the air duct pipe without the use of tools.
Installing
– If the seal is replaced, place it in the groove on the air duct
hose.
• The seal must sit in the groove all the way around and must
not be twisted.
– Lubricate the sealing surfaces and the seal.
– Bring the clip into the release position -1-.

– Slide the air duct pipe into the connector all the way.
– Bring the clip into the locked position -2- and press the air duct
pipe back. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check for correct seating and proper locking of the connector
coupling by pulling on the air duct pipe.

2.3 Charge Air Cooler, Removing and In‐

stalling
Refer to ⇒ Rep. Gr. 21 ; Charge Air System; Charge Air Cooler,
2.4 Charge Air Pressure Sensor - G31- ,

Refer to ⇒ Rep. Gr. 21 ; Charge Air System; Charge Air Pressure
Sensor - G31- , Removing and Installing .
2.5 Charge Air System, Checking for Leaks

♦ Turbo System Tester Kit - VAG1687-
♦ Turbo System Tester Kit - Adapter - VAG1687/10- , Turbo
System Tester Kit - Adapter 11 - VAG1687/11- or Turbo Sys‐
tem Tester Kit - Adapter 12 - VAG1687/12-
♦ Ultrasonic Tester - VAG1842-
♦ Leak detection spray, commercially available
Procedure
– Follow the guidelines for clean working conditions. Refer to
⇒ “3.1 Guidelines for Clean Working Conditions”, page 5 .
and Installing .
move it to the side.

– Depending on the hose diameter, insert the -VAG1687/10- , -

VAG1687/11- or -VAG1687/12- in the air guide hose -1- and
secure with a hose clamp.
– Connect the - VAG1687- as shown.

Prepare the -VAG1687- as follows:

– Completely remove the pressure regulating valve -2- and
close the valves -3 and 4-.
• Pull the knob in order to rotate the pressure regulating valve.
– Connect the -VAG1687- to compressed air -1- with a com‐
mercially available intermediate piece.
– Drain the water in the viewing glass via the water drain plug
-6-.
– Open the valve -3-.
NOTICE
Risk of Damaging the Components If the Pressure Is Set Too
High
– Never set the test pressure specified.
– Set the pressure to 0.2 bar (2.9 psi) using the pressure regu‐
lating valve -2-.
– Open the valve -4- and wait until the test circuit is filled. Reg‐
ulate the pressure to 0.2 bar (2.9 psi) again if necessary.
– Check the charge air system for leaks by listening, feeling and
using commercially available leak detection spray or the Ul‐
trasonic Tester - VAG1842S- . Refer to the Owner's Manual
for information ontheusing
with respect to theof-VAG1842S-
correctness .
information in this document. Copyright by AUDI AG.
TIP:
A small quantity of air dissipates via the valves in the engine. For
this reason a pressure retention test is not possible.
Assembling
– Release the pressure in the test circuit by removing the hose
coupling before removing the adapter.
♦ Refer to

3 Special Tools
Special tools and workshop

equipment required

♦ Pressure Control Valve - VAS6342-
♦ Digital Pressure Sensor - VAG1397B-
♦ Torque Wrench 1783 - 2-10Nm - VAG1783-

♦ Turbo System Tester Kit - VAG1687-
♦ Turbo System Tester Kit - Adapter - VAG1687/10- , -1687/11-

or -1687/12-
♦ Torque Wrench 1783 - Open Jaw - 10mm - VAG1783/1-

24 – Multiport Fuel Injection

1 Injection System
⇒ “1.1 Component Location Overview - Injection System”,
page 208
⇒ “1.2 Fuel System Leak Test”, page 208
1.1 Component Location Overview - Injec‐

tion System
Refer to ⇒ Rep. Gr. 24 ; Injection System; Component Location
Overview - Injection System .
1.2 Fuel System Leak Test

– Let the engine run a few minutes at a moderate RPM.
– Switch off the ignition.
– Check the entire fuel system for leaks.
– Replace the affected component if there are leaks in spite of
correct tightening specifications.
– Perform a road test and fully depress the accelerator pedal at
least one time.
– Then check the high pressure area again for leaks.
208 Rep. Gr.24 - Multiport Fuel Injection

2 Vacuum System
⇒ “2.1 Vacuum System, Checking”, page 209
⇒ “2.2 Double Check-Valve, Checking”, page 209
2.1 Vacuum System, Checking

Procedure
– Check all vacuum lines in the entire vacuum system for:
♦ Cracks
♦ Damage caused by animals
♦ Pinching
♦ Porous locations and other leaks
– Check the vacuum line leading both to and from the solenoid
valve to the respective component.
– If there is a DTC memory entry, check the vacuum lines for the
named component, but also check all the vacuum lines.
– If using the -VAS6213- does not produce any vacuum or if the
vacuum drops again right away, then check the hand vacuum
pump and the connection hoses for leaks.
2.2permitted Double Check-Valve, Checking

♦ Connector Test Set - VAG1594D-
Procedure
• The EVAP Canister Purge Regulator Valve 1 - N80- was tes‐
ted with the Vehicle Diagnostic Tester and is OK.
Note

positions.
– Remove the connector -1- and the ventilation hose -3- from
the EVAP Canister Purge Regulator Valve 1 - N80- -2-.
2. Vacuum System 209

– Set the slide ring -1- of the -VAS6213- in position -A- for "vac‐
uum".
– Connect the -VAS6213- to the EVAP Canister Purge Regula‐

tor Valve 1 - N80- .
– Using the adapter cables, connect the contacts on the EVAP
Canister Purge Regulator Valve 1 - N80- -1- to the battery. This
opens the EVAP Canister Purge Regulator Valve 1 - N80- .
– Operate the - VAS6213- several times.
• A vacuum must form.
– Disconnect the adapter cables form the battery again (inter‐
rupt the voltage supply).
If no vacuum forms:
The double check-valve, the EVAP Canister Purge Regulator
Valve 1 - N80- and the plastic hoses are a single component and
can only be replaced together.

3 Air Filter
Refer to ⇒ Rep. Gr. 24 ; Air Filter .
3. Air Filter 211

4 Intake Manifold
⇒ “4.1 Overview - Intake Manifold”, page 212
⇒ “4.2 Intake Manifold, Removing and Installing”, page 216
⇒ “4.3 Throttle Valve Control Module J338 , Removing and In‐
⇒ “4.4 Throttle Valve Control Module, Cleaning”, page 216
⇒ “4.5 Intake Manifold Change-Over, Checking”, page 217
4.1 Overview - Intake Manifold

⇒ “4.1.1 Overview - Intake Manifold, Vehicles with Gasoline En‐
gine”, page 212
⇒ “4.1.2 Overview - Intake Manifold, Vehicles with MultiFlex En‐
gine”, page 214
4.1.1 Overview - Intake Manifold, Vehicles with Gasoline Engine
1 - Bolt
❑ 20 Nm
2 - Intake Manifold Support
3 - Nut
❑ 10 Nm
4 - Throttle Valve Control Mod‐
ule - J338-
❑ With EPC Throttle Drive
- G186- , EPC Throttle
Drive Angle Sensor 1 -
G187- and EPC Throttle
G188-
ling. Refer to Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “4.3 Throttle Valve with respect to the correctness of information in this document. Copyright by AUDI AG.
Control Module J338 ,
ling”, page 216
❑ Cleaning. Refer to
⇒ “4.4 Throttle Valve
Control Module, Clean‐
ing”, page 216 .
❑ After replacing, perform
an “adaptation”. Refer to
Vehicle Diagnostic
Tester , Guided Func-
tions
5 - Bolt
❑ 7 Nm
6 - Seal
moving
7 - Bolt
❑ 5 Nm

8 - Intake Air Temperature Sensor - G42-

⇒ “6.1 Intake Air Temperature Sensor G42 , Removing and Installing”, page 229
9 - O-Ring
10 - Nut
❑ Pre-tightening specification 3 Nm
❑ Final tightening specification 10 Nm
11 - Intake Manifold Runner Position Sensor - G336-
12 - Bolt
❑ 0.8 Nm
❑ Thread cutting
❑ Position the bolt by hand and tighten it until it finds the old threads. Then tighten the bolt to the specifi‐
cation.
13 - Intake Manifold
❑ Removing and installing. Refer to ⇒ Rep. Gr. 24 ; Intake Manifold; Intake Manifold, Removing and
Installing .
14 - Bolt
15 - O-Ring
16 - Bolt
❑ 4 Nm
❑ Thread cutting Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Position the bolt by handunless
permitted andauthorised
tightenbyitAUDI
untilAG. it AUDI
findsAGthedoesold threads.
not guarantee Thenanytighten
or accept liability the bolt to the specifi‐
cation.
17 - Vacuum Hose
18 - Seal
19 - O-Ring
20 - Hose
❑ For the crankcase ventilation
21 - Bracket
❑ For the connectors
22 - Bolt
❑ 4 Nm
❑ Thread cutting
cation.
23 - Bonded Rubber Bushing
❑ 10 Nm
4. Intake Manifold 213

4.1.2 Overview - Intake Manifold, Vehicles with MultiFlex Engine
1 - Bolt
❑ 20 Nm
2 - Intake Manifold Support
3 - Bonded Rubber Bushing
❑ 10 Nm
4 - Bolt
❑ 9 Nm
5 - Throttle Valve Control Mod‐
ule - J338-
❑ With EPC Throttle Drive
- G186- , EPC Throttle
G187- and EPC Throttle
G188-
ling. Refer to
Control Module J338 ,
ling”, page 216
❑ Cleaning. Refer to
Control Module, Clean‐
ing”, page 216 .
❑ After replacing, perform
an “adaptation”. Refer to
Vehicle Diagnostic
Tester , Guided Func-
tions
6 - Gasket
moving
7 - Hose
8 - O-Rings
❑ Always
with respectreplace after ofremoving
to the correctness information in this document. Copyright by AUDI AG.
9 - Bolt
❑ 5 Nm
10 - Intake Air Temperature Sensor - G42-
⇒ “6.1 Intake Air Temperature Sensor G42 , Removing and Installing”, page 229
11 - O-Ring
12 - Nut
13 - Intake Manifold Upper Section
Installing .

14 - Bolt
15 - Seals
16 - Bolt
❑ 0.8 Nm
❑ Thread cutting
cation.
17 - Intake Manifold Runner Position Sensor - G336-
18 - Connection
19 - O-Rings
20 - O-Rings
21 - Connection
22 - Seal
23 - Intake Manifold Lower Section
Installing .
24 - Low Fuel Pressure Sensor - G410-
❑ 27 Nm
25 - Bolt
❑ 9 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
26 - Fuel Line
❑ With a bracket for the Cold Start Injector - N17-
27 - Bolt
❑ 9 Nm
28 - Bracket
❑ For the connectors
29 - Bolt
❑ 4 Nm
❑ Thread cutting
cation.
30 - Clip
31 - O-Ring
32 - Cold Start Injector - N17-
❑ Removing and installing. Refer to ⇒ “5.5 Cold Start Injector N17 , Removing and Installing”, page 228
33 - O-Ring

34 - Nut
❑ 10 Nm
4.2 Intake Manifold, Removing and Instal‐

ling
Refer to ⇒ Rep. Gr. 24 ; Intake Manifold; Intake Manifold, Re‐
4.3 Throttle Valve Control Module - J338- ,

Removing
to ⇒ Rep. Gr. 24 ; Intake Manifold; Throttle Valve Control Module
- J338- , Removing and Installing .
– Remove the bolts -arrows- and the Throttle Valve Control
Module - J338- .
Installing
– Clean the gasket sealing surface.
to ⇒ Rep. Gr. 24 ; Intake Manifold; Throttle Valve Control Module
- J338- , Removing and Installing .
– After installing the Throttle Valve Control Module - J338- , per‐
form an “adaptation”. Refer to Vehicle Diagnostic Tester in
Guided Functions .
4.4 Throttle Valve Control Module, Cleaning

♦ Acetone, commercially available
♦ Safety Gloves permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Procedure
• The throttle valve connections must not be scratched when
cleaning.
– Remove the Throttle Valve Control Module - J338- . Refer to
⇒ “4.3 Throttle Valve Control Module J338 , Removing and

– Open the throttle valve by hand and lock it in this position using
a plastic or wood wedge -arrow-.
WARNING
Risk of injury from acetone. Acetone is highly flammable and
can cause eye and skin irritation.
– Clean the throttle valve connection thoroughly with acetone

and a brush especially in the area -arrows- near the closed
throttle valve.
– Wipe the throttle valve connections with a lint-free cloth.
– Let the acetone dry completely.
– Install the Throttle Valve Control Module - J338- . Refer to
⇒ “4.3 Throttle Valve Control Module J338 , Removing and
4.5 Intake Manifold Change-Over, Check‐

ing
Only perform the test if there is a loss of torque. That means there
is reduced elasticity or reduced engine acceleration.
Test Conditions
• The Intake Manifold Runner Control Valve - N316- was
checked with a Vehicle Diagnostic Tester .
If the Intake Manifold Runner Control Valve - N316- is OK, per‐
form the following tests:
Procedure
– Start engine and let run at idle.
– Have a second person increase engine speed abruptly (press
accelerator pedal) at the same time pay attention to the vac‐
uum actuator for the intake manifold change-over.

• The linkage -1- from the adjusting element for the intake mani‐
fold flap must tighten in direction of -arrow-.
If change over does not function as specified:
– Check the vacuum system for leaks.
– Check the vacuum lines for correct connection.
– Check that the vacuum hoses are not porous.
– Set the slide ring -1- of the -VAS6213- in position -A- -- for
"vacuum"
– Connect the -VAS6213- to the actuator for the Intake Manifold

Runner Control Valve - N316- .
– Operate the - VAS6213- several times.
• The linkage -1- from the adjusting element for the intake mani‐
fold flap must tighten.
– Discharge the vacuum.
• The linkage returns to the starting position.
• The linkage must move in both directions in direction of
-arrow-.
– If the linkage does not move, replace the intake manifold.
to ⇒ Rep. Gr. 24 ; Intake Manifold; Intake Manifold Change-Over,
Checking .

5 Fuel Injectors
⇒ “5.1 Overview - Fuel Rail with Fuel Injectors”, page 219
⇒ “5.2 Fuel Rail, Removing and Installing”, page 222
⇒ “5.3 Fuel Injectors, Removing and Installing”, page 223
⇒ “5.4 Fuel Injectors, Cleaning”, page 227
⇒ “5.5 Cold Start Injector N17 , Removing and Installing”,
page 228
5.1 Overview - Fuel Rail with Fuel Injectors

⇒ “5.1.1 Overview - Fuel Rail With Fuel Injectors, Vehicles with
Gasoline Engine”, page 219
⇒ “5.1.2 Overview - Fuel Rail with Fuel Injectors, Vehicles
permitted with
MultiFlex Engine”, page 221 with respect to the correctness of information in this document. Copyright by AUDI AG.
5.1.1 Overview - Fuel Rail With Fuel Injectors, Vehicles with Gasoline Engine
1 - High Pressure Line

❑ Tighten the union nut to
27 Nm
❑ Connections should not
show any signs of dam‐
age
❑ Do not change the
bending shape.
❑ Coat the thread on the
union nut with clean en‐
gine oil.
2 - Fuel Rail
ling. Refer to
⇒ “5.2 Fuel Rail, Re‐
moving and Installing”,
page 222
age
3 - Fuel Pressure Sensor -
G247-
❑ 27 Nm
ling. Refer to
⇒ “6.3 Fuel Pressure
Sensor G247 , Remov‐
ing and Installing”, page
230
❑ Coat the threads with
clean engine oil.
4 - Bolt
❑ 5 Nm
5 - Support Ring
❑ Check for proper seating
❑ The strength of the support ring allows the fuel rail to hold the fuel injector tightly in the cylinder head.
5. Fuel Injectors 219

6 - O-Ring
❑ Coat with clean engine oil
7 - Spacer Ring
8 - Fuel Injector
❑ There are different versions. Refer to the Parts Catalog for the allocation.
❑ Make sure it is in the installation position
❑ Removing and installing. Refer to ⇒ “5.3 Fuel Injectors, Removing and Installing”, page 223
9 - Sealing Washer
10 - Mount
❑ For sealing washer
11 - Combustion Chamber Seal
❑ Replacing. Refer to ⇒ “5.3 Fuel Injectors, Removing and Installing”, page 223 .
12 - Bolt
❑ 5 Nm
cation.
❑ Thread cutting
13 - Clamp
❑ For the high pressure line
14 - Connection
❑ 40 Nm
❑ For fuel return line
❑ Counterhold when loosening the union nuts

5.1.2 Overview - Fuel Rail with Fuel Injectors, Vehicles with MultiFlex Engine
1 - High Pressure Line

❑ Tighten the union nut to
27 Nm
age
❑ Do not change the
bending shape.
❑ Coat the thread on the
union nut with clean en‐
gine oil.
2 - Fuel Rail
age
ling. Refer to
⇒ “5.2.2 Fuel Rail, Re‐
moving and Installing,
Vehicles with MultiFlex
Engine”, page 222
3 - Fuel Pressure Sensor -
G247-
❑ 27 Nm
ling. Refer to
⇒ “6.3 Fuel Pressure
Sensor G247 , Remov‐
ing and Installing”, page
230
❑ Coat the threads with
clean engine oil.
4 - Bolt
❑ 9 Nm
5 - Support Ring
❑ Check for proper seating
❑ The strength of the support ring allows thepermitted
fuel rail to authorised
unless hold thebyfuel
AUDI injector
AG. AUDI AG tightly inguarantee
does not the cylinder
or accept head.
any liability
6 - O-Ring
❑ Coat with clean engine oil
7 - Spacer Ring
8 - Fuel Injector
❑ There are different versions. Refer to the Parts Catalog for the allocation.
❑ Make sure it is in the installation position
❑ Removing and installing. Refer to ⇒ “5.3 Fuel Injectors, Removing and Installing”, page 223
9 - Sealing Washer
10 - Mount
❑ For sealing washer
11 - Combustion Chamber Seal
❑ Replacing. Refer to ⇒ “5.3 Fuel Injectors, Removing and Installing”, page 223 .

12 - Clamp
❑ For the high pressure line
13 - Bolt
❑ 5 Nm
14 - Connection
❑ 40 Nm
❑ For fuel return line
5.2 Fuel Rail, Removing and Installing

⇒ “5.2.1 Fuel Rail, Removing and Installing, Vehicles with Gaso‐
line Engine”, page 222
⇒ “5.2.2 Fuel Rail, Removing and Installing, Vehicles with byMulti‐
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
Flex Engine”, page 222 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5.2.1 Fuel Rail, Removing and Installing, Ve‐

hicles with Gasoline Engine
Removing
– Remove the intake manifold. Refer to ⇒ Rep. Gr. 24 ; Intake
Manifold; Intake Manifold, Removing and Installing .
– Remove the fuel rail from the intake manifold.
Note
Ignore -1-.
Installing
– Always replace both fuel supply line connections.
– Tighten the fuel line.
– Reconnect the connector.
– Install the intake manifold. Refer to ⇒ Rep. Gr. 24 ; Intake
Manifold; Intake Manifold, Removing and Installing .
♦ Refer to
⇒ “5.1.1 Overview - Fuel Rail With Fuel Injectors, Vehicles with
Gasoline Engine”, page 219
5.2.2 Fuel Rail, Removing and Installing, Ve‐

hicles with MultiFlex Engine
Removing
– Remove the intake manifold lower section. Refer to ⇒ Rep.
Gr. 24 ; Intake Manifold; Intake Manifold, Removing and In‐
stalling .

– Disconnect the connector -1- on the Fuel Pressure Sensor -

G247- .
– Remove the bolts -arrows- and pull the fuel rail off the fuel
injectors.
Note
The fuel injectors could remain stuck in the fuel rail. Disconnect
the connector from the fuel injector.
Installing
Note
Make sure the fuel injectors are installed correctly.
– Install the intake manifold lower section. Refer to ⇒ Rep. Gr.

24 ; Intake Manifold; Intake Manifold, Removing and Instal‐
ling .
♦ Refer to
⇒ “5.1.2 Overview - Fuel Rail with Fuel Injectors, Vehicles with
MultiFlex Engine”, page 221
5.3 Fuel Injectors, Removing and Installing

♦ Injector/Combustion Chamber Seal Tool Set - T10133C-
Removing
• The fuel injectors can only be removed when the engine
permitted unlessis
cold. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Vehicles with gasoline engine: remove the intake manifold.
Refer to ⇒ Rep. Gr. 24 ; Intake Manifold; Intake Manifold,
– Vehicles with MultiFlex engine: remove the fuel rail. Refer to
⇒ “5.2 Fuel Rail, Removing and Installing”, page 222 .
• If the fuel injectors are stuck in the fuel rail, carefully pull out
the fuel injectors from the fuel rail.
– Remove the fuel injectors, in the event that they are stuck in
the cylinder head.
– Cover the open intake channels with a clean cloth.

– Remove the support ring -7- from the fuel injector -4-.
– Slide the -T10133/18- over the fuel injector.
– Carefully tap the fitting sleeve with a plastic mallet -1- to loosen
the fuel injector.
• Use a torque wrench to remove the fuel injector.

– Adjust to 5 Nm on the torque wrench
– Guide the -T10133/2A- in the groove on the fuel injector.
– Install the T10133/16A .
– Remove the fuel injector by using the torque wrench -1- to turn
the bolt.
– If the tightening specification limit of »5 Nm« is achieved with‐
out the fuel injector loosening, remove the puller and loosen
the fuel injector with the sleeve.
– Repeat this on each fuel injector.

Disassembling the Fuel Injector

– Remove the O-ring -6- and the spacer ring -5- from the fuel
injector -4-.
– Unclip the sealing washer -1-.
– Carefully remove the old combustion chamber seal -3- by cut‐
ting the combustion chamber seal with a knife or prying it open
with a small screwdriver and removing it toward the front.
• Make sure that the groove of the fuel injector does not become
damaged. If the groove is damaged, the fuel injector must be
replaced.
Installing
• Use the complete repair kit when installing.
• Replace the support ring after removing.
• Replace the combustion chamber seal before reinstalling the
fuel injector.
– Clean the hole in the cylinder head with a -T10133/4- .

– When reinstalling a fuel injector, use a clean towel to clean
combustion residue from the groove for combustion chamber
seal and the shaft of the fuel injector.
– Place the -T10133/5- with the new combustion chamber seal

-1- onto the fuel injector -2-.
– Push the combustion chamber seal -1- onto the -T10133/5- as

far as possible using the -T10133/6- .

– Turn the -T10133/6- and the combustion chamber seal until

the they slide into the seal groove.
• When pushing the combustion chamber seal onto the fuel in‐
jector, the seal spreads open. After pushing it on, it must be
tightened again in two steps, as described in the following.
– Press the -T10133/7- with a gentle turning movement (ap‐
proximately 180°) all the way onto the fuel injector.
– Pull off the -T10133/7- again using turning motion in opposite
direction.
– Press the -T10133/8- with a gentle turning movement (ap‐

proximately 180°) all the way onto the fuel injector.
– Pull off -T10133/8- again using turning motion in opposite di‐
rection.
– Coat the new O-ring -6- with clean engine oil before installing
the fuel injector -4-.
• The combustion chamber seal -3- must not be oiled.

– Press the fuel injector by hand all the way in the oil and grease
free opening for the cylinder head. Make sure the fuel injectors
are positioned -arrow- correctly inside the cylinder head.
• The tab -1- and the opening -arrow- must be aligned in the
cylinder head.
• The fuel injector must not be difficult to install. Otherwise wait
as the combustion chamber seal continues to pull itself to‐
gether.
– Install the support ring onto the fuel injector.
– Vehicles with gasoline engine: install the intake manifold. Re‐
fer to ⇒ Rep. Gr. 24 ; Intake Manifold; Intake Manifold,
– Vehicles with MultiFlex engine: install the fuel rail. Refer to
⇒ “5.2 Fuel Rail, Removing and Installing”, page 222 .
5.4 Fuel Injectors, Cleaning

♦ Ultrasonic Cleaning Unit - VAS6418-
♦ Ultrasonic CleaningProtected
Unit - Mounting Plate for Injection Mod‐
ules - VAS6418/1- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Ultrasonic Cleaning Unit - Cleaning Fluid - VAS6418/2-
The procedure refers to the FSI fuel injectors.
Procedure
– Connect the drain valve -arrow- to the -VAS6418- on the right
side of the housing.
– Fill the ultrasonic unit.
• Cleaning fluid mixture ratio: 2100 ml (2.2 quarts) settled tap
water and 20 ml (0.68 oz) -VAS6418/2- .
• The ideal fluid level is reached when the cleaning fluid is ap‐
proximately 1 to 4 mm above the bottom of the mounting plate.
A fluid level which is too low can damage the -VAS6418- .
– Remove the fuel injectors. Refer to
⇒ “5.3 Fuel Injectors, Removing and Installing”, page 223 .
– Place the -VAS6418/1- on the cleaning unit.

• Before operating the -VAS6418- pay attention to the safety
precautions in the Owner's Manual.
– Insert the FSI fuel injectors all the way into the guides on the
-VAS6418/1- .

– Switch on the cleaning unit by pressing the on/off button

-C-.
– Set the cleaning time on the knob -A- to 30 minutes.
– Set the temperature on the knob -B- to 50 °C (122 °F).
– Press the ► button -D- to start cleaning.
• The cleaning must take at least 30 minutes and first begins
once a temperature of at least 50 °C (122 °F) is reached.
– Install the fuel injectors with a new combustion chamber seal.
Refer to
⇒ “5.3 Fuel Injectors, Removing and Installing”, page 223 .
5.5 Cold Start Injector - N17- , Removing

and Installing
Flex MultiFlex Only
Removing
– Remove the intake manifold upper section. Refer to ⇒ Rep.
Gr. 24 ; Intake Manifold; Intake Manifold, Removing and In‐
stalling .
– Remove the clamp -1-.
– Remove the bolts -arrow- and remove the fuel supply lines with
bracket -2- from the Cold Start Injector - N17- .
– Remove the Cold Start Injector - N17- from the intake manifold
upper section and/or from bracket with fuel supply line.
Installing
– Install the intake manifold upper section. Refer to ⇒ Rep. Gr.
24 ; Intake Manifold; Intake Manifold, Removing and Instal‐
ling .
♦ Refer to
⇒ “5.1.2 Overview - Fuel Rail with Fuel Injectors, Vehicles with
MultiFlex Engine”, page 221

6 Sensors
⇒ “6.1 Intake Air Temperature Sensor G42 , Removing and In‐
⇒ “6.2 Mass Airflow Sensor G70 , Removing and Installing”, page
229
⇒ “6.3 Fuel Pressure Sensor G247 , Removing and Installing”,
page 230
⇒ “6.4 Fuel Pressure Sensor G247 , Checking”, page 232
6.1 Intake Air Temperature Sensor - G42- ,

Removing
Note

positions.

– Remove the bolt and then remove the Intake Air Temperature
Sensor - G42- .
Installing
6.2 Mass Airflow Sensor - G70- , Removing

and Installing
Removing
to ⇒ Rep. Gr. 24 ; Sensors; Mass Airflow Sensor - G70- , Re‐
6. Sensors 229
– Remove the bolts -arrows- for the Mass Airflow Sensor - G70- .
– Carefully pull the Mass Airflow Sensor - G70- out of the guide
from air filter housing.
Installing
For problem-free operation of the Mass Airflow Sensor - G70- it
is very important to observe the following notes and procedures.
Note
♦ If the air filter element is very dirty or soaked, dirt particles or

moisture may have contaminated the Mass Airflow Sensor -
G70- and may be causing false mass airflow values. This
results in reduced performance, since a lower injection quan‐
tity is calculated.
♦ Always use an original air filter element.
♦ Use a silicone-free lubricant for installing the air duct hose.
♦ Secure all hose connections with hose clamps that match the
– Check the mass airflow sensor and air duct hose (intake air
side) for salt residue, dirt, and leaves.
– Check the intake channels for debris up to the air filter element.
If any contaminants are discovered, clean the air filter housing
(upper and lower sections) of salt residue, dirt and leaves (if
necessary, clean by washing or vacuuming).
Further installation is the reverse order of removal.
to ⇒ Rep. Gr. 24 ; Sensors; Mass Airflow Sensor - G70- , Re‐
♦ Refer to ⇒ Rep. Gr. 24 ; Air Filter; Overview - Air Filter Hous‐
ing .
6.3 Fuel Pressure Sensor - G247- , Remov‐

ing and Installing
♦ Socket - 27mm - T40218- or a commercially available 27 mm
socket
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the engine cover.
with respect to theRefer to of information in this document. Copyright by AUDI AG.
correctness
Note

positions.

– Remove the bolts -1 and 2- and move the coolant line, with the
coolant hoses -arrows- still connected, to the side.
– If installed, remove the bolts -arrows-, push the After-Run

Coolant Pump - V51- to the side by disconnecting the con‐
nector -1-.
Note

positions.
– Release the connector on the Fuel Pressure Sensor - G247-

-1- using the - T10118- .
WARNING
The fuel system is under pressure.
Risk of injury from fuel spraying out.
– Reduce the pressure: place clean cloths around the con‐
nection point and carefully open the connection point.
– Remove the fuel pressure sensor using the -T40218- .

Installing
– Check the connection tightening specification before installing
the Fuel Pressure Sensor - G247- .
♦ Refer to
♦ Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Coolant Regulation;
Overview - Electric Coolant Pump .
♦ Refer to ⇒ Rep. Gr. 19 ; Coolant Pipes; Overview - Coolant
Pipes .
6. Sensors 231
6.4 Fuel Pressure Sensor - G247- , Check‐

ing
♦ Pressure Sensor Tester - VAS6394-
♦ Vehicle Diagnostic Tester - Test Adapter - 3 Pin - VAS5570-
♦ Vehicle Diagnostic Tester
Procedure:
– Remove the Fuel Pressure Sensor - G247- . Refer to
page 230 .
– Install the -VAS6394/2- in place of the Fuel Pressure Sensor
- G247- and tighten it to the specification used for the Fuel
Pressure Sensor - G247- .
– Remove the plug -2- on the - VAS6394/1- and install the Fuel
Pressure Sensor - G247- to the tightening specification in its
place.
– Use the -VAS5570- in order establish the electrical connection

between the vehicle and the Fuel Pressure Sensor - G247- .
– Connect the Vehicle Diagnostic Tester .
– Switch the ignition on.
– Select “engine electronics” in OBD.
– Select “measured values”
– Select “fuel pressure” from the list.
• The current value is displayed in the display field, which the
Fuel Pressure Sensor - G247- reports to the engine control
module.

– Briefly press the button -A- once to turn on the -VAS6394/1- .

• The -VAS6394/1- should display 0 bar.
– On other displays press the -C- button once quickly to set it
back to zero.
– Connect the -VAS6394/1- to the -VAS6394/2- .

– Start the engine.
– Compare the pressure shown on the -VAS6394/1- with the
actual value in the Vehicle Diagnostic Tester .
• The pressures may have a maximum difference of 5 bar (72.51
psi).
– If the difference is greater than 5 bar (72.51 psi), install a new
Fuel Pressure Sensor - G247- .
– Place a cloth underneath to catch any escaping fuel.
WARNING
– Insert the new Fuel Pressure Sensor - G247- in the -

VAS6394/1- .
– Repeat the test with the new Fuel Pressure Sensor - G247-
and compare both values.
– If the measured values do not match again, checkby the
Protected wireCopying for private or commercial purposes, in part or in whole, is not
copyright.
connection between the Fuel Pressure Sensor - G247-
permitted and by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
the engine control module. Refer to ⇒ Wiringwith
diagrams,
respect to theTrou‐
bleshooting & Component locations.
– If the measured values now align, install the new Fuel Pres‐
sure Sensor - G247- . Refer to
page 230 .
♦ Refer to
6. Sensors 233
7 High Pressure Pump

⇒ “7.1 Overview - High Pressure Pump”, page 234
page 235
7.1 Overview - High Pressure Pump
1 - Quick-Release Coupling
❑ With stop valve
❑ No replacement part; in‐
cluded in the delivery
package -item 11-
⇒ Item 11 (page 235)
2 - Connector
3 - Fuel Pressure Regulator
Valve or Fuel Metering Valve
❑ There are different ver‐
sions.
❑ Depending on the man‐
ufacture of the high
pressure pump:
♦ Fuel Pressure Regulator
Valve - N276- or
♦ Fuel Metering Valve -
N290-
❑ Integrated in the high
pressure pump, cannot
be replaced separately
4 - High Pressure Pump
ling. Refer to
⇒ “7.2 High Pressure
Pump, Removing and
❑ Do not bend when in‐
stalling.
5 - O-Ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Always replace after
with respect to there‐
moving
❑ Coat with engine oil
6 - Roller Tappet
❑ Remains inserted in the vacuum pump after removing the high pressure pump
7 - Vacuum Pump
8 - Connection
❑ 40 Nm
❑ Replace every time it is loosened
❑ For the high pressure pipe.
9 - High Pressure Pipe
❑ Tighten the union nut to 27 Nm
❑ Do not change the bending shape.
❑ Do not install when under stress

❑ Coat the thread on the union nut with clean engine oil.
10 - Bolt
⇒ Fig. ““High Pressure Pump - Tightening Specifications and Sequence”“ , page 235 .
❑ M6 replace after removal
11 - Fuel Supply Hose
❑ From the fuel tank
12 - Spring Clamp
13 - Spring Clamp
❑ No replacement part; included in the delivery package -item 11- ⇒ Item 11 (page 235)
High Pressure Pump - Tightening Specifications and Sequence

– Tighten the bolts -arrows- in steps as follows to prevent the
high pressure pump flange from becoming deformed when in‐
stalling:
Step Bolts Tightening Specification
1. Install by hand all the way
2. Tighten one turn from side to side until
the flange on the high pressure pump
contacts the vacuum pump
3. M6 8 Nm
90° additional turn
M8 20 Nm
7.2 High Pressure Pump, Removing and In‐
stalling
♦ Wrench - 21mm - T40263-
♦ 24 mm Socket
♦ Safety Gloves
Removing
• Only remove the high pressure pump when the engine is cold.
7. High Pressure Pump 235


WARNING
– Open both fuel lines -arrows-.
– Disconnect the connector -1- for the Fuel Pressure Regulator

Valve - N276- / Fuel Metering Valve - N290- .
– Carefully remove the high pressure pump -2-. The roller tappet
may remain in the vacuum pump.
Installing
• Replace the O-ring and spring clamps after removing.
• When reinstalling, replace the connection on the used high
pressure pump.
– Check the roller tappet -1- for damage and replace it if nec‐
essary.
– Coat the roller tappet with oil and insert it with the tab
-arrow A- into the guide -arrow B-.

• The help of a second technician is necessary for the following

step.
CAUTION
– Have a second technician turn the crankshaft in the direction

of engine rotation -arrow- using the -T40263- , -T40314- and
a 24 mm socket until the roller tappet has reached its lowest
point in the vacuum pump.
– Insert the high pressure pump with the O-ring into the vacuum
pump and tighten the bolts in stages.
– Secure permitted
fuel hosesunless with spring
authorised clamps.
– Tighten the high pressure pipe union nut hand-tight, align it
without tension and tighten it to the tightening specification.
– Check the fuel system for leaks.
♦ Refer to
⇒ Fig. ““High Pressure Pump - Tightening Specifications and
7. High Pressure Pump 237

8 Heated Oxygen Sensor

⇒ “8.1 Overview - Heated Oxygen Sensor”, page 238
⇒ “8.2 Heated Oxygen Sensor, Removing and Installing”,
page 240
8.1 Overview - Heated Oxygen Sensor

⇒ “8.1.1 Overview - Heated Oxygen Sensor, Version 1”,
page 238
⇒ “8.1.2 Overview - Heated Oxygen Sensor,
Protected by copyright. Version 2”, or commercial purposes, in part or in whole, is not
Copying for private
page 239 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
8.1.1 Overview - Heated Oxygen Sensor, Version 1
1 - Nut
❑ -item 1-
2 - Gasket
❑ -item 2-
3 - Turbocharger
4 - Heated Oxygen Sensor -
G39- and Oxygen Sensor
Heater - Z19-
❑ 55 Nm
❑ Coat the threads on the
new heated oxygen
sensors with assembly
paste.
❑ When installing a used
oxygen sensor, coat
threads with hot bolt
paste. Refer to Parts
Catalog for the correct
hot bolt paste.
❑ Assembly paste or hot
bolt paste must not en‐
ter the slots on the heat‐
ed oxygen sensor body.
ling. Refer to ⇒ Rep.
Gr. 24 ; Heated Oxygen
Sensor; Heated Oxygen
Sensor, Removing and
Installing .
5 - Oxygen Sensor after Cata‐
lytic Converter - G130- and
Heater for Oxygen Sensor 1
after Catalytic Converter - Z29-
❑ 55 Nm
❑ Coat the threads on the new heated oxygen sensors with assembly paste.
❑ When installing a used oxygen sensor, coat threads with hot bolt paste. Refer to Parts Catalog for the
correct hot bolt paste.
❑ Assembly paste or hot bolt paste must not enter the slots on the heated oxygen sensor body.
❑ Removing and installing. Refer to ⇒ Rep. Gr. 24 ; Heated Oxygen Sensor; Heated Oxygen Sensor,

6 - Catalytic Converter
❑ -item 6- ⇒ Item 6 (page 249)
7 - Nut
8 - Gasket
9 - Front Muffler
8.1.2 Overview - Heated Oxygen Sensor, Version 2
1 - Nut
❑ -item 1-
2 - Gasket
❑ -item 2-
3 - Turbocharger
Heater - Z19-
❑ 55 Nm
❑ Coat the threads on the
new heated oxygen
sensors with assembly
paste.
❑ When installing a used
oxygen sensor, coat
threads with hot bolt
paste. Refer to Parts
Catalog for the correct
hot bolt paste.
❑ Assembly paste or hot
bolt paste must not en‐
ter the slots on the heat‐
ed oxygen sensor body.
Installing .
5 - Oxygen
ProtectedSensor after
by copyright. Cata‐
lytic Converter - G130-
permitted unless and
Heater forwithOxygen Sensor
respect to the 1 of information in this document. Copyright by AUDI AG.
correctness
❑ 55 Nm
❑ Coat the threads on the new heated oxygen sensors with assembly paste.
❑ When installing a used oxygen sensor, coat threads with hot bolt paste. Refer to Parts Catalog for the
correct hot bolt paste.
❑ Assembly paste or hot bolt paste must not enter the slots on the heated oxygen sensor body.
❑ Removing and installing. Refer to ⇒ Rep. Gr. 24 ; Heated Oxygen Sensor; Heated Oxygen Sensor,
8. Heated Oxygen Sensor 239

7 - Nut
8 - Gasket
9 - Front Exhaust Pipe
8.2 Heated Oxygen Sensor, Removing and

Installing
Refer to ⇒ Rep. Gr. 24 ; Heated Oxygen Sensor; Heated Oxygen
Sensor, Removing and Installing .

9 Engine Control Module

⇒ “9.1 Engine Control Module J623 , Removing and Installing”,
page 241
⇒ “9.2 Wiring and Components”, page 241
9.1 Engine Control Module - J623- , Remov‐

ing and Installing
Refer to ⇒ Rep. Gr. 24 ; Engine Control Module; Engine Control
Module - J623- , Removing and Installing .
9.2 Wiring and Components

⇒ “9.2.1 Wiring and Components, Non-Hybrid Vehicles”,
page 241
⇒ “9.2.2 Wiring and Components, Hybrid Vehicles”, page 242
9.2.1 Wiring and Components, Non-Hybrid

Vehicles
♦ Test Box Kit - Adapter Cable - 60-pin - VAG1598/39-1-
♦ Test Box Kit - 94 Pin Adapter - VAG1598/39-2-
♦ Test Box Kit - 105 Pin Test Box Kit - VAG1598/42-
9. Engine Control Module 241

Note
♦ The test box has 105 terminals. The connection cable can be
separated from the test box. This means that as new engine
control module connectors are introduced in the future, only a
new cable must be designed and no longer the entire test box.
♦ The smaller of the two connectors on the engine control mod‐
ule is assigned with terminals 1 to 60. The larger of the two
connectors is assigned with terminals 1 to 94.
♦ For testing at the 60-pin wiring harness connector, the -
VAG1598/39-1- is connected to the test box with the connector
“A”. Components on the 60-pin wiring harness connector. Re‐
fer to ⇒ Wiring diagrams, Troubleshooting & Component lo‐
cations.
♦ For testing at the 94-pin wiring harness connector, the -
VAG1598/39-2- is connected to the test box with the connec‐
tors -A- and -B-. Components on the 94-pin wiring harness
connector. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations.
♦ The -VAG1598/42- is designed so that it can be connected
simultaneously to the wiring harness to the engine control
module and the engine control module itself.
♦ This is advantageous because electronic engine management
remains fully functional (for example measurement of signals
with engine running) when the test box is attached.
♦ The respective test sequences will indicate whether the en‐
gine control module is to remain connected to the test box or
not.
This allows the multi-pin connectors to be disconnected from the

engine control module; the engine control module must be re‐
moved. Refer to ⇒ Rep. Gr. 24 ; Engine Control Module; Engine
Control Module - J623- , Removing and Installing .
• To avoid damaging electronic components, switch to the cor‐
responding measuring range and observe all test conditions
before connecting the test leads.
– Connect the -VAG1598/42- to the wiring harness using the -
VAG1598/39-1- or -VAG1598/39-2- . Clamp the test box
ground clip to the battery negative terminal. The test sequence
will indicate whether the engine control module is to be con‐
nected to the test box or not.
– Perform the test as it is described in the respective repair se‐
quences.
9.2.2 Wiring and Components, Hybrid Vehi‐

cles
♦ Test Adapter - Isolator Box 1 - VAS6606/1-
♦ Isolator Box - Module 2 - VAS6606/2-
♦ Isolator Box Module 3 - VAS6606/3-
♦ Template - Isolator Box - VAS6606/1-1-
♦ Isolator Box - Module 2 Template - VAS6606/2-1-

♦ Test Adapter for ECU - Isolator Box - 1m - VAS6606/7-1- and

Test Adapter for ECU - Isolator Box - 1.7m - VAS6606/7-2- .
♦ Breakout Box w/Detachable Terminals - VAS6606-
Note
♦ Always make sure the cables are connected correctly.

♦ Never use any damaged or worn tools or accessories.
♦ Refer to the Owner's Manual.
– Connect both -VAS6606/7-1- and -VAS6606/7-2- completely

to the three -VAS6606- .
– Use the following foils:
♦ -VAS6606/1-1- for the -VAS6606/1-
♦ -VAS6606/2-1- for the -VAS6606/1-2-
♦ -VAS6606/3-1- for the -VAS6606/3-
Note
Make sure all connection bridges are connected completely on all

breakout boxes. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Connect the ground cable to awithbreakout box and to a ground
respect to the correctness of information in this document. Copyright by AUDI AG.
connection on the vehicle.

This allows the multi-pin connectors to be disconnected from the
engine control module; the engine control module must be re‐
moved. Refer to ⇒ Rep. Gr. 24 ; Engine Control Module; Engine
Control Module - J623- , Removing and Installing .
• To avoid damaging electronic components, switch to the cor‐
responding measuring range and observe all test conditions
before connecting the test leads.
– Connect the engine control module to the -VAS6606/7-1- .
– Connect the wiring harness from the vehicle to the -
VAS6606/7-2- .
The connection on the engine control module consists of a large
and small connector.
The large connector has 105 pins and is assigned from “A 1
through A 105” on the breakout box foil.
The smaller connector has 91 pins and is assigned from “B 1
through B 91” on the breakout box foil.
The wire connection will get interrupted when the connection
bridge is disconnected.
9. Engine Control Module 243

Note
♦ The “In contact” -1- (red socket) goes to the engine control
module.
♦ The “Out contact” -2- (blue socket) goes to the wiring harness.
– Perform the test as it is described in the respective repair se‐

quences.

10 Special Tools
♦ Injector/Combustion Chamber Seal Tool Set - T10133C-
♦ Socket - 27mm - T40218- or a commercially available
permitted unless authorised 27 mm
socket with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Wrench - 21mm - T40263-

♦ Connector Test Set - VAG1594D-
♦ Test Box Kit - Adapter Cable - 60-pin - VAG1598/39-1-
♦ Test Box Kit - 94 Pin Adapter - VAG1598/39-2-

♦ Test Box Kit - 105 Pin Test Box Kit - VAG1598/42-

♦ Vehicle Diagnostic Tester - Test Adapter - 3 Pin - VAS5570-
♦ Test Adapter - Isolator Box 1 - VAS6606/1-

♦ Isolator Box - Module 2 - VAS6606/2-
♦ Isolator Box Module 3 - VAS6606/3-
♦ Isolator Box - Module 2 Template - VAS6606/2-1-
♦ Test Adapter for ECU - Isolator Box - 1m - VAS6606/7-1- and
Test Adapter for ECU - Isolator Box - 1.7m - VAS6606/7-2- .
♦ Vehicle Diagnostic Tester

♦ Pressure Sensor Tester - VAS6394-
♦ Ultrasonic Cleaning Unit - VAS6418-
♦ Ultrasonic Cleaning Unit - Mounting Plate for Injection Mod‐
ules - VAS6418/1-
♦ Ultrasonic Cleaning Unit - Cleaning Fluid - VAS6418/2-

26 – Exhaust System, Emission Controls

1 Exhaust Pipes/Mufflers
⇒ “1.1 Overview - Muffler”, page 248
⇒ “1.2 Exhaust Pipes/Mufflers, Disconnecting”, page 248
⇒ “1.3 Front Muffler, Removing and Installing”, page 248
⇒ “1.4 Muffler, Removing and Installing”, page 248
⇒ “1.5 Exhaust System, Installing without Tension”, page 248
⇒ “1.6 Exhaust System, Checking for Leaks”, page 248
1.1 Overview - Muffler

Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview -
Mufflers .
1.2 Exhaust Pipes/Mufflers, Disconnecting

Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Exhaust Pipes/
Mufflers, Disconnecting .
1.3 Front Muffler, Removing and Installing

Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Front Muffler,
1.4 Muffler, Removing and Installing

Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Muffler; Muffler, Remov‐
ing and Installing .
1.5 Exhaust System, Installing without Ten‐

sion Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Exhaust
with respect to the correctness Sys‐ in this document. Copyright by AUDI AG.
of information
tem, Aligning Free of Tension .
1.6 Exhaust System, Checking for Leaks

Procedure
– Start the engine and let it run in idle.
– Seal the tailpipes, for example, with a cloth or a plug, for the
duration of the leak test.
– Check for leaks by listening at connection areas of cylinder
head/turbocharger, turbocharger/front exhaust pipe etc.
– Repair the determined leaks.
248 Rep. Gr.26 - Exhaust System, Emission Controls

2 Emissions Control System

⇒ “2.1 Overview - Emissions Control System”, page 249
⇒ “2.2 Catalytic Converter, Removing and Installing”, page 251
2.1 Overview - Emissions Control System

⇒ “2.1.1 Overview - Emissions Control System, Version 1”, page
249
⇒ “2.1.2 Overview - Emissions Control System, Version 2”, page
250
2.1.1 Overview - Emissions Control System, Version 1
1 - Nut
❑ 40 Nm
moving
❑ Coat turbocharger stud
bolts with hot bolt paste.
❑ Hot bolt paste. Refer to
the Parts Catalog.
2 - Gasket
moving
3 - Turbocharger
Heater - Z19-
Installing .
Installing .
❑ Protect catalytic con‐
verter from shocks and
impact stress
❑ Removing and installing. Refer to ⇒ Rep. Gr. 26 ; Emissions Control System; Catalytic Converter,
Removing and Installing . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Align the exhaust system without tension. Refer
with respect tocorrectness
to the ⇒ Rep.ofGr. 26 ;inExhaust
information Pipes/Mufflers;
this document. Copyright by AUDI AG. Exhaust
System, Aligning Without Tension .
7 - Nut
❑ 25 Nm
2. Emissions Control System 249

8 - Gasket
9 - Front Muffler
2.1.2 Overview - Emissions Control System, Version 2
1 - Nut
❑ 40 Nm
moving
❑ Coat turbocharger stud
bolts with hot bolt paste.
❑ Hot bolt paste. Refer to
the Parts Catalog.
2 - Gasket
moving
3 - Turbocharger
Heater - Z19-
Installing .
Installing .
❑ Protect catalytic con‐
verter from shocks and
impact stress
❑ Removing and installing. Refer to ⇒ Rep. Gr. 26 ; Emissions Control System; Catalytic Converter,
❑ Align the exhaust system without tension. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Exhaust
System, Aligning Without Tension .
7 - Nut with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 25 Nm
8 - Gasket
9 - Front Exhaust Pipe

2.2 Catalytic Converter, Removing and In‐

stalling
Refer to ⇒ Rep. Gr. 26 ; Emissions Control System; Catalytic
Converter, Removing and Installing .
2. Emissions Control System 251

3 Secondary Air System

Refer to ⇒ Rep. Gr. 24 ; Secondary Air System .

28 – Ignition/Glow Plug System

1 Ignition System
⇒ “1.1 Overview - Ignition System”, page 253
⇒ “1.3 Knock Sensor 1 G61 , Removing and Installing”,
page 256
⇒ “1.4 Camshaft Position Sensor, Removing and Installing”, page
256
⇒ “1.5 Engine Speed Sensor G28 , Removing and Installing”,
page 257
1.1 Overview - Ignition System
1 - Bolt
❑ 20 Nm
❑ The tightening specifi‐
cations affect function of
the knock sensor
2 - Knock Sensor 1 - G61- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ling. Refer to
⇒ “1.3 Knock Sensor 1
G61 , Removing and In‐
3 - Bolt
❑ 9 Nm
4 - Camshaft Position Sensor -
G40-
ling. Refer to
⇒ “1.4 Camshaft Posi‐
tion Sensor, Removing
and Installing”,
page 256
5 - O-Ring
moving
6 - Ignition Coil with Power
Output Stage
♦ Ignition Coil 1 with Power
Output Stage - N70-
Output Stage - N127-
⇒ “1.2 Ignition Coils with Power Output Stages, Removing and Installing”, page 254
1. Ignition System 253

7 - Spark Plug
❑ 30 Nm
8 - O-Ring
9 - Engine Speed Sensor - G28-
⇒ “1.5 Engine Speed Sensor G28 , Removing and Installing”, page 257
10 - Bolt
❑ 4.5 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Ignition Coil Connectors - Tightening Specification

– Tighten the bolts -arrow- to 5 Nm.
1.2 Ignition Coils with Power Output Stages,

♦ Puller - Ignition Coil - T40039-
♦ Refer to the Parts Catalog for the correct silicone paste.
The ignition coils are easier to remove when the engine is warm.
The grease used during the shop assembly helps the ignition coils
or spark plug connectors to free up more easily when the engine
is warm.
Removing
– Remove the bolt -arrow- from the connector strip.
254 Rep. Gr.28 - Ignition/Glow Plug System

Note
♦ To remove the ignition coils, place the -T40039- on topmost

thick rib -arrow- of the ignition coil with power output stage.
♦ The lower ribs may be damaged if they are used.
– Pull all ignition coils approximately 30 mm out of spark plug

shaft using the -T40039- .
– Release the connectors and pull all connectors simultaneously

off from the ignition coils.
Installing
CAUTION
Risk of Destroying the Ignition Coils by Using the Incorrect Lu‐
bricant
– Only use the silicone paste approved for this.
– Apply a thin bead of silicone paste around the sealing hose for
the ignition coil with power output stage -arrow-.

– Insert all ignition coils loosely into the spark plug shaft.
– Align the ignition coils to the connectors and then connect all
of the connectors simultaneously onto the ignition coils.
– Press the ignition coils uniformly onto the spark plugs by hand
(do not use any impact tools).
♦ Refer to
⇒ Fig. ““Ignition Coil Connectors - Tightening Specification”“ ,
page 254
1.3 Knock Sensor 1 - G61- , Removing and

Installing
Removing
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
The Knock Sensor 1 - G61- is located below the intake manifold

behind the coolant pump.
Hybrid Vehicles:
Safety precautions. Refer to ⇒ Rep. Gr. 28 ; Ignition System;
Knock Sensor 1 - G61- , Removing and Installing .
All Vehicles:
– Remove the coolant thermostat. Refer to
page 182 .
– Remove the Knock Sensor 1 - G61- .
Installing
– Install the coolant thermostat. Refer to
page 182 .
♦ Refer to ⇒ “1.1 Overview - Ignition System”, page 253
1.4 Camshaft Position Sensor, Removing

and Installing
Removing


– Remove the bolt -2- and then remove the Camshaft Position
Sensor - G40- .
Installing
• Replace the O-ring after removing.
1.5 Engine Speed Sensor - G28- , Remov‐

ing and Installing
Hybrid Vehicles:
Safety precautions. Refer to ⇒ Rep. Gr. 28 ; Ignition System;
Engine Speed Sensor - G28- , Removing and Installing .
Removing
– Disconnect the connector on the Engine Speed Sensor - G28-
-2- with the -T10118- .
– Remove the bolt -1- and remove the Engine Speed Sensor -
G28- .
Installing
Install in reverse order of removal.

2 Special Tools
♦ Puller - Ignition Coil - T40039-
♦ Refer to the Parts Catalog for the correct silicone paste.

3 Revision History
DRUCK NUMBER: A005A023621
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
Edi‐ tion ck d By
tion
06.2 07/1 Fac‐ N/A Eric P.

019 9/20 tory
19 Up‐
date
06.2 01/0 Cor‐ N/A MRP’s removal process Eric P.
018 3/20 rec‐
19 tion
06.2 06/1 Fac‐ 134 Performed Factory update. Juan S.
018 3/20 tory 466
18 Up‐ 2
date
01.2 02/0 Fac‐ N/A Joe Y.
018 2/20 tory
18 Up‐
date
12.2 11/2 Fac‐ N/A Performed Factory update. Juan S.
017 7/20 tory
17 Up‐
date
10.2 11/0 Cor‐ N/A Updated the special tools Eric P.
017 7/20 rec‐ in the sealing flange proce‐
17 tion dure.
10.2 10/1 Fac‐ N/A Performed Factory update. Juan S.
017 3/20 tory
17 Up‐
date
03.2 06/3 Fac‐ 126 Changed vacuum to pres‐ Eric P.
017 0/20 tory 534 sure in the Turbocharger
17 New 1 Vacuum Diaphragm,
Checking
3. Revision History 259

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Service

Service Department. Technical Information

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.1 Overview - Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

4.1 Overview - Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

00 – General, Technical Data

1.1 Engine Number/Engine Specifications

2.1 Safety Precautions when Working on

– Wear protective eyewear.

– Before opening the fuel system, interrupt the power supply to

2.2 Safety Precautions when Working on

– Deactivate the Start/Stop System: switch off the ignition.

2 Rep. Gr.00 - General, Technical Data

2.3 Safety Precautions during Road Test

– Secure the testing equipment on the rear seat.

2.4 Safety Precautions when Working on

– Wear safety gloves.

2.5 Safety Precautions when Working on

– Allow the exhaust system to cool.

– Coupling must not be bent more than 10°.

2.6 Safety Precautions when Working on Ig‐

– Never touch or remove the ignition wires when the engine is

– Switch off the ignition before connecting and disconnecting

2.7 Safety Precautions when Working on

Risk of Damaging the Components

– Never place the vehicle with loosened suspension compo‐

4 Rep. Gr.00 - General, Technical Data

3.1 Guidelines for Clean Working Condi‐

3.2 Foreign Objects in Engine

3.3 Contact Corrosion

3.4 Line Routing and Securing

3.5 Radiator and Condenser Assembly

3.6 Bolts and Nuts

3.7 Identification Plates

6 Rep. Gr.00 - General, Technical Data

3.8 Impact Wrench, Using

1.1 Engine, Removing

1.2 Engine, Securing to Engine and Trans‐

– Remove the drive plate. Refer to

– Fasten the engine to the -VAS6095/1- using the -VAS6095A- .

8 Rep. Gr.10 - Engine Assembly

1.3 Engine, Installing

1. Engine, Removing and Installing 9

10 Rep. Gr.10 - Engine Assembly

3.1 Engine Cover, Removing and Installing

♦ Holding Fixture - VW540-

12 Rep. Gr.10 - Engine Assembly

13 – Crankshaft, Cylinder Block

1.1 Overview - Cylinder Block, Belt Pulley

1. Cylinder Block, Belt Pulley Side 13

❑ Use the Counterhold -

14 Rep. Gr.13 - Crankshaft, Cylinder Block

Ribbed Belt Routing

1. Cylinder Block, Belt Pulley Side 15

Sub-Assembly Bracket - Tightening Sequence