100% found this document useful (2 votes)

130 views

Service: Audi A6 1998

Audi a6 c5

Uploaded by

Kovács Endre

Available Formats

Download as PDF, TXT or read online on Scribd

100% found this document useful (2 votes)

130 views

Service: Audi A6 1998

Audi a6 c5

Uploaded by

Kovács Endre

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 180

Service

Workshop Manual
Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI),
mechanics
Engine ID AFN AVG

Edition 02.2005

Service Department. Technical Information

Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
26 - Exhaust system

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Audi AG, Ingolstadt A0056005820

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Poly V-belt drive for power steering pump, alternator, coolant pump and viscous fan -
exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Poly V-belt drive for air conditioner - exploded view of components . . . . . . . . . . . . . . . . . . 26
1.3 Routing of poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1.7 Toothed belt drive - exploded viewpermitted
of components
unless authorised. by . .AUDI
. . .AG.. .AUDI
. . .AG. .does
. . not
. . guarantee
. . . . . .or.accept
. . . .any. .liability
34
1.8 Removing and installing toothed beltwith .respect. . . .to. the
. . correctness
. . . . . . .of.information
. . . . . .in. this
. . document.
. . . . . . Copyright
. . . . . by
. .AUDI
. . . AG.
. 37
1.9 Checking semi-automatic tensioning roller for toothed belt . . . . . . . . . . . . . . . . . . . . . . . . 43
1.10 Positioning crankshaft at TDC with engine removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Removing and installing sealing flanges and dual-mass flywheel/drive plate . . . . . . . . . . 45
2.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view of components . . . . 45
2.2 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Crankshaft - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 Removing and installing sender wheel for engine speed sender G28 . . . . . . . . . . . . . . . . 54
3.3 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1 Pistons and conrods - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Cylinder head - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.3 Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.4 Installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.5 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 Valve gear - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.2 Checking axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Contents i
Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2.5 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.6 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.7 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.8 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.9 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Sump, oil pump - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.2 Oil filter bracket, oil filter - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.6 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.7 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.3 Coolant pump and thermostat - exploded view of components . . . . . . . . . . . . . . . . . . . . . . 118
1.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.5 Removing, installing and checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.6 Removing and installing coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.7 Removing and installing viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.8 Removing and installing bearing for viscous fan in bracket . . . . . . . . . . . . . . . . . . . . . . . . 124
1.9 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.10 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1 Checking charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Requirements for turbocharging check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.3 Effects of leaks in the intake and exhaust systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.4 Checking turbocharger and charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Hose connection diagram for charge pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.6 Checking solenoid valve for charge pressure control N75 . . . . . . . . . . . . . . . . . . . . . . . . 142
1.7 Checking intake manifold pressure sender G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2 Servicing charge air system with turbocharger Protected by. copyright.
. . . . . .Copying
. . . . for
. .private
. . . .or.commercial
. . . . . . purposes,
. . . . . .in .part
. . or. in149
whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2.1 Rules for cleanliness . . . . . . . . . . . . . . . .with
. . respect
. . . . to. .the. .correctness
. . . . . .of. information
. . . . . . in. this
. . .document.
. . . . . Copyright
. . . . . .by 149 AUDI AG.
2.2 Turbocharger - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.4 Charge air cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Exhaust system - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.2 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.4 Removing and installing catalytic converter with front exhaust pipe . . . . . . . . . . . . . . . . . . 163
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 Exhaust gas recirculation system - exploded view of components . . . . . . . . . . . . . . . . . . 167
2.2 Hose connection diagram for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

ii Contents
Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2.3 Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2.4 Checking exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.5 Checking exhaust gas recirculation valve N18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Contents iii
Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

iv Contents
Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

00 – Technical data
1 Technical data

1.1 Engine number

The engine number (“Engine code” and “Serial number”) can be
found on the left of the cylinder block.
Additionally there is a sticker on the toothed belt cover showing
the “engine code” and “serial number”.
The engine code is also indicated on the vehicle data stickers.

1.2 Engine data

Code letters AFN AVG
Capacity ltr. 1.9 1.9
Power output kW at rpm 81/4150 81/4000
Torque Nm at rpm 235/1900 235/1900
Bore ∅ in mm 79.5 79.5
Stroke mm 95.5 95.5
Compression ratio 19.5 19.5
CN At least 45 45
Exhaust gas recirculation yes yes
Turbocharging/supercharging yes yes
Catalytic converter yes yes
Charge air cooling yes yes
Firing order 1-3-4-2 1-3-4-2

1. Technical data 1
Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

10 – Removing and installing engine

1 Removing and installing engine

1.1 Removing engine

Special tools and workshop

equipment required Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Support bracket -10-222 A- with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Lifting tackle -2024 A-

♦ Gearbox support -3147-
♦ 2-hole pin wrench -3212-
♦ Workshop hoist -V.A.G
1202 A- or -VAS 6100-
♦ Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208-

2 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

♦ Used oil collection and ex‐

traction unit -V.A.G 1782-
♦ Hose clip pliers -V.A.G
1921-
♦ Removing tool -VAS
1978/8- from the wiring har‐
ness repair set -VAS
1978- .
♦ 15 mm socket insert -Matra
V/175- for vehicles with au‐
tomatic gearbox 01N

Procedure

Note

♦ The engine is removed from the front without the gearbox.

♦ All cable ties which are released or cut open when removing
must be fitted in the same position when installing.
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.

Caution

Observe notes on procedure for disconnecting the battery ⇒

Electrical system; Rep. Gr. 27 .

1. Removing and installing engine 3

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach rubber seal from plenum chamber cover in direction of

-arrow-.
– Detach plenum chamber cover -1- towards the front.

– With ignition switched off, disconnect battery earth cable

-arrow-.

WARNING

Hot steam/hot coolant may escape when opening expansion

tank; cover filler cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Unscrew bolts -arrows-.

– Remove air ducts -1- and -2-.

– Remove cover -arrow- at power steering fluid reservoir.

4 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove front bumper ⇒ General body repairs, exterior; Rep.

Gr. 63 .
– Vehicles with auxiliary heater: remove bolts -arrows- securing
exhaust pipe for auxiliary/additional heater to noise insulation.

– Release quick-release fasteners -1 … 3- and take off front and

rear noise insulation.

– Unbolt bracket for noise insulation -arrow-.

– Remove air duct in front of charge air cooler -arrows-.

1. Removing and installing engine 5

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unclip ambient temperature sensor -G17- from bracket.

– Unscrew bolts -arrows- and move cooling pipe for power steer‐
ing clear; hydraulic fluid system remains closed.

– Place drip tray -V.A.G 1306- or -VAS 6208- under engine.

– Turn drain plug -arrow- on radiator anticlockwise and drain
coolant (attach hose to connection if necessary).

– Pull off retaining clip for coolant hose (bottom) -arrow- and re‐
move coolant hose from radiator.

– Unscrew bolts -arrows- and take out hose connection with O-

ring and thermostat to drain remaining coolant.

6 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach air intake hose going to charge air cooler at lock carrier
(bottom left) -arrow-.
– Detach turbocharger air intake hose at lock carrier (bottom
right).
Vehicles with automatic gearbox:

Note

Note the rules for cleanliness when working on the automatic

gearbox ⇒ Automatic gearbox 01N; Rep. Gr. 37 .

– Place used oil collection and extraction unit -V.A.G 1782- un‐
der engine.
– Disconnect ATF pipes at connection point.
– Unbolt bracket for ATF pipe at engine.

All models:
– Unplug electrical connector (green) -arrow- for magnetic
clutch of air conditioner compressor at lock carrier (bottom
right) and move electrical wire clear.

– Unplug electrical connector -arrow- for headlights on both

sides.
– Detach bonnet cable at lock carrier ⇒ General body repairs,
exterior; Rep. Gr. 55 .

– Unplug electrical connectors -arrows- at front of ABS unit.

– Unplug electrical connector for anti-theft alarm at lock carrier
(top left).
– Move wiring clear.

1. Removing and installing engine 7

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove top coolant hose at radiator.

– Remove the left and right-hand air ducts from the radiator.
– Unplug electrical connector -1- at low pressure switch for air
conditioner -F73- .
– Release both retaining pins -2- and pull out to side -arrows-.

WARNING

The air conditioner refrigerant circuit must not be opened.

– Detach both brackets -3- and pull condenser upwards out of

bracket

Note

To prevent damage to the condenser and refrigerant pipes/hoses,

ensure that the pipes and hoses are not stretched, kinked or bent.

– Move condenser to side with pipes/hoses connected and tie

onto right front wheel with wire.

Note

Protect wing panels from damage.

– Remove bolts -arrows- at lock carrier (left and right).

– Remove engine compartment seal from lock carrier and wing
panel flanges.

– Unscrew bolts from impact absorbers -arrows- (left and right).

Note

A second mechanic is required for removing the lock carrier.

– Remove lock carrier and place down in a secure position.

8 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unclip cover caps.

– Unscrew nuts -arrows- and detach engine cover panel.

– Detach coolant hoses -1- and -3-.

– Unbolt coolant expansion tank -2- -arrows-.
– Unplug electrical connector for coolant shortage indicator
switch -F66- at expansion tank (below).

Fuel filter - version I:

– Detach fuel supply pipe -1- and fuel return pipe -2- from filter
cover and move clear to one side.

Fuel filter - version II:

– Disconnect fuel return hose -2- and fuel supply hose -1- from
fuel filter.

1. Removing and installing engine 9

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

All models:
– Remove air intake hose from charge air cooler -arrow-.

– Unplug electrical connectors -3- and -4-.

– Disconnect breather hose -3- from air cleaner housing.

– Unplug electrical connector -1- at air mass meter -G70- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Move wiring harness
permitted going tobyair
unless authorised cleaner
AUDI AG. AUDI clear
AG does-arrow-.
not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Loosen hose clip -4- to remove air intake hose.
– Remove bolt -2-.
– Detach air cleaner housing.

10 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach vacuum hose -2-.

– Detach electrical connector -3- and cut open cable tie
-arrow-.
– Place wiring harness on engine.
– Unscrew bolts -5- and detach cover -4-.
– Move charge pressure control solenoid valve -N75- -item 1-
clear to one side with hoses connected.

– Detach coolant hoses -1- and -3- going to heat exchanger at

engine.
– Detach vacuum hose -2- going to brake servo.

– Unscrew bolts -arrows- and take off cover for electronics box
in plenum chamber.

– Pry off retainer bar with a screwdriver -arrow-.

1. Removing and installing engine 11

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Release retainer catches -arrows- and unplug connectors -1-

and -2- from engine control unit.

Note

Illustration shows vehicle manufactured from 07.1999.

– Release retainer -arrow- and pull auxiliary relay carrier in elec‐

tronics box upwards to remove.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Pull off fuse.
– Release fuse holder at additional relay carrier and pull off from
above.
– Release electrical contact in chamber 2 with removing tool -
VAS 1978/8- and remove.
– Unplug electrical connectors at rear of connector console.

– Unscrew earth connection -1- from bulkhead.

– Disengage engine wiring harness at electronics box and bulk‐
head and move clear -arrows-.

12 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unplug electrical connector at speedometer sender -G22- at

left of gearbox -bottom arrow-.
– On vehicles with manual gearbox unplug electrical connector
at reversing light switch -F4- on gearbox -top arrow-.
– Move wiring clear.

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.

– Turn the tensioner in the direction of the -arrow- to slacken the

poly V-belt.
– Remove poly V-belt from alternator pulley.

– Slacken nut -arrow- and remove fuel filter from bracket (fuel
hoses remain connected).

– Counterhold viscous fan pulley using 2-hole pin wrench -3212-

and unbolt viscous fan from bearing with an 8 mm hexagon
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

withkey.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.

1. Removing and installing engine 13

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Counterhold pulley with drift to unbolt power steering pump

pulley.
– Unbolt power steering pump -arrows- and tie up to one side;
the hoses/pipes remain connected.

– Unbolt cable clamp for positive wire to starter on engine at right

underneath exhaust manifold.
– Unscrew nuts securing turbocharger to catalytic converter
-arrows-.

– Loosen nuts on clamp -arrows-.

– Push the clamp back in order to separate the exhaust system.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Do not bend the flexible joint (de-coupling element) in the exhaust

system more than 10°, otherwise it could be damaged.

– Disconnect catalytic converter with front exhaust pipe from

turbocharger.

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.

– Loosen securing bolts of tensioning roller for air conditioner

compressor poly V-belt -arrows-.
– Remove poly V-belt.

WARNING

The air conditioner refrigerant circuit must not be opened.

– Unbolt air conditioner compressor from bracket.

– Tie up air conditioner compressor to vehicle, with lines attach‐
ed.

14 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove bolt -1- from noise insulation cover above drive shaft
(right-side).
– Disengage hook -2- and detach noise insulation.

– Unscrew earth wire at engine support (right-side) -1-.

– Remove bracket -2- for turbocharger -arrows-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Detach electrical wires -1- and -2- at starter.

– Unscrew clamp -3-.
– Unbolt starter from gearbox and remove.

Vehicles with automatic gearbox:

– Unscrew 3 nuts -arrow- for torque converter through opening
of removed starter using 15 mm socket insert -Matra V/175-
(turn crankshaft 1/3 turn each time).

Note

Counterhold at central bolt of vibration damper when unscrewing

nuts for torque converter.

1. Removing and installing engine 15

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

All models:
– Mark positions of bolt connections -1- and locating sleeves
-2- on bottom of engine mounts (left and right).

Note

Different mounting holes are provided for the different engine ver‐
sions.

– Loosen nut -1- at bottom of engine mountings (left and right)

several turns.

– Unscrew engine/gearbox securing bolts (accessible from be‐

low) -arrows-.

Note

♦ If it is not possible to remove bolts:

♦ Lift engine and gearbox by applying workshop hoist -
V.A.G 1202 A- or -VAS 6100- at bracket for torque reaction
support.
♦ Make sure no wires/pipes are damaged at the top on the bulk‐
head.

WARNING

To avoid injury, ensure adequate support.

Vehicles with automatic gearbox:

– Unbolt bracket for ATF pipes (left-side) at engine.
All models:
– Lower the engine back down.

16 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unscrew the top nuts -arrow- from both engine mountings.

– Unscrew top engine/gearbox securing bolts. Leave one bolt in
place (finger-tight).

– Pull off engine compartment seals in area of suspension tur‐

rets.
– Set up support bracket -10-222 A- behind gas-filled strut on
suspension turrets. The spindle must be at the front.
– Insert gearbox support -3147- into bolt hole in gearbox bell
housing.
– Connect gearbox support -3147- to support bracket -10-222
A- .

Note

Illustration shows engine removed.

1. Removing and installing engine 17

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Hook lifting tackle -2024 A- onto engine and workshop hoist -

V.A.G 1202 A- or -VAS 6100- .

Note

To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.

WARNING

The hook attachments and locating pins on the lifting tackle

must be secured with locking pins.

– Unscrew remaining securing bolt for engine/gearbox assem‐

Note

Check that all hoses and other connections between engine and
body have been detached.

– Lift engine until studs are clear of engine mountings.

– Tension spindles of support bracket -10-222 A- again.

Note

Make sure no wires/pipes are damaged at the top on the bulk‐

head.

– Detach engine from gearbox and lift engine forwards out of

engine compartment.
Vehicles with automatic gearbox:
– Secure torque converter in gearbox to prevent it falling out.

1.2 Securing engine to assembly stand

Special tools and workshop equipment required
♦ Support clamp -VW 313-

18 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

♦ Engine and gearbox support -VW 540-

Procedure
– Secure engine with engine and gearbox support -VW 540- to
engine stand prior to performing assembly work.

1.3 Installing engine

Installation is carried out in the reverse order; note the following:

Note

♦ Renew self-locking nuts and bolts when performing assembly

work.
♦ Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use lubricant.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.
♦ Fit all cable ties in the original position when installing.

1. Removing and installing engine 19

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Check whether both dowel sleeves for centring the engine/

gearbox assembly are fitted in the cylinder block; install if nec‐
essary.
– Ensure that the intermediate plate is engaged on the sealing
flange and pushed onto the dowel sleeves -arrows-.
Vehicles with manual gearbox:
– Check clutch release bearing for wear; renew if necessary.
– Lubricate splines of gearbox input shaft lightly with grease -G
000 100- . The guide sleeve for the release bearing should not
be lubricated.
– Check that the clutch plate is properly centralised (only nec‐
essary if you have carried out other work on the clutch).
– A needle bearing must be fitted in the crankshaft on vehicles
with manual gearbox; insert needle bearing if not yet fitted
⇒ page 55 .
Vehicles with automatic gearbox:
– In vehicles with automatic gearbox, the needle bearing must
NOT be fitted in the crankshaft; remove needle bearing if fitted
⇒ page 55 .
– To secure the torque converter to drive plate, use only the
correct nuts (same as original equipment) ⇒ Parts catalogue .
– Tighten nuts for torque converter using 15 mm socket insert -
Matra V/175- .

20 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Checking installation depth of torque converter

If the torque converter has been inserted properly in the gearbox,
gap -A- between the contact surfaces at the studs on the torque
converter and the joint surface of the gearbox flange will be ap‐
prox. 23 mm.
If the torque converter has not been completely inserted, this dis‐
tance will be approx. 13 mm.

Caution

If the torque converter is not installed correctly, the drive lugs

of the torque converter and the ATF pump will be seriously
damaged when the gearbox is joined to the engine.

All models:
– Attach engine to gearbox and screw in one bolt finger-tight.
– Before securing engine mountings, align engine so that
mountings are free of stress by shaking back and forth.
– Install air conditioner compressor ⇒ Air conditioning system;
Rep. Gr. 87 .
– Install power steering pump ⇒ Running gear, front-wheel drive
and four-wheel drive; Rep. Gr. 48 .
– Align exhaust system free of stress ⇒ page 165 .
– Install poly V-belt ⇒ page 29 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. Gr.
50 .
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
Vehicles with automatic gearbox:
– Secure the ATF pipes ⇒ Automatic gearbox 01N; Rep. Gr.
37 .
All models:
– Connect hoses and pipes for exhaust gas recirculation system
⇒ page 168 .
– Connect hoses and pipes for charge pressure control
⇒ page 140 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Connect battery and observe notes on procedures required
after connecting battery ⇒ Electrical system; Rep. Gr. 27 .

Caution

Do not use a battery charger to boost starting. There is danger

of damaging the vehicle's control units.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Check oil level ⇒ page 109 .

– Fill cooling system ⇒ page 115 .

1. Removing and installing engine 21

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.
♦ Contaminated or dirty coolant must not be used again.

– Top up power steering fluid and bleed steering system: ⇒

Running gear, front-wheel drive and four-wheel drive; Rep.
Gr. 48 .
– Check headlight adjustment ⇒ Maintenance ; Booklet 402 .
Vehicles with automatic gearbox:
– Check ATF level ⇒ Automatic gearbox 01N; Rep. Gr. 37
Tightening torques

Note

♦ Tightening torques only apply to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques ± 15 %.

Engine/gearbox connecting bolts (manual gearbox)

Item Bolt Nm
1, 3, 4 M12x67 65
2, 6 M12x90 65
5, 11 M12x110 65
7, 8, 9, 10 M10x45 45
A Dowel sleeves for centralising
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

22 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Engine/gearbox connecting bolts (automatic gearbox)

Item Bolt Nm
1, 8, 9, 10 M10x45 45
2, 3, 4, 11 M12x67 65
5 M12x110 65
6 M12x90 65
7 M10x60 45
A Dowel sleeves for centralising

Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Except for the following:
Engine mounting to subframe 23
Engine support to engine mounting 23
Catalytic converter to turbocharger 25 1)
Pulley to power steering pump 25
Bracket for torque reaction support to engine 23
Longitudinal member to bracket for torque re‐ 23
action support
engine support 23
Stop for torque reaction support to bracket for 23
torque reaction support
Drive plate to torque converter 85
Bracket for turbocharg‐ turbocharger 20
er to cylinder block 40
Viscous fan to bearing 45
Hose clips for air hoses 3.5
1) Renew nuts.

1. Removing and installing engine 23

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

13 – Crankshaft group
1 Dismantling and assembling engine

1.1 Poly V-belt drive for power steering pump, alternator, coolant pump and
viscous fan - exploded view of components

1 - 9 Nm
❑ Self-locking
❑ Renew
2 - Fan wheel for viscous fan
❑ Removing and installing
⇒ page 122
3 - 25 Nm
4 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen.
If the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
❑ Removing and installing
⇒ page 27
5 - Bolt
❑ If bolt strength rating is
8.8, tighten to 25 Nm
❑ If bolt strength rating is
10.9, tighten to 35 Nm ⇒
Parts catalogue
❑ Renew
6 - Vibration damper
❑ With pulley for poly V-
belt
❑ Can only be installed in
one position
❑ Removing and installing
⇒ page 29
7 - Poly V-belt tensioner
❑ Can only be installed in one position
8 - Pulley for viscous fan
❑ Removing and installing ⇒ page 122
9 - RetainingProtected
ring for viscousCopying
by copyright. fan bearing
for private or commercial purposes, in part or in whole, is not
❑ Removing and installing ⇒ page 124
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - O-ring
❑ Renew
11 - 25 Nm
❑ Tightening sequence ⇒ page 25

24 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

12 - Bracket for engine cover panel

13 - 25 Nm
❑ Tightening sequence ⇒ page 25
14 - Alternator
❑ Removing ⇒ Electrical system; Rep. Gr. 27
❑ To facilitate the positioning of alternator on bracket, knock back bush for retaining bolt slightly
15 - 45 Nm
16 - 25 Nm
17 - 45 Nm
18 - 25 Nm
19 - Mounting bracket for alternator, power steering pump and viscous fan
❑ With coolant pump and thermostat
❑ Removing and installing ⇒ page 30
20 - Power steering pump
❑ Removing and installing ⇒ Running gear, front-wheel drive and four-wheel drive; Rep. Gr. 48
21 - 25 Nm
22 - Bearing for viscous fan
❑ Removing and installing ⇒ page 124
23 - Ribbed bolt, 28 Nm
❑ Renew
24 - Pulley for power steering pump
❑ Counterhold with drift to unbolt
25 - 25 Nm
26 - Pulley for coolant pump
27 - Viscous coupling
❑ Removing and installing ⇒ page 122

Tightening sequence for bracket for ancillaries

– Fit bolts and tighten hand-tight initially.
– Tighten the bolts to 25 Nm in the sequence -1 … 5-.

1. Dismantling and assembling engine 25

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1.2 Poly V-belt drive for air conditioner - exploded view of components

1 - 25 Nm
❑ Bolt strength rating
10.9; use only genuine
bolts (same as original
equipment) ⇒ Parts
catalogue
2 - Refrigerant lines
❑ Do not unscrew/detach
3 - Dowel sleeve
❑ Check for correct seat‐
ing in bracket
4 - Bolt
❑ If bolt strength rating is
8.8, tighten to 25 Nm
❑ If bolt strength rating is
10.9, tighten to 30 Nm ⇒
Parts catalogue
5 - Bracket for air conditioner
compressor
6 - Tensioning roller for poly V-
belt
❑ Removing and installing
⇒ “1.4 Removing and in‐
stalling poly V-belt”,
page 27
7 - Washer
8 - 20 Nm
9 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen.
If the belt runs in the op‐
posite direction when it is refitted, this can cause breakage.
❑ Do not kink
❑ Removing and installing ⇒ page 27
❑ Routing of poly V-belt ⇒ page 27
10 - Air conditioner compressor

WARNING
The air conditioner re‐
frigerant circuit must not
be opened.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ After removing compressor from mountings, secure it to longitudinal member with wire or similar. Do not
leave it suspended from refrigerant pipes.
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
❑ Removing and installing ⇒ Air conditioning system; Rep. Gr. 87
11 - Washer

26 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1.3 Routing of poly V-belt

1 - Air conditioner compressor

2 - Poly V-belt tensioner
3 - Pulley for viscous fan
4 - Alternator
5 - Poly V-belt for alternator,
power steering pump, coolant
pump and viscous fan
❑ Removing and installing
⇒ page 27
6 - Power steering pump
7 - Coolant pump
8 - Vibration damper
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - Poly V-belt tensionerpermitted
for airunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
conditioner compressor with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Poly V-belt for air condi‐
tioner compressor
❑ Removing and installing
⇒ page 27

1.4 Removing and installing poly V-belt

Removing
– Vehicles with auxiliary heater: remove bolts -arrows- securing
exhaust pipe for auxiliary/additional heater to noise insulation.

1. Dismantling and assembling engine 27

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Release quick-fasteners -1- and -2- and take off front noise
insulation. Leave rear noise insulation in position.

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.

– Loosen securing bolts of tensioning roller for air conditioner

compressor poly V-belt -arrows-.
– Remove poly V-belt.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Unscrew bolts -arrows-.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove air ducts -1- and -2-.

28 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.

– Turn the tensioner in the direction of the -arrow- to slacken the

poly V-belt.
– Remove poly V-belt.
– Release tensioner.
Installing
• Routing of poly-V belt ⇒ page 27 .
– Fit poly V-belt onto pulleys for crankshaft, coolant pump, vis‐
cous fan, power steering pump and tensioner (note direction
of rotation).
– Turn the tensioner in the direction of the -arrow- in order to fit
the poly V-belt.
– Then fit poly V-belt on alternator pulley and release tensioner.

– Fit poly V-belt for air conditioner compressor.

– Apply torque wrench to hexagon flats on tensioning roller in
“seven o'clock” position as shown and tension with a torque of
30 Nm in direction of -arrow-.
– At the same time tighten bolts -A-.
– Check both poly V-belts for proper seating.
– Start engine and check that belt runs properly.
Tightening torque
Component Nm
Tensioning roller to bracket 25

1.5 Removing and installing vibration damp‐

er
Removing
• Front bumper is removed ⇒ General body repairs, exterior;
Rep. Gr. 63 .
• Lock carrier is moved into its service position ⇒ General body
repairs, exterior; Rep. Gr. 50 .
• Poly V-belt must be removed ⇒ page 27 .
– Unbolt vibration damper; counterhold on centre bolt with ring
spanner.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installation is carried out in the reverse order;
withnote
respectthe following:
to the correctness of information in this document. Copyright by AUDI AG.

– Use new bolts for securing.

1. Dismantling and assembling engine 29

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– When installing the vibration damper, use only genuine bolts

(same as original equipment): ⇒ Parts catalogue .
• The vibration damper can only be installed in one position. The
hole in the vibration damper must be located over the projec‐
tion on the toothed belt sprocket -arrow-.
– Install poly V-belt ⇒ page 29 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. Gr.
50 .
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Tightening torque with respect to the correctness of information in this document. Copyright by AUDI AG.

Component Nm
Vibration damper to crankshaft sprocket
Bolt strength 8.8 25
Bolt strength 10.9 35

1.6 Removing and installing bracket for an‐

cillaries
Special tools and workshop equipment required
♦ Drip tray -V.A.G 1306- or drip tray for workshop hoist -VAS
6208-

♦ 2-hole pin wrench -3212-

30 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Removing

Note

All cable ties which are released or cut open when removing must
be fitted in the same position when installing.

Caution

Observe notes on procedure for disconnecting the battery ⇒

Electrical system; Rep. Gr. 27 .

– Detach rubber seal from plenum chamber cover in direction of

-arrow-.
– Detach plenum chamber cover -1- towards the front.

– With ignition switched off, disconnect battery earth cable

-arrow-.

– Unclip cover caps.

– Unscrew nuts -arrows- and detach engine cover panel.

– Unscrew bolts -arrows-.

– Remove air ducts -1- and -2-.

1. Dismantling and assembling engine 31

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Turn the tensioner in the direction of the -arrow- to slacken the

poly V-belt.
– Remove poly V-belt from alternator pulley.
– Release tensioner.

Note

The air conditioner poly V-belt remains fitted.

– Slacken nut -arrow- and remove fuel filter from bracket (fuel
hoses remain connected).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Counterhold viscous fan pulley using 2-hole pin wrench -3212-
and unbolt viscous fan from bearing with an 8 mm hexagon
key.
– Detach viscous fan from bearing and lay it forwards in radiator
cowl.

– Unscrew wire -1- at alternator.

– Detach electrical connector -2-.
– Move wiring clear.

32 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove bolts -1- and -2-.

– Remove alternator.

– Counterhold pulley with drift to unbolt power steering pump

pulley.
– Unbolt power steering pump -arrows- and tie up to one side;
the hoses/pipes remain connected.

– Remove poly V-belt tensioner.

– Remove bolt -arrow- for toothed belt cover (bottom).

– Place drip tray -V.A.G 1306- or drip tray for workshop hoist -
VAS 6208- under engine.
– Drain off coolant ⇒ page 113 .
– Unscrew bolts -1 ... 5-.
– Disconnect both coolant hoses -arrows- at rear of bracket.
– Remove bracket for ancillaries.
Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Renew O-ring.
♦ When installing, pay attention to dowel sleeve at top right be‐
tween bracket and cylinder block.
♦ Fit all cable ties in the original position when installing.

1. Dismantling and assembling engine 33

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Clean and smoothen sealing surface for O-ring as required.

– To make sure bracket is fitted to injection pump console free
of stress, knock back bush for top securing bolt slightly.
– Fit bolts and tighten hand-tight initially.
– Tighten bolts in the sequence -1 ... 5-.
– Install coolant hoses -arrows-.

– Tighten bolt -arrow- for toothed belt cover.

– Install viscous fan ⇒ page 122 .
– Install poly V-belt ⇒ page 29 .
– Connect battery and observe notes on procedures required
after connecting battery ⇒ Electrical system; Rep. Gr. 27 .
– Fill cooling system ⇒ page 115 .
Tightening torques
Component Nm
Bracket for ancilla‐ cylinder block 25
ries to injection pump console 25
Alternator to bracket for ancillaries 25
Terminal 30/B+ to alternator 16
Toothed belt
Protected cover (bottom)
by copyright. to bracket
Copying for private or commercial purposes,10in part or in whole, is not
Poly V-belt tensioner to bracket
of information in this document.45
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness Copyright by AUDI AG.
Power steering pump to bracket for ancillaries 25
Pulley to power steering pump 25

1.7 Toothed belt drive - exploded view of components

34 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1 - Toothed belt cover (top)

❑ To remove, remove poly
V-belt tensioner
⇒ Item 7 (page 24)
❑ Engage carefully in
toothed belt cover (bot‐
tom) when installing
2 - Toothed belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen.
If the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage
❑ Removing ⇒ page 37
❑ Installing (adjusting
valve timing)
⇒ page 40
3 - 20 Nm
❑ Self-locking
❑ Renew
4 - Tensioning roller
❑ Checking semi-auto‐
matic tensioning roller
for toothed belt
⇒ page 43
❑ Installation position
⇒ page 36
5 - 45 Nm
❑ Use counterhold tool
-3036- to loosen and
tighten
6 - Camshaft sprocket
❑ Loosen camshaft sprocket from camshaft taper by applying a blow through mounting hole in toothed belt
cover using a hammer and a drift
7 - 25 Nm
8 - Idler roller
9 - 10 Nm
10 - Toothed belt cover (rear)
11 - 10 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - 25 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
13 - Woodruff key
❑ Check that it is securely seated
14 - Injection pump sprocket
❑ Removing and installing injection pump sprocket ⇒ page 37
❑ Ensure that Woodruff key is fitted
15 - Intermediate shaft sprocket
❑ Installation position ⇒ page 36
❑ Ensure that Woodruff key is fitted

1. Dismantling and assembling engine 35

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

16 - Crankshaft sprocket
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
17 - 90 Nm +90° (1/4 turn) further
❑ Renew
❑ Do not lubricate with oil
❑ Use counterhold tool for toothed belt sprocket -3099- or counterhold tool -3415- to loosen and tighten
❑ Fit counterhold tool for toothed belt sprocket -3099- ⇒ page 47
❑ Remove bracket for torque reaction support ⇒ Item 11 (page 97) to secure counterhold tool
18 - 45 Nm
❑ Use counterhold tool -3036- to loosen and tighten
19 - 45 Nm
20 - 10 Nm
21 - Toothed belt cover (bottom)
❑ Unbolt vibration damper prior to removing
22 - Spreader clip

Installation position of semi-automatic tensioning roller

• Retaining lug -arrow- must engage in slot on toothed belt cover
(rear).

Installation position of intermediate shaft sprocket

• The deep shoulder -arrows- on the intermediate shaft sprocket
faces towards the front.
• The identification marking on the sprocket faces to the rear.

36 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Removing injection pump sprocket

• Toothed belt is removed ⇒ page 37 .
– Unscrew injection pump sprocket nut.
– Slacken arms of puller and fit puller -3032- .
– Align arms with drillings in injection pump sprocket and tighten.
– Screw in bolt on puller until injection pump sprocket is under
tension.
– Apply light blow onto spindle of puller -arrow- to release injec‐
tion pump sprocket from taper on injection pump shaft (hold
sprocket to prevent it from dropping).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

1.8 Removing and installing toothed belt

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop

equipment required
♦ Locking pin -2064-
♦ Setting bar -2065 A-
♦ Counterhold tool -3036-
♦ Special tool -Matra V/159-

1. Dismantling and assembling engine 37

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Removing
• Engine in vehicle.
• Front bumper is removed ⇒ General body repairs, exterior;
Rep. Gr. 63 .
• Lock carrier is moved into its service position ⇒ General body
repairs, exterior; Rep. Gr. 50 .
– Unclip cover caps.
– Unscrew nuts -arrows- and detach engine cover panel.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Remove poly V-belt ⇒ page 27 .

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Slacken nut -arrow- and remove fuel filter from bracket (fuel
hoses remain connected).

– Counterhold viscous fan pulley using 2-hole pin wrench -3212-

and unbolt viscous fan from bearing with an 8 mm hexagon
key.
– Remove viscous fan from bearing.
– Remove poly V-belt tensioner.

– Unscrew bolts -3- and detach cover -2-.

– Move charge pressure control solenoid valve -N75- -item 1-
clear to one side with hoses connected.

38 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unbolt vibration damper; counterhold on centre bolt with ring

spanner.

– Remove toothed belt cover (top and bottom) -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

The engine must only be turned at the crankshaft, in the direc‐

tion of normal engine rotation (clockwise).

Note

Turn over the engine at the central bolt on the crankshaft.

– Position crankshaft at TDC for cylinder 1 (vehicles with manual

gearbox).

– Position crankshaft at TDC for cylinder 1 -arrow- (vehicles with

automatic gearbox).

Note

Positioning crankshaft at TDC for cylinder 1 with engine removed

⇒ page 43 .

1. Dismantling and assembling engine 39

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove cylinder head cover ⇒ page 65 .

– Lock camshaft with setting bar -2065 A- .
– If the setting bar -2065 A- cannot be attached, turn crankshaft
one full turn (360°) in normal rotation direction.

– Centralise setting bar as follows: turn locked camshaft until

one end of setting bar makes contact with cylinder head.
Measure resulting clearance at other end of setting bar using
feeler gauge. Slide in a feeler gauge with half the measured
thickness between setting bar and cylinder head. Now turn
camshaft until setting bar makes contact with feeler gauge.
Insert a second feeler gauge of the same thickness between
the other end of the setting bar and the cylinder head.

– Lock injection pump sprocket in position with locking pin

-2064- .
– Mark the rotation direction of toothed belt with chalk or a felt-
tipped pen.
– Loosen securing nut for tensioning roller.
– Remove idler roller.
– Remove toothed belt.
Installing (adjusting valve timing)
• Camshaft locked in position with setting bar.
• Injection pump locked in position with locking pin -2064- . AG. AUDI AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

♦ The toothed belt adjustment must also be performed as de‐

scribed below, even if the toothed belt has only been removed
from the camshaft sprocket.
♦ Toothed belt adjustment must always be performed when the
engine is cold.
♦ The crankshaft must not be at TDC at any cylinder when the
camshaft is turned. Otherwise, there is a risk of damage to
valves and piston crowns.
♦ Do NOT use the setting bar as a counterhold tool when loos‐
ening and tightening the camshaft sprocket. Counterhold us‐
ing counterhold tool -3036- .

40 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Ensure that tensioning roller is seated properly in rear toothed

belt cover -arrow-.
– Loosen camshaft sprocket securing bolt a 1/2 turn.

– Detach camshaft sprocket from camshaft taper (apply a blow

through mounting hole in toothed belt cover (rear) using a
hammer and a drift).
– Check once again that TDC marking on dual-mass flywheel
and reference mark are aligned.
– Fit toothed belt on crankshaft sprocket, intermediate shaft, in‐
jection pump sprocket and tensioning roller (note direction of
rotation).
– Fit camshaft sprocket together with toothed belt and secure
lightly via securing bolt.
• The camshaft sprocket must just about still turn, and must not
tilt.
– Install idler roller.

– Turn eccentric adjuster of tensioning roller in clockwise direc‐

tion using pin wrench (e.g. special tool -Matra V/159- ), until
notch and lug -arrows- face each other.

Note

If the eccentric adjuster is turned in clockwise direction further

than intended, the tensioning roller must be turned all the way
back to its initial position. Then turn eccentric adjuster in clockwise
direction again.

– Tighten lock nut on tensioning roller.

– Check once again that TDC marking on dual-mass flywheel
and reference mark are aligned.

Note

Do NOT use the setting bar as a counterhold tool when loosening

and tightening the camshaft sprocket. Counterhold using coun‐
terhold tool -3036- .

– Tighten camshaft sprocket securing bolt.

– Remove setting bar -2065 A- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove
permitted lockingbypin
unless authorised AUDI-2064-
AG. AUDI.AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Turn crankshaft two rotations in normal direction of rotation
until the crankshaft is TDC again.

1. Dismantling and assembling engine 41

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Check tension of toothed belt.

• The marks -arrows- must align.
– Tension toothed belt if necessary.
– Check whether it is possible to lock the injection pump sprock‐
et using locking pin -2064- .
– Check position of camshaft with setting bar -2065 A- .

Note

Repeat adjustment procedure if it is not possible to insert setting

bar -2065 A- or locking pin -2064- .

– Remove setting bar -2065 A- .

– Remove locking pin -2064- .
Assembling
Remaining installation steps are carried out in reverse sequence;
note the following:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Renew gaskets.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

– Install toothed belt cover (bottom and top section).

– Install viscous fan ⇒ page 122 .
– Install poly V-belt ⇒ page 29 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. Gr.
50 .
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
– Perform dynamic check of commencement of injection ⇒ Rep.
Gr. 23 .
Tightening torques
Component Nm
Tensioning roller for toothed belt to cylinder 20 2)

head
Camshaft sprocket to camshaft 45
Toothed belt cover (bottom) to cylinder block 10
Idler roller to console 25
Tensioner for poly V-belt to bracket for ancilla‐ 45
ries
Vibration damper to crankshaft sprocket
Bolt strength 8.8 25
Bolt strength 10.9 35
2) Renew nut.

42 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1.9 Checking semi-automatic tensioning

roller for toothed belt
Test requirement
• Toothed belt fitted and tensioned.
Test sequence
– Push in toothed belt with firm thumb pressure. Notch and lug
-arrows- should move out of alignment.
– Release thumb pressure on toothed belt. Tensioner should
return to initial position.
• The marks -arrows- must align.

1.10 Positioning crankshaft at TDC with en‐

gine removed

Special tools and workshop equipment required

♦ TDC adjustment bar -2068 A-
Vehicles with manual gearbox:
• Oil filter must be removed.
– Fit TDC adjustment bar -2068 A- as shown in illustration.
– Set TDC adjustment bar -2068 A- to 107 mm (left notch on
vernier scale -arrow- is point of reference).
– Turn crankshaft until TDC marking “0” on dual-mass flywheel
and end of TDC adjustment bar -2068 A- are aligned.

1. Dismantling and assembling engine 43

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Vehicles with automatic gearbox:

• Oil filter must be removed.
– Fit TDC adjustment bar -2068 A- as shown in illustration.
– Set TDC adjustment bar -2068 A- to 99 mm (left notch on ver‐
nier scale -arrow- is point of reference).
– Turn crankshaft until TDC marking “0” on drive plate and end
of TDC adjustment bar -2068 A- are aligned.

Note

The TDC marking “0” is stamped on the side of the drive plate
facing the cylinder block.

44 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2 Removing and installing sealing

flanges and dual-mass flywheel/drive
plate

2.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view of com‐
ponents

Note

Service to the clutch ⇒ Manual gearbox; Rep. Gr. 30

1 - Oil seal
❑ Remove sealing flange
⇒ Item 27 (page 46)
prior to removing
❑ Install using fitting tool
-10 - 203-
❑ Do not lubricate sealing
lip of oil seal
2 - Intermediate shaft sprocket
❑ Installation position
⇒ page 47
❑ Ensure that Woodruff
key
⇒ Item 25 (page 46) is
fitted
3 - 45 Nm
❑ Use counterhold tool
-3036- to loosen and
tighten
4 - 25 Nm
5 - Oil seal
❑ Renewing ⇒ page 47
❑ Do not lubricate sealing
lip of oil seal
6 - 10 Nm
7 - Sealing flange (front)
❑ Before fitting sump, ap‐
ply a thin coat of sealant
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to sealing points be‐to the correctness of information in this document. Copyright by AUDI AG.
with respect
tween sealing flange
and cylinder block
❑ Apply sealant prior to in‐
stalling
❑ Sealant ⇒ Parts catalogue
8 - Gasket
❑ Renew
9 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 53
❑ Dismantling and assembling pistons and conrods ⇒ page 57

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 45

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

10 - Exhauster pump for brake servo

11 - O-ring
❑ Renew
12 - Cover
13 - 10 Nm
14 - 20 Nm
15 - Bracket for exhauster pump
16 - O-ring
❑ Renew
17 - Oil seal
❑ Renew
18 - 10 Nm
19 - Sealing flange (rear) with oil seal
❑ With gasket for cylinder block
❑ Do not lubricate sealing lip of oil seal
❑ Before fitting sump, apply a thin coat of sealant to sealing points between sealing flange and cylinder
block
❑ Apply sealant prior to installing
❑ Sealant ⇒ Parts catalogue
❑ To install, push guide sleeve from assembly kit onto crankshaft.
20 - Gasket
❑ Fit only if sealing flange has no sealing lip on cylinder block side
21 - Dual-mass flywheel/drive plate
❑ Removing
Protected and installing
by copyright. Copying for private or dual-mass flywheel
commercial purposes, ⇒inpage
in part or 50
whole, is not
❑ Removing and installing drive plate ⇒ page 51
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
22 - Securing bolt for dual-mass flywheel/drive plate
❑ Renew
❑ Tightening torque: vehicles with manual gearbox ⇒ page 51 ; vehicles with automatic gearbox
⇒ page 52
23 - Intermediate plate
❑ Must be positioned on dowel sleeves
❑ Do not damage/bend when assembling
❑ Is fitted on sealing flange ⇒ page 47
24 - Intermediate shaft
❑ Axial clearance: max. 0.25 mm
25 - Woodruff key
❑ Check for firm attachment
26 - O-ring
❑ Renew
27 - Sealing flange for intermediate shaft
28 - 25 Nm

46 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Installation position of intermediate shaft sprocket

• The deep shoulder -arrows- on the intermediate shaft sprocket
faces towards the front.
• The identification marking on the sprocket faces to the rear.

Installing intermediate plate

– Fit intermediate plate to sealing flange and push onto dowel
sleeves -arrows-.

2.2 Renewing crankshaft oil seal (pulley end)

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 47

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

equipment required
♦ Oil seal extractor -2085-
♦ Oil seal fitting tool -3083-
♦ Counterhold tool -3415-

Procedure
• Engine in vehicle.
• Front bumper is removed ⇒ General body repairs, exterior;
Rep. Gr. 63 .
• Lock carrier is moved into its service position ⇒ General body
repairs, exterior; Rep. Gr. 50 .
– Remove poly V-belt ⇒ page 27 .
– Remove toothed belt ⇒ page 37 .
– Unscrew bolts -arrows- and remove torque reaction support.

48 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove crankshaft sprocket; use counterhold tool -3415- to

lock sprocket in place.

Note

Counterhold tool for toothed belt sprocket -3099- can be used as

an alternative.

– Screw socket head bolt from oil seal fitting tool -3083- 5 ... 6
turns into crankshaft before applying oil seal extractor.

– Unscrew inner section of oil seal extractor -2085- 2 turns out

of outer section and lock with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice.
– Remove oil seal with pliers.

Note

Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.

– Clean running surface and sealing surface.

– Place guide sleeve from oil seal fitting tool -3083- onto crank‐
shaft journal.

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 49

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Slide oil seal over guide sleeve.

– Press oil seal in as far as the stop using press sleeve and bolt
from oil seal fitting tool -3083- .

– Renew centre bolt for toothed belt sprocket.

• Contact surface between toothed belt sprocket and crankshaft
must be free of oil.
• Do not lubricate bolt for crankshaft sprocket.
– Install crankshaft sprocket; use counterhold tool -3415- to lock
sprocket in place.
– Fit toothed belt (adjust valve timing) ⇒ page 40 .
– Install poly V-belt ⇒ page 29 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. Gr.
50 .
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
Tightening torques
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Component Nm Copyright by AUDI AG.
with respect to the correctness of information in this document.

Stop for torque reaction support to bracket for 23

torque reaction support
Toothed belt sprocket to crankshaft 90 + 90° 3) 4)
3) Renew bolt.
4) 90° = one quarter turn.

2.3 Removing and installing dual-mass fly‐

wheel
Special tools and workshop equipment required
♦ Counterhold tool -10-201-

50 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Removing
• Gearbox removed.
– Mark installation position of dual-mass flywheel on engine.
– Attach counterhold tool -10-201- in order to loosen bolts.
– Unbolt dual-mass flywheel.
Installing
Installation is carried out in the reverse order; note the following:
– Use new bolts for securing.
– Reverse position of counterhold tool -10-201- in order to tight‐
en bolts.
Tightening torque
Component Nm
Dual-mass flywheel to crankshaft
Bolt length 22.5 mm 60 + 90° 5) 6)
43 mm 60 + 180° 5) 7)
5) Renew bolts.
6) 90° = one quarter turn.
7) 180° = one half turn. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.4 Removing and installing drive plate

Special tools and workshop equipment required
♦ Counterhold for clutch -VW 558-

♦ M8×45 hexagon bolt and two M10 hexagon nuts

♦ Depth gauge
Removing
• Gearbox removed.
– Mark installation position of drive plate on engine.
– Secure counterhold tool for clutch -VW 558- to drive plate us‐
ing hexagon bolt M8x45. Insert two M10 hexagon nuts -1-
between counterhold tool and drive plate.
– Unbolt drive plate.

2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 51

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Installing
– Install drive plate with shims -2- and -1-.
• Lug -arrow- on washer must face torque converter.
– Fit at least 3 old securing bolts and tighten to 30 Nm.

– Measure depth -a- at three points and calculate average value.

• Specification: 26 … 28 mm.

If specification is exceeded:
– Remove drive plate for a second time.
– Install drive plate without shim -2-. Re-tighten bolts in diagonal
sequence to 30 Nm.
– Repeat measurement.
If reading matches specification:
– Use new bolts for securing.
Tightening torque
Component Nm
Drive plate to crankshaft
Bolt length 17 mm 60 + 90° 8) 9)
8) 90° = a quarter of a turn.
9) Renew bolts.

52 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

3 Removing and installing crankshaft

3.1 Crankshaft - exploded view of components

Note

When carrying out repairs, secure engine to assembly stand with engine and gearbox support -VW 540-
⇒ page 18 .

1 - Thrust washers for bearing

No. 3
❑ Different types for cylin‐
der block and bearing
cap
❑ Note location
2 - Bearing shell
❑ For cylinder block with
oil groove
❑ Do not interchange
used bearing shells
(mark positions)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 -permitted
Crankshaft
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Axial clearance (new):
0.07 ... 0.17 mm; wear
limit: 0.37 mm
❑ Check radial clearance
with Plastigage (new):
0.03 ... 0.08 mm; wear
limit: 0.17 mm
❑ Do not rotate the crank‐
shaft when checking the
radial clearance
❑ Crankshaft dimensions
⇒ page 56
4 - Bearing shell
❑ For bearing cap without
oil groove
❑ Do not interchange
used bearing shells
(mark positions)
5 - Thrust washers for bearing
No. 3
❑ Different types for cylin‐
der block and bearing cap
❑ Note location
6 - 65 Nm +90° (1/4 turn) further
❑ Renew
❑ For measuring radial clearance of crankshaft, tighten to 65 Nm but not further
7 - Bearing cap
❑ Bearing cap 1: Pulley end
❑ Bearing cap 3 with recesses for thrust washers
❑ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side

3. Removing and installing crankshaft 53

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

8 - 10 Nm +90° (1/4 turn) further

❑ Renew
❑ Sender wheel must be renewed if bolts are loosened
9 - Needle bearing on vehicles with manual gearbox
❑ Extracting and driving in ⇒ page 55
10 - Sender wheel
❑ For engine speed sender -G28-
❑ Can only be installed in one position. Holes are off-set
❑ Sender wheel must be renewed if bolts are loosened
❑ Removing and installing ⇒ page 54
11 - Dowel pin
❑ Checking projection from crankshaft ⇒ page 54

Checking dowel pin projection out of crankshaft

Projection of dowel pin -3- out of crankshaft
• Dimension -a- = 2.5 ... 3.0 mm.

3.2 Removing and installing sender wheel

for engine speed sender -G28-
Removing
– Unscrew bolts -2- and remove sender wheel -1- from crank‐
shaft.
Installing
Installation is carried out in the reverse order; note the following:
– Sender wheel -1- must always be renewed after slackening off
bolts -2-.

54 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

♦ If the same sender wheel is installed again, the seat for the
countersunk bolts in the sender wheel will be deformed to such
an extent that the bolt heads make contact with crankshaft
-3- -arrows- and sender wheel -2- will be loose beneath bolts
-1- .
♦ Sender wheel can only be fitted in one position because holes
are offset.

Tightening torque
Component Nm
Sender wheel to crankshaft 10 + 90° 10) 11)
10) Renew bolts.
11) 90° = a quarter of a turn.

3.3 Extracting and driving in needle bearing

for crankshaft

Note

♦ A needle bearing must be fitted in the crankshaft on vehicles

with manual gearbox; insert needle bearing if not yet fitted.
♦ In vehicles with automatic gearbox, the needle bearing must
NOT be fitted in the crankshaft; remove needle bearing if fitted.

Special tools and workshop equipment required

♦ Drift -VW 207 C- or centring drift -3176-

♦ 1 - Internal puller -Kukko 21/1-

♦ 4 - Counterhold -Kukko 22/1-

3. Removing and installing crankshaft 55

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

♦ Depth gauge
Pulling out
– Remove needle bearing using internal puller -Kukko 21/1- and
counterhold tool -Kukko 22/1- .

Driving in
– Drive in needle bearing using drift -VW 207 C- or centring
mandrel -3176- .
• The lettering on the needle bearing must be visible when in‐
stalled.

• Needle bearing must be inserted to a depth of -a- = 1.5 mm

3.4 Crankshaft dimensions

Honing dimen‐ Crankshaft main Conrod
sion bearing journal ∅ bearing journal ∅
(in mm)
Basic dimen‐ 54.00 –0.022 47.80 –0.022
sion –0.042 –0.042
1st undersize 53.75 –0.022 47.55 –0.022
–0.042 –0.042
2nd undersize 53.50 –0.022 47.30 –0.022
–0.042 –0.042
3rd undersize 53.25 –0.022 47.05 –0.022
–0.042 –0.042

56 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

4 Dismantling and assembling pistons

and conrods

Note

♦ The following alternative types of conrod can be installed:

♦ Conrod with dowel pin ⇒ Item 6 (page 58) . Use conrod bolts
without centralising function.
♦ Conrod without dowel pin. Use conrod bolts with centralising
function.

4.1 Pistons and conrods - exploded view of components

1 - Piston rings
❑ Offset gaps by 120°
❑ Remove and install us‐
ing piston ring clamp
❑ Marking “TOP” or in‐
scription must face pis‐
ton crown.
❑ Checking ring gap
⇒ page 58
❑ Checking ring-to-groove
clearance ⇒ page 59
2 - Piston
❑ With combustion cham‐
ber
❑ Mark installation posi‐
tion and cylinder alloca‐
tion
❑ Installation position and
allocation of piston/cyl‐
inder ⇒ page 59
❑ If cracking is visible on
piston skirt, renew pis‐
ton
❑ Arrow on piston crown
points to pulley end
❑ Install using piston ring
clamp
❑ Checking piston projec‐
tion at TDC
⇒ page 60
❑ Piston and cylinder di‐
mensions ⇒ page 61
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ unless
permitted Checking
authorised⇒by page
AUDI AG. 59AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
3 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift -VW 222 A-
4 - Circlip
5 - Conrod
❑ See note ⇒ page 57
❑ Only renew as a complete set

4. Dismantling and assembling pistons and conrods 57

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

❑ Mark cylinder allocation -A-

❑ Installation position: Marking -B- faces towards pulley end
❑ Measuring radial clearance ⇒ page 61
6 - Dowel pin
❑ Make sure that dowel pin is fitted securely in conrod and not in conrod bearing cap
7 - Bearing shell
❑ Note installation position
❑ Do not interchange used bearing shells (mark positions)
❑ Ensure tight fit in retaining lugs
❑ Axial clearance: Wear limit: 0.37 mm
❑ Measuring radial clearance ⇒ page 61
8 - Cylinder block
❑ Checking cylinder bore ⇒ page 60
❑ Piston and cylinder dimensions ⇒ page 61
9 - Bearing shell
❑ Note installation position
❑ Do not interchange used bearing shells (mark positions)
❑ Ensure tight fit in retaining lugs
❑ Axial clearance: Wear limit: 0.37 mm
❑ Measuring radial clearance ⇒ page 61
10 - Conrod bearing cap
❑ Mark cylinder allocation -A-
❑ Installation position: Marking -B- faces towards pulley end
11 - Oil spray jet
❑ For piston cooling
❑ Renew if damage from piston seizure has occurred
12 - Pressure relief valve, 27 Nm
❑ Opens at: 1.3 ... 1.6 bar
❑ Insert without locking fluid
13 - Conrod bolt - 30 Nm + 90° (1/4 turn) further
❑ See note ⇒ page 57
❑ Renew
❑ Lubricate threads and contact surface
❑ To measure radial clearance, tighten used bolt to 30 Nm but not further

Checking piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder. To do so, use a piston without rings.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.20 … 0.40 1.0
2nd compression ring 0.20 … 0.40 1.0
Oil scraper ring 0.25 … 0.50 1.0
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

58 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Checking ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15

Piston installation position and piston/cylinder allocation

– Mark installation position and assignment on inside of pistons
(not on piston crown) with an electric marker or felt-tip pen.
Pistons in cylinders 1 and 2:
• Larger inlet valve chamber towards flywheel -arrows-.
Pistons in cylinders 3 and 4:
• Larger inlet valve chamber towards pulley end -arrows-.

Note

♦ With new pistons, cylinder allocation is indicated by a coloured

marking on piston crown.
♦ Piston for cylinder 1 and 2: marked 1/2.
♦ Piston for cylinder 3 and 4: marked 3/4.

Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 10 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension ⇒ page 61 .

4. Dismantling and assembling pistons and conrods 59

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Checking cylinder bore

– Use 50 ... 100 mm internal dial gauge to take measurements
at 3 points in transverse direction -A- and longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.10 mm.
Nominal dimension ⇒ page 61 .

4.2 Checking piston projection at TDC

Special tools and workshop

equipment required
♦ -VW 382/7- from measuring
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
tool -VW 382-
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ -VW 385/17- from universal
measuring tool -VW 385-
♦ Dial gauge -VAS 6079-

60 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Test sequence
– Check piston projection at TDC when installing new pistons or
short engine.
– Install cylinder head gasket corresponding to individual piston
projection according to table below:
Piston projection above top surface of Identification
cylinder block (No. of holes)
0.91 mm … 1.00 mm 1
1.01 mm … 1.10 mm 2
1.11 mm … 1.20 mm 3

Identification of cylinder head gasket

♦ Part No. = arrow 1
♦ Holes = arrow 2
♦ Production code = arrow 3 (can be disregarded)

Note

If the measured values for piston projection are not the same for
all pistons, use the highest value to determine the correct gasket
size.

4.3 Piston and cylinder dimensions

Honing dimension Piston ∅ Cylinder bore ∅
(in mm)
Basic dimension 79.47 79.51
Repair oversize I 79.72 79.76
Repair oversize II 79.97 80.01

4.4 Measuring radial clearance of conrods

Special tools and workshop equipment required
♦ Plastigage
Procedure
– Remove conrod bearing caps.
– Clean bearing caps and bearing journals.
– Place Plastigage onto bearing journal or into bearing shells
corresponding to width of bearing.
– Fit conrod bearing caps and tighten to 30 Nm without rotating
crankshaft.
– Remove conrod bearing caps once more.
– Compare width of width of Plastigage with measurement
scale:
• Radial clearance: Wear limit: 0.08 mm.

4. Dismantling and assembling pistons and conrods 61

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Renew bolts for conrod bearings.

62 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

15 – Cylinder head, valve gear

1 Removing and installing cylinder
head

1.1 Cylinder head - exploded view of components

1 - Cylinder head
❑ Removing ⇒ page 66
❑ Checking for distortion
⇒ page 64
❑ Installing ⇒ page 74
❑ If renewed, refill system
with fresh coolant
2 - 25 Nm
3 - Lifting eye
4 - Tapered sealing element
(bottom)
5 - Gasket for cylinder head
cover
❑ Renew if damaged or
leaking
❑ Before fitting, apply
sealant at sealing points
⇒ page 65 and
⇒ page 65
❑ Insert lugs into holes on
cylinder head
6 - Cylinder head cover
❑ Removing and installing
⇒ page 65
7 - Sealing element (top)
❑ Renew if damaged
8 - Dished washer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - 10 Nm unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Cap
11 - Seal
❑ Renew if damaged or leaking
12 - Filler cap
13 - Vent hose
14 - Hose clip
❑ Fit hose clip and hose onto retaining tab on cylinder head cover
15 - Pressure control valve for crankcase breather system
16 - Seal
❑ Renew if damaged
17 - Cylinder head bolt
❑ Renew

1. Removing and installing cylinder head 63

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

❑ Note correct sequence when loosening ⇒ page 74

❑ Note correct sequence when tightening ⇒ page 76
18 - Injector pipes
❑ Tighten to 25 Nm
❑ Use ring spanner -3035- for removal
❑ Always remove pipework complete
❑ Do not alter shape.
19 - 10 Nm
20 - Coolant flange
21 - O-ring
❑ Renew
22 - Coolant flange
❑ With coolant temperature sender -G62-
23 - 10 Nm
24 - Connector
❑ For needle lift sender -G80-
25 - Return pipe
❑ To injection pump
26 - Cylinder head gasket
❑ Renewing ⇒ “1.3 Removing cylinder head”, page 66
❑ Note marking ⇒ page 65
❑ If renewed, refill system with fresh coolant

Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure for distortion
at several points.
• Max. permissible distortion: 0.1 mm

Note

The cylinder heads of diesel engines must not be machined.

64 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Cylinder head gasket identification

♦ Part No. = arrow 1
♦ Holes = arrow 2
♦ Production code = arrow 3 (can be disregarded)

Note

Cylinder head gaskets of different thicknesses are fitted depend‐

ing on the amount of piston projection ⇒ page 60 . Fit new gasket
with same identification if only gasket is renewed.

Sealing points between bearing cap and cylinder head

– Apply one drop of sealant each to sealing points between
bearing cap and cylinder head -arrows- (∅ approx. 5 mm);
sealant ⇒ Parts catalogue .

Sealing transitions
– Apply small quantity of sealant to transitions for semi-circular
seal -arrows- at sealing surfaces of cylinder head; sealant ⇒
Parts catalogue .

1.2 Removing and installing cylinder head

cover
Removing
– Unclip cover caps.
– Unscrew nuts -arrows- andProtected
detach engine cover panel.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Removing and installing cylinder head 65

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Slacken hose clips -arrows- and detach crankcase breather

hoses from pressure control valve.

– Remove caps -7-.

– Unscrew nuts -6- for cylinder head cover.
– Detach dished washer -5- and sealing element (top) -4-.
– Remove cylinder head cover -3-.
– Detach gasket -2- and tapered
Protected sealing
by copyright. element
Copying (bottom)
for private or commercial-1-.
purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.

Installation is carried out in the reverse order; note the following:

Note

Renew gasket for cylinder head cover, sealing element (top) and
tapered sealing element if damaged.

– Apply one drop of sealant each to sealing points between

bearing cap and cylinder head -arrows- (∅ approx. 5 mm);
sealant ⇒ Parts catalogue .

– Apply small quantity of sealant to transitions for semi-circular

seal -arrows- at sealing surfaces of cylinder head; sealant ⇒
Parts catalogue .
– Fit cylinder head cover with relevant components.
Tightening torque
Component Nm
Cylinder head cover to cylinder head 10

1.3 Removing cylinder head

66 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

equipment required
♦ Locking pin -2064-
♦ Setting bar -2065 A-
♦ Ring spanner -3035-
♦ Counterhold tool -3036-
♦ Guide pin -3070-
♦ Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208-

Note

All cable ties which are released or cut open when removing must
be fitted in the same position when installing.

Caution

Observe notes on procedure for disconnecting the battery ⇒

Electrical system; Rep. Gr. 27 .

1. Removing and installing cylinder head 67

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach rubber seal from plenum chamber cover in direction of

-arrow-.
– Detach plenum chamber cover -1- towards the front.

– With ignition switched off, disconnect battery earth cable

-arrow-.

– Disconnect breather hose -3- from air cleaner housing.

– Unplug electrical connector -1- at air mass meter -G70- .
– Move wiring harness going to air cleaner clear -arrow-.
– Loosen hose clip -4- to remove air intake hose.
– Remove bolt -2-.
– Detach air cleaner housing.

– Disconnect air intake hose from turbocharger -arrows-.

68 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach vacuum hose -2- from vacuum unit for charge pressure
control.
– Remove bolt -1- on bracket for oil supply pipe.
– Unscrew oil supply pipe -3- at turbocharger.
– Unscrew nuts securing turbocharger to catalytic converter
-arrows-.

– Loosen nuts on clamp -arrows-.

– Push the clamp back in order to separate the exhaust system.

Note

Do not bend the flexible joint (de-coupling element) in the exhaust

system more than 10°, otherwise it could be damaged.

– Disconnect catalytic converter with front exhaust pipe from

turbocharger.

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.

– Loosen securing bolts of tensioning roller for air conditioner

compressor poly V-belt -arrows-.
– Remove
Protected poly
by copyright. V-belt.
Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING

The air conditioner refrigerant circuit must not be opened.

– Unbolt air conditioner compressor from bracket.

– Tie up air conditioner compressor to vehicle, with lines attach‐
ed.

– Disconnect air intake hose from turbocharger (bottom)

-arrows-.

1. Removing and installing cylinder head 69

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove bolt -1- from noise insulation cover above drive shaft
(right-side).
– Disengage hook -2- and detach noise insulation.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove bracket for turbocharger -arrows-.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Detach oil return pipe at cylinder block -arrow-.

– Detach fuel hose -1- going to injectors/injection pump.

– Unplug electrical connectors -2 ... 5-.
– Drain off coolant ⇒ page 113 .
– Detach rear coolant hose from cylinder head -arrow-.

70 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach coolant hose (left-side) from cylinder head and expan‐

sion tank -arrows- and move clear to one side.
– Remove injector pipes using ring spanner -3035- .

Note

Always remove complete set of pipes.

– Detach electrical connectors at glow plugs.

– Detach coolant hose (bottom left) from cylinder head -arrow-.

– Remove air intake hose from charge air cooler -arrow-.

– Unplug electrical connectors -3- and -4-.

– Detach vacuum hose -6-.
– Detach vacuum hose -1- going to mechanical exhaust gas re‐
circulation valve.
– Loosen hose clip -2- to remove air intake hose at intake con‐
necting pipe.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– unless
permitted Unscrew bolt
authorised -5- AG.
by AUDI andAUDI
remove
AG doesair pipe. or accept any liability
not guarantee
with respect to the correctness of information in this document. Copyright by AUDI AG.

Caution

The engine must only be turned at the crankshaft, in the direc‐

tion of normal engine rotation (clockwise).

1. Removing and installing cylinder head 71

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

Turn over the engine at the central bolt on the crankshaft.

– Position crankshaft at TDC for cylinder 1 (vehicles with manual

gearbox).

– Position crankshaft at TDC for cylinder 1 -arrow- (vehicles with

automatic gearbox).
– Remove cylinder head cover ⇒ page 65 .
– Remove oil supply pipe for turbocharger.

– Lock camshaft with setting bar -2065 A- .

– Centralise setting bar as follows:
1. Turn locked camshaft until one end of setting bar makes
contact with cylinder head.
2. Measure resulting clearance at other end of setting bar us‐
ing feeler gauge.
3. Slide in a feeler gauge with half the measured thickness be‐
tween setting bar and cylinder head.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4. Now turnunless
permitted camshaft until
authorised setting
by AUDI barAG
AG. AUDI makes
does notcontact with
guarantee or feel‐
accept any liability
er gauge.
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Insert a second feeler gauge of the same thickness between

the other end of the setting bar and the cylinder head.
– Remove poly V-belt ⇒ page 27 .
– Remove viscous fan (with pulley) ⇒ page 122 .
– Remove poly V-belt tensioner.

72 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove toothed belt cover (top) ⇒ Item 1 (page 35) .

– Remove bolts -arrows- for toothed belt cover (rear) at both
sides of cylinder head.

– Lock injection pump sprocket in position with locking pin

-2064- .
– Loosen securing nut for tensioning roller.
– Remove idler roller.
– Remove toothed belt from camshaft sprocket.
– Remove toothed belt tensioning roller.

Note

Do NOT use the setting bar as a counterhold tool when loosening

and tightening the camshaft sprocket. Counterhold using coun‐
terhold tool -3036- .

– Loosen camshaft sprocket securing bolt a 1/2 turn.

– Detach camshaft sprocket from camshaft taper (apply a blow

through mounting hole in toothed belt cover (rear) using a
hammer and a drift).
– Remove camshaft sprocket.

1. Removing and installing cylinder head 73

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

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

– Carefully lift off the cylinder head with the assistance of a 2nd
mechanic.

1.4 Installing cylinder head

Installation is carried out in the reverse order; note the following:

Note

♦ Carefully remove any sealant residue from the cylinder head

and cylinder block. Ensure that no long scores or scratches
are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive material.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ Renew the cylinder head bolts.
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
♦ When installing a replacement cylinder head with fitted cam‐
shaft, the contact surfaces between hydraulic tappets and cam
running surfaces must be oiled after installing the cylinder
head.
♦ The plastic protectors fitted to protect the open valves should
not be removed until the cylinder head is ready to be fitted.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use lubricant.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.
♦ Fit all cable ties in the original position when installing.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

74 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Check whether the camshaft is still positioned at TDC.

• It should be possible to attach setting bar -2065 A- into cam‐
shaft.

Note

If the setting bar -2065 A- cannot be attached, turn camshaft 1/2

turn (180°) in normal rotation direction.

– Check whether the crankshaft is still positioned at TDC.

• The TDC marking should align with the point of reference.

Note

Illustration shows vehicle with manual gearbox.

– Note identification markings on cylinder head gasket.

♦ Part No. = arrow 1
♦ Holes = arrow 2
♦ Production code = arrow 3 (can be disregarded)

Note

♦ If the cylinder head gasket or cylinder head have been re‐

placed, select the new cylinder head gasket according to the
number of holes on the old gasket.
♦ If parts of the crankshaft drive have been renewed, the new
cylinder head gasket must be selected by measuring the pis‐
ton projection at TDC ⇒ page 60 .

– Fit guide pins -3070/9- into outer drillings in cylinder block to

position cylinder head gasket
– Fit cylinder head gasket.
• Note position of centring sleeve in cylinder block.
• Check installation position of cylinder head gasket: the word
“oben” (top) or the Part No. should face towards the cylinder
head.
– Fit the cylinder head.
– Insert 8 new cylinder head bolts and tighten finger-tight.
– Remove guide pins -3070/9- (insert pin driver -3070- through
bolt holes) and fit remaining cylinder head bolts.

1. Removing and installing cylinder head 75

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Tighten cylinder head bolts in 4 stages in the sequence shown:

1. Tighten with torque wrench to 40 Nm.
2. Tighten with torque wrench to 60 Nm.
3. Turn 90° (1/4 turn) further using a rigid wrench.
4. Turn 90° (1/4 turn) further using a rigid wrench.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Cylinder head bolts do not have to be torqued down again
permitted unlesslater
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
after repair work. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fit toothed belt (adjust valve timing) ⇒ page 40 .

Note

Follow all instructions for removing and installing toothed belt.

– Install cylinder head cover ⇒ page 66 .

– Install poly V-belt ⇒ page 29 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. Gr.
50 .
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
– Install exhaust system and align it free of stress
⇒ page 165 .
– Check oil level ⇒ page 109 .

Note

If engine oil is contaminated, perform oil change ⇒ Maintenance ;

Booklet 402 .

– Connect battery and observe notes on procedures required

after connecting battery ⇒ Electrical system; Rep. Gr. 27 .
– Fill cooling system with fresh coolant ⇒ page 115 .

76 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Tightening torques
Component Nm
Rear toothed belt cover to cylinder head 10
Oil return pipe to cylinder block 30
Injection pipes to injectors and injection pump 25
Viscous fan to bearing 45
Idler roller to console 25
Tensioner for poly V-belt to bracket for ancilla‐ 45
ries
Oil supply pipe to turbocharger 22
Toothed belt sprocket to camshaft 45
Catalytic converter to turbocharger 2512)
Bracket for turbocharger turbocharger 25
to cylinder block 25
Hose clips for air hoses 3.5
12) Renew self-locking nuts.

1.5 Removing and installing intake manifold

Removing
– Remove exhaust gas recirculation pipe with mechanical ex‐
haust gas recirculation valve -arrows-.

Note

Vacuum hose -1- remains connected.

– Move exhaust gas recirculation pipe withbymechanical

Protected exhaust
copyright. Copying for private or commercial purposes, in part or in whole, is not
gas recirculation valve clear to onepermitted
side. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Removing and installing cylinder head 77

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Loosen hose clip -1- to remove air intake hose from intake
manifold.
– Unfasten bracket for oil supply pipe from exhaust manifold,
slacken clip and move bracket clear to one side.
– Unscrew bolts -arrows-.
– Remove intake manifold.
Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Renew gaskets and self-locking nuts.

♦ Note the installation position of intake manifold gasket.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use lubricant.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

Tightening torques
Component Nm
Intake manifold to cylinder head 25
Connecting pipe for exhaust gas recirculation to 25
exhaust manifold
Mechanical exhaust gas recirculation valve to 25 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
intake manifold with respect to the correctness of information in this document. Copyright by AUDI AG.
Bracket for oil supply pipe to exhaust manifold 25
Hose clips for air hoses 3.5

1.6 Checking compression

78 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

equipment required
♦ Jointed spanner -3220-
♦ Compression tester -
V.A.G 1763-
♦ Adapter -V.A.G 1381/12-

Test requirements
• Engine oil temperature at least 30 °C
• Battery voltage at least 12.5 V
Test sequence
– Unclip cover caps.
– Unscrew nuts -arrows- and detach engine cover panel.
– Detach electrical connector for fuel shut-off valve -N109- at
injection pump.
– Detach electrical connector for metering adjuster -N146- at in‐
jection pump.

1. Removing and installing cylinder head 79

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach electrical connectors at glow plugs.

– Unscrew all glow plugs using jointed spanner -3220- .
– Screw in adapter -V.A.G 1381/12- in place of the glow plug in
each cylinder.
– Test the compression pressure with the compression tester -
V.A.G 1763- .

Note

Using the compression tester ⇒ operating instructions .

– Have a 2nd mechanic operate starter until tester shows no

further pressure increase.
Compression pressure bar
When new 25 … 31
Wear limit 19
Difference between cylinders 5 (maximum)
Installation is carried out in the reverse order; note the following:
– Install glow plugs ⇒ Rep. Gr. 28 .
– Interrogate and erase the fault memory for engine control unit,
as faults are stored when the electrical connectors are un‐
plugged ⇒ Vehicle diagnosis, testing and information system
VAS 5051.

80 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2 Servicing valve gear

Note

♦ After installing the camshaft, the engine must NOT be started

for about 30 minutes. Hydraulic valve compensation elements
have to settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
♦ Renew seals and gaskets.
♦ Cylinder heads with cracksProtected
between the valve
by copyright. seats
Copying may
for private be
or commercial purposes, in part or in whole, is not
used without reducing engine life, unless
permitted provided thebycracks
authorised AUDI AG. areAUDI AG does not guarantee or accept any liability
small and not more than 0.5 mm wide.
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Before applying sealant, check updated information: ⇒ Parts

catalogue

2.1 Valve gear - exploded view of components

1 - Bearing cap
❑ Installation position
⇒ page 82
❑ Installation sequence
⇒ “2.3 Removing and in‐
stalling camshaft”,
page 83
❑ Applying sealant to
bearing cap 1
⇒ page 65
❑ Sealant ⇒ Parts cata‐
logue
2 - 20 Nm
3 - Camshaft
❑ Checking axial clear‐
ance ⇒ page 82
❑ Removing and installing
⇒ page 83
❑ Check radial clearance
with Plastigage
❑ Radial clearance: wear
limit: 0.11 mm
❑ Runout: max. 0.01 mm
❑ Valve timing ⇒ page 1
4 - Hydraulic bucket tappet
❑ Checking ⇒ page 87
❑ Removing and installing
⇒ “2.3 Removing and in‐
stalling camshaft”,
page 83
❑ Do not interchange
(mark allocation)
❑ Place down with contact
surface facing down‐
wards

2. Servicing valve gear 81

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

❑ Before installing check camshaft axial clearance ⇒ page 82

❑ Lubricate contact surface
5 - Valve cotters
6 - Upper valve spring plate
7 - Valve spring
❑ Removing and installing with cylinder head installed ⇒ “2.5 Renewing valve stem oil seals”, page 88
❑ Remove and install with cylinder head removed using valve spring compressor -2037-
8 - Valve stem oil seal
❑ Renewing ⇒ page 88
9 - Valve guide
❑ Checking ⇒ page 94
❑ If wear limit is exceeded, renew cylinder head
10 - Oil seal
❑ Different versions possible ⇒ Parts catalogue
❑ Remove bearing cap and toothed belt sprocket to remove and install
❑ Removing and installing toothed belt ⇒ page 37
❑ Before installing, use clean cloth to wipe oil residue off camshaft journal.
❑ When fitting, mask groove on taper of camshaft (using transparent adhesive tape, etc.)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 - Cylinder head permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Checking valve guides ⇒ page 94
with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Machining valve seats ⇒ page 92

12 - Valve
❑ Do not machine, only grinding-in is permitted
❑ Checking ⇒ page 95
❑ Valve dimensions ⇒ page 92

Installation position of camshaft bearing caps

– Make sure bearing cap drillings are not offset when installing
bearing cap.
– Before installing, fit bearing cap and determine correct position
for installation.

2.2 Checking axial clearance of camshaft

Special tools and workshop equipment required

82 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

♦ Universal dial gauge bracket -VW 387-

♦ Dial gauge -VAS 6079-

Test sequence
– Measure with bucket tappets removed and with first and last
bearing caps fitted.
• Wear limit: 0.15 mm.

2.3 Removing and installing camshaft

2. Servicing valve gear 83

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

equipment required
♦ Locking pin -2064-
♦ Setting bar -2065 A-
♦ Counterhold tool -3036-

Procedure
• Cylinder head installed
• Front bumper is removed ⇒ General body repairs, exterior;
Rep. Gr. 63 .
• Lock carrier is moved into its service position ⇒ General body
repairs, exterior; Rep. Gr. 50 .
– Remove poly V-belt ⇒ page 27 .
– Remove viscous fan (with pulley) ⇒ page 122 .
– Remove poly V-belt tensioner.
– Remove toothed belt cover (top) ⇒ Item 1 (page 35) .
– Remove cylinder head cover ⇒ page 65 .

Caution

The engine must only be turned at the crankshaft, in the direc‐

tion of normal engine rotation (clockwise).

84 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

Turn over the engine at the central bolt on the crankshaft.

– Position crankshaft at TDC for cylinder 1 (vehicles with manual

gearbox).

– Position crankshaft at TDC for cylinder 1 -arrow- (vehicles with

automatic gearbox).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Lock camshaft with setting bar -2065 A- .

– Lock injection pump sprocket in position with locking pin

-2064- .
– Loosen securing nut for tensioning roller.
– Remove idler roller.
– Remove toothed belt from camshaft sprocket.

2. Servicing valve gear 85

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

Do NOT use the setting bar as a counterhold tool when loosening

and tightening the camshaft sprocket. Counterhold using coun‐
terhold tool -3036- .

– Loosen camshaft sprocket securing bolt a 1/2 turn.

– Detach camshaft sprocket from camshaft taper (apply a blow

through mounting hole in toothed belt cover (rear) using a
hammer and a drift).
– Remove camshaft sprocket.
– First remove the bearing caps 1, 3 and 5.
– Then loosen bearing caps 2 and 4 alternately in diagonal se‐
quence.
– Remove camshaft.
Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Renew camshaft oil permitted

seal. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Before installing, fit bearing caps and determine correct posi‐
tion for installation; make sure they are not offset.

86 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Lubricate contact surfaces of camshaft.

– Install camshaft in TDC position:
• The cams for cylinder 1 must point upwards on camshaft
-arrows-.
– Tighten bearing caps 2 and 4 alternately in diagonal se‐
quence.
– Apply a thin and even coat of sealant to surfaces on bearing
cap 1; sealant ⇒ Parts catalogue .
– Install bearing caps 1, 3 and 5 and tighten in the same way.
– Fit toothed belt (adjust valve timing) ⇒ page 40 .

Note

♦ Follow all instructions for removing and installing toothed belt.

♦ After installing the camshaft, the engine must NOT be started
for about 30 minutes. The hydraulic tappets have to settle
(otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.

– Install cylinder
Protected headCopying
by copyright. coverfor ⇒ page
private 66 . purposes, in part or in whole, is not
or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Perform
with dynamic
respect to thecheck of of
correctness commencement of injection
information in this document. Copyright ⇒ Rep.
by AUDI AG.
Gr. 23 .
Tightening torque
Component Nm
Bearing cap to cylinder head 20

2.4 Checking hydraulic bucket tappets

Special tools and workshop equipment required
♦ Feeler gauge
♦ Wooden or plastic wedge

Note

♦ Hydraulic bucket tappets cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

Test sequence
– Start engine and run until coolant temperature reaches ap‐
prox. 80 °C.
– Increase engine speed to about 2500 rpm for approx. 2 mi‐
nutes; perform test drive if necessary.

Note

If the irregular valve noises stop but recur repeatedly during short
journeys, then the oil retention valve is defective. Fitting location:
in oil filter bracket ⇒ Item 4 (page 99) .

2. Servicing valve gear 87

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

If the hydraulic tappets are still noisy, locate defective tappet as

follows:
– Remove cylinder head cover ⇒ page 65 .
– Turn crankshaft until cam of the bucket tappet to be checked
faces upwards; to do so, push vehicle forwards with 4th gear
engaged and ignition switched off.
Vehicles with automatic gearbox:
– Vehicles with auxiliary heater: remove bolts -arrows- securing
exhaust pipe for auxiliary/additional heater to noise insulation.

– Release quick-fasteners -1- and -2- and take off front noise
insulation.
– Rotate crankshaft clockwise at centre bolt for toothed belt
sprocket until cams of cylinder to be checked are pointing up‐
wards.

All models:
– Determine clearance between cams and bucket tappets.
– Push tappet down with a wooden or plastic wedge.
If it is possible to insert a feeler gauge of 0.20 mm between cam‐
shaft and bucket tappet:
– Renew hydraulic bucket tappet
⇒ “2.3 Removing and installing camshaft”, page 83 .

Note

♦ After installing the camshaft, the engine must NOT be started

for about 30 minutes. The hydraulic tappets have to settle
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
(otherwise valves will strike pistons). with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ After working on the valve gear, turn the engine carefully at

least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.

2.5 Renewing valve stem oil seals

88 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

equipment required
♦ Fitting tool -10-204-
♦ Puller -3047 A-
♦ Jointed spanner, 10 mm
-3220-
♦ Disassembly and assembly
tool -VAS 5161-

Removing
• Cylinder head installed.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
If cylinder head is removed, the valve stem oil seals can be re‐
newed using valve spring compressor -2037- .

– Remove the camshaft ⇒ page 83 .

Note

Make sure that the hydraulic bucket tappets are not interchanged;
mark allocation on rear with a waterproof felt-tipped pen.

2. Servicing valve gear 89

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove bucket tappets out of guides.

– Place bucket tappets down on a clean surface with contact
surface facing downwards in the order in which they were re‐
moved.
– Insert punch -VAS 5161/3- into bucket tappet guide.
– Knock loose valve cotters on all valves using a plastic ham‐
mer.
– Detach electrical connectors at glow plugs.
– Unscrew all glow plugs using jointed spanner -3220- .
– Set piston of the respective cylinder to “bottom dead centre”.

– Screw adapter -VAS 5161/11- finger-tight into the glow plug

hole of the relevant cylinder.
– Screw snap-in device -VAS 5161/6- with interlocking fork (M6)
-VAS 5161/4- into threaded hole on cylinder head.
– Push guide bush -VAS 5161/16- as far as it will go into bucket
tappet guide of the valve to be removed.
• Installation position of guide bush: hatched areas are perpen‐
dicular to driving direction.
– Insert assembly cartridge -VAS 5161/15- into guide bush.
– Connect adapter -VAS 5161/11- to compressed air supply us‐
ing a commercially available connection piece.
• Air pressure: at least 6 bar
– Attach pressure fork -VAS 5161/2- to snap-in device -VAS
5161/6- and push assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the cartridge.
– Release the pressure fork.
– Remove assembly cartridge, guide bush, valve spring plate
and valve springs.

– Detach valve stem oil seals using puller -3047 A- .

90 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Installing

Note

A plastic sleeve -A- is included with the new valve stem oil seals.

– Insert plastic sleeve -A- onto the valve stem to prevent dam‐
age to the new valve stem oil seal -B-.
– Lightly lubricate sealing lip of valve stem oil seal.
– Slip valve stem oil seal over plastic sleeve.
– Carefully press valve stem oil seal down onto valve guide us‐
ing fitting tool -10-204- .
– Remove the plastic sleeve.

– If valve cotters have been removed from assembly cartridge,

they need to be put into insertion device -VAS 5161/18- first.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Note
with respect to the correctness of information in this document. Copyright by AUDI AG.

Larger diameter of valve cotters faces upwards.

– Press assembly cartridge -VAS 5161/15- onto insertion device

from above and take up valve cotters.

– Reinstall the assembly cartridge -VAS 5161/15- into guide

bush -VAS 5161/16- .
– Push pressure fork down and pull knurled screw upwards
while turning to left and right - this will insert the valve cotters.
– Release the pressure fork with knurled screw still in pulled po‐
sition.
– Insert bucket tappets.
– Install camshaft ⇒ page 86 .
– Install glow plugs ⇒ Rep. Gr. 28 .

Note

♦ After installing the camshaft, the engine must NOT be started

for about 30 minutes. The hydraulic tappets have to settle
(otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.

2. Servicing valve gear 91

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2.6 Valve dimensions

Dimension Inlet valve Exhaust valve
∅a mm 35.95 31.45
∅b mm 6.963 6.943
c mm 96.85 96.85
α ∠° 45 45

Note

Valves are not to be machined. Only grinding-in is permitted.

2.7 Machining valve seats

Note

If a good seating pattern cannot be obtained by grinding the valve

seats (lapping), they must be refaced (machined):

Special tools and workshop equipment required

♦ Depth gauge
♦ Valve seat machining tool

Note

♦ When servicing engines with leaking valves, it is not sufficient

to machine (reface) the valve seats and renew the valves. The
valve guides must also be checked for wear. This is particu‐
larly important on high-mileage engines ⇒ page 94 .
♦ Valve seats should only be machined to the extent required to
give a proper seating pattern.
♦ The maximum permissible machining dimension must be cal‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
culated before starting work. with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ If the machining dimension is exceeded, the function of the

hydraulic valve play compensation can no longer be guaran‐
teed and the cylinder head must be renewed.

92 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Calculating maximum permissible machining dimension

– Insert valve and press firmly against valve seat.

Note

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

for the measurement.

– Measure distance -a- between end of valve stem and upper

cylinder head surface with a depth gauge.
– Calculate the maximum permissible machining dimension us‐
ing the measured distance and the minimum dimension.
• Minimum dimension for inlet valve: 35.8 mm.
• Minimum dimension for exhaust valve: 36.1 mm.
Measured distance minus minimum dimension = max. permissi‐
ble machining dimension.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Example for inlet valve:
Measured distance 36.5 mm
– Minimum dimension – 35.8 mm
= Maximum permissible machining dimen‐ = 0.7 mm
sion

Note

If the maximum permissible machining dimension is 0 mm or less

than 0 mm, repeat the measurement with a new valve. If the
measured result is again 0 mm or less than 0 mm, renew the cyl‐
inder head.

Machining inlet valve seat

a - ∅ 35.7 mm
b - 1.6 mm
45° - Valve seat angle

Note

♦ Calculating maximum permissible machining dimension

⇒ page 93 .
♦ The 30° lower valve seat chamfer is necessary to ensure that
the inlet channel flow characteristics are maintained.

2. Servicing valve gear 93

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Machining exhaust valve seat

a - ∅ 31.4 mm
b - 2.7 mm
45° - Valve seat angle

Note

Calculating maximum permissible machining dimension

⇒ page 93 .

2.8 Checking valve guides

Special tools and workshop equipment required
♦ Universal dial gauge bracket -VW 387-

♦ Dial gauge -VAS 6079-

Test sequence
– Insert valve into valve guide.
• End of valve stem must be flush with guide.
– Determine amount of sideways play.
• Wear limit (sideways play): 1.3 mm.

Note

♦ If the wear limit is exceeded, repeat the measurement with

new valves. Renew cylinder head if wear limit is still exceeded.
♦ If the valve has to be renewed as part of a repair, use a new
valve for the measurement.

94 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2.9 Checking valves

– Visually inspect for scoring on stem and surface of seat.
– Renew valves with significant score marks.

2. Servicing valve gear 95

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

17 – Lubrication
1 Removing and installing parts of lu‐
brication system

Note

♦ If large quantities of metal particles are found in the engine oil

when repairing the engine, the oil passages must be cleaned
carefully, and the oil cooler renewed in order to prevent further
damage.
♦ The oil level must not be above the max. mark – otherwise the
catalytic converter can be damaged.
♦ Before applying sealant, check updated information: ⇒ Parts
catalogue

Viscosity grades and oil specifications ⇒ Maintenance ; Booklet

402 .
Oil capacities ⇒ Data sheets for exhaust emission test.

1.1 Sump, oil pump - exploded view of components

96 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1 - Sump
❑ Removing and installing
⇒ page 100
❑ Clean sealing surface
before installing
❑ Apply sealant prior to in‐
stalling
❑ Sealant ⇒ Parts cata‐
logue
2 - Gasket
❑ Renew
❑ Install dry
❑ Apply sealant prior to in‐
stalling
❑ Sealant ⇒ Parts cata‐
logue
3 - Intake pipe
❑ Clean strainer if dirty
4 - 10 Nm
5 - 23 Nm
6 - Longitudinal strut (right-
side)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
7 - 23
withNm
respect to the correctness of information in this document. Copyright by AUDI AG.

8 - Stop for torque reaction

support
❑ Allow stop for torque re‐
action support to rest on
rubber buffer for torque
reaction support under
its own weight, and
tighten bolts.
9 - 23 Nm
10 - 23 Nm
11 - Bracket for torque reaction support
12 - Shim
13 - 23 Nm
14 - Longitudinal strut (left-side)
15 - 23 Nm
16 - Oil pump housing
17 - Gears
❑ Checking backlash ⇒ page 98
❑ Checking axial clearance ⇒ page 98
18 - Oil pump cover with pressure relief valve
❑ Opening pressure: 5.7 ... 6.7 bar
19 - 10 Nm
20 - 25 Nm
21 - O-ring
❑ Renew

1. Removing and installing parts of lubrication system 97

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

22 - Engine/gearbox support
❑ Unbolt to remove sump ⇒ page 100
❑ When installing engine/gearbox support with engine removed from vehicle, make sure engine/gearbox
support is positioned flush with intermediate plate at flywheel end, i.e. engine/gearbox support should
protrude 0.8 mm from cylinder block
23 - 45 Nm
24 - 45 Nm
25 - Oil drain plug, 30 Nm
26 - Seal
❑ Renew
27 - 18 Nm
❑ Tighten in stages and in diagonal sequence

Checking backlash of oil pump

• New: 0.05 mm.
• Wear limit: 0.20 mm.

Checking axial clearance of oil pump

• Wear limit: 0.15 mm.

98 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1.2 Oil filter bracket, oil filter - exploded view of components

1 - O-ring
❑ Renew
❑ Engage in lugs on oil
cooler
2 - 25 Nm
3 - Gasket
❑ Renew
4 - Oil retention valve
❑ Tighten to 8 Nm
5 - Oil filter bracket
6 - Seals
❑ Renew
7 - Banjo bolt, 25 Nm
8 - Oil supply pipe
❑ To turbocharger
9 - 20 Nm
10 - Coolant pipe
11 - 0.9 bar oil pressure switch
-F1-
❑ Different versions possi‐
ble ⇒ Parts catalogue
❑ Checking ⇒ page 107
❑ Tighten to 25 Nm
12 - Seal
❑ If seal is leaking, cut
open and renew
13 - Oil temperature sender -
G8-
❑ Tighten to 10 Nm
14 - Seal
❑ If seal is leaking, cut open and renew
15 - Oil cooler
❑ See note ⇒ page 96
16 - 25 Nm
17 - Oil filter
❑ Observe change intervals ⇒ Maintenance ; Booklet 402
❑ Loosen with strap wrench
❑ Observe installation instructions on oil filter

1. Removing and installing parts of lubrication system 99

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1.3 Removing and installing sump

Special tools and workshop

equipment required
♦ Support bracket -10-222 A-
♦ Lifting tackle -2024 A-
♦ Jointed spanner -3185-
♦ Hexagon key extension, 5
mm -3249-
♦ Workshop hoist -V.A.G
1202 A- or -VAS 6100-

♦ Used oil collection and extraction unit -V.A.G 1782-

♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Parts catalogue

100 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Removing
– Unclip cover caps.
– Unscrew nuts -arrows- and detach engine cover panel.

– Unscrew bolts -arrows-.

– Remove air ducts -1- and -2-.

– Unscrew bolts -3- and detach cover -2-.

– Move charge pressure control solenoid valve -N75- -item 1-
clear to one side with hoses connected.

– Set up support bracket -10-222 A- on wing panel flanges.

• The spindle must be at the front.

1. Removing and installing parts of lubrication system 101

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove eyelets of lifting tackle -2024 A- .

– Re-insert pin -1- in centre hole of lifting tackle and secure with
split pin.
– Hang the pin of lifting tackle -2024 A- onto the spindle of sup‐
port bracket -10-222 A- .
– Engage lifting tackle -2024 A- in front and rear lifting eyes on
engine.

WARNING

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

– Take up weight of engine with the spindle of support bracket,

but do not lift.

– Vehicles with auxiliary heater: remove bolts -arrows- securing

exhaust pipe for auxiliary/additional heater to noise insulation.

– Release quick-release fasteners -1 … 3- and take off front and

rear noise insulation.
– Drain engine oil.
Vehicles with automatic gearbox:

Note

Note the rules for cleanliness when working on the automatic

gearbox ⇒ Automatic gearbox 01N; Rep. Gr. 37 .

– Unbolt bracket for ATF pipe at engine.

All models:
– Unbolt bracket for noise insulation -arrow-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

102 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove bolt -2- from noise insulation cover above drive shaft
(left-side).
– Disengage hook -1- and detach noise insulation.

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.

– Loosen securing bolts of tensioning roller for air conditioner

compressor poly V-belt -arrows-.
– Remove poly V-belt.
– Remove tensioning roller.

– Unscrew bolts -arrows- and remove torque reaction support.

– Remove longitudinal strut (left and right) and unbolt bracket

for torque reaction support from engine -arrows-.

Note

Illustration shows engine removed.

1. Removing and installing parts of lubrication system 103

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– If fitted, unclip actuator rod for vehicle level sender at bottom

transverse link -arrow-.

– Cut through cable ties -arrows-. Open retainer for starter wiring
and take out wiring.

– Unbolt bracket for wiring harness at left engine mounting.

– Mark positions of bolt connections -1- and locating sleeves
-2- on bottom of engine mounts (left and right).

Note

Different mounting holes are provided for the different engine ver‐
sions.

– Remove bottom nut -1- at engine mounting (left and right).

– Support subframe using workshop hoist -V.A.G 1202 A- or -

VAS 6100- .

104 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– First remove front subframe bolts -2- and -3- (left and right).
Then unscrew bolts -1-.

Note

To avoid having to check and adjust wheel alignment, only loosen

the front subframe mountings and lower the subframe at the front.

– Loosen rear bolt -2- for gearbox mounting (right-side) a few

turns, then unscrew front bolt -1- for gearbox mounting (right-
side).

– Loosen nut -arrow- for gearbox mounting (left-side) until it

aligns with the lower edge of the bolt (turned approx. 4
threads).

– Carefully lower subframe using workshop hoist -

V.A.G 1202 A- or -VAS 6100- .
– Remove workshop hoist and move anti-roll bar downwards.

1. Removing and installing parts of lubrication system 105

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unscrew bolts -1 ... 8- securing engine/gearbox support.

Note

On removal, note down bolt lengths and original installation po‐

sition for re-installation.

– Guide engine/gearbox support to rear and take out.

– Unscrew bolts securing sump.

Note

Use hexagon key extension -3249- to unscrew the two rear sump
bolts -1- and -2-. For this purpose, turn the dual-mass flywheel
-3- (on vehicles with manual gearbox) until the recess -arrow- is
aligned with the bolt.

– Take off sump; if necessary loosen it by striking lightly with a

rubber hammer.
Installing
Installation is carried out in the reverse order; note the following:

Note

Renew gaskets and seals.

– Clean sealing surfaces; they must be free of oil and grease.

– Apply a thin coat of sealant to front and rear sealing flange/
cylinder block transitions at sealing surface of sump; sealant
⇒ Parts catalogue .
– Fit sump and tighten bolts in two stages and diagonal se‐
quence.

Note

When installing the engine/gearbox support -3- with the engine

removed from the vehicle, make sure that it is positioned flush
with the intermediate plate -1- at the flywheel end. In other words,
the engine/gearbox support should protrude by 0.8 mm (dis‐
tance -a-) from cylinder block -2-.

– Install subframe ⇒ Running gear, front-wheel drive and four-

wheel drive; Rep. Gr. 40

106 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Allow stop for torque reaction support to rest on rubber buffer

for torque reaction support under its own weight and tighten
bolts -arrows-.
– Install tensioning roller for poly V-belt and poly V-belt for air
conditioner compressor ⇒ page 29 .
– Secure the ATF pipes ⇒ Automatic gearbox 01N; Rep. Gr.
37 .
– Fill up with engine oil and check oil level.
– Check ATF level ⇒ Automatic gearbox 01N; Rep. Gr. 37

Tightening torques
Securing engine/gearbox support
Item Bolt Nm
1 M10x28 45
2, 4, 5, 6 M10x45 45
3, 7 M10x95 45
8 M10x65 45

Component Nm
Sump to cylinder block 18 13)
Bracket for torque reaction support to engine 23
Engine mounting to subframe 23
Longitudinal strut to bracket for torque reaction 23
support
Longitudinal strut to engine support 23
Stop for torque reaction support to bracket for 23
torque reaction support
Oil drain plug 30
13) Special bolts; use only genuine bolts ⇒ Parts catalogue .

1.4 Removing and installing oil pump

Removing
– Remove sump ⇒ page 100 .
– Unscrew bolt -arrows-.
– Press subframe down and remove oil pump.
Installing
Installation is carried out in the reverse order; note the following:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install sump ⇒ page 106 .
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Fill up with engine oil and check oil level.
Tightening torque
Component Nm
Oil pump to cylinder block 25

1.5 Checking oil pressure and oil pressure switch

1. Removing and installing parts of lubrication system 107

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

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

Test requirements
• Oil level OK
• Engine oil temperature approx. 80 °C
• Oil pressure warning lamp -K3- should come on when ignition
is switched on.
• On vehicles with driver information system (DIS), the message
“OK” should light up in the display.

108 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Preparation for test

– Unplug electrical connector at oil pressure switch -F1- .
– Unscrew oil pressure switch.
– Connect oil pressure tester -V.A.G 1342- to threaded hole for
oil pressure switch.
– Screw oil pressure switch -F1- -Item 2- into oil pressure tester
-V.A.G 1342- .
Checking oil pressure switch
– Connect brown wire -1- of oil pressure tester to earth (–).
– Connect voltage tester -V.A.G 1527 B- with test leads from
auxiliary measuring set -V.A.G 1594 C- to oil pressure switch
and battery positive (+).
• LED should not light up.
If LED lights up now:
– Renew oil pressure switch.
– Start engine.

Note

Observe tester and LED while starting, as switching point of oil

pressure switch may already be exceeded when starting.

• LED should light up at 0.75 ... 1.05 bar.

If the LED does not light up:
– Renew oil pressure switch.
Checking oil pressure
– Start engine.
• Minimum oil pressure at idling speed: 0.8 bar.
• Minimum oilbypressure
Protected at 2000
copyright. Copying rpm:
for private 2.0 bar. purposes, in part or in whole, is not
or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Maximum oil pressure
with respect at higher
to the correctness engine
of information speeds:
in this document.7.0 bar by AUDI AG.
Copyright

The pressure relief valve or oil pump is defective if the specifica‐

tions are not attained.
– Renew the oil pump ⇒ page 107 .
Assembling
Assemble in reverse order.

1.6 Engine oil

Viscosity grades and oil specifications
⇒ Maintenance ; Booklet 402 .

1.7 Checking oil level

Test requirements
• Engine oil temperature at least 60 °C.
• Vehicle must be level (horizontal)
• Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.

1. Removing and installing parts of lubrication system 109

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Test sequence
– Pull out the dipstick, wipe off with a clean cloth and insert it
again as far as it will go.
– Pull out the dipstick again and read off the oil level.
Markings on oil dipstick:
a - Do not top up oil.
b - Oil may be topped up. The oil level may rise as far as area
-a- after topping up. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
c - Oil must be topped up. It with
is sufficient if the oil level is some‐
respect to the correctness of information in this document. Copyright by AUDI AG.

where in area -b- after topping up.

Note

The oil level must not be above the MAX marking -a- and not
below the MIN marking -c-.

110 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

19 – Cooling
1 Removing and installing parts of cool‐
ing system

WARNING

Hot steam/hot coolant may escape when opening expansion

tank; cover filler cap with cloth and open carefully.

Note

♦ The cooling system is under pressure when the engine is hot.

If necessary, relieve pressure before commencing repair work.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Renew gaskets and seals.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ The arrow markings on coolant pipes and on ends of hoses

must align.

1.1 Coolant hose connection diagram

1. Removing and installing parts of cooling system 111

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1 - Radiator
❑ Removing and installing
⇒ page 127
❑ If renewed, refill system
with fresh coolant
2 - Coolant hose
❑ To expansion tank
3 - Expansion tank
4 - Filler cap
❑ With pressure relief
valve
❑ Checking pressure re‐
lief valve ⇒ page 133
5 - Oil cooler
❑ Removing and installing
⇒ Item 15 (page 99)
6 - Bleed hole
❑ In return pipe from heat
exchanger for heater
7 - Heat exchanger for heater
❑ If renewed, refill system
with fresh coolant
8 - Coolant hose
❑ To heat exchanger
9 - Coolant pump/thermostat
❑ Removing and installing
coolant pump
⇒ page 119
❑ Removing and installing
thermostat ⇒ page 120
❑ Checking thermostat
⇒ page 121

112 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1.2 Draining and filling cooling system

Special tools and workshop

equipment required
♦ Adapter for cooling system
tester -V.A.G 1274/8-
♦ Pipe for cooling system
tester -V.A.G 1274/10-
♦ Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208-
♦ Hose clip pliers -
V.A.G 1921-
♦ Cooling system charge unit
-VAS 6096-
♦ Refractometer -T10007-

Draining

Note

Collect drained coolant in a clean container for re-use or disposal.

WARNING

Hot steam/hot coolant may escape

Protected when
by copyright. opening
Copying expansion
for private or commercial purposes, in part or in whole, is not
tank; cover filler cap with permitted
cloth and open
unless carefully.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Open filler cap on coolant expansion tank.

1. Removing and installing parts of cooling system 113

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Vehicles with auxiliary heater: remove bolts -arrows- securing

exhaust pipe for auxiliary/additional heater to noise insulation.

– Release quick-fasteners -1- and -2- and take off front noise
insulation.
– Place drip tray -V.A.G 1306- or drip tray for workshop hoist -
VAS 6208- under engine.

– Pull off retaining clip -arrow- for coolant hose (bottom)

– Disconnect coolant hose from radiator and drain off coolant.

Note

When the bumper is removed the coolant can also be drained

from the radiator via the drain plug -arrow-.

114 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unscrew bolts -arrows- and take out hose connection with O-

ring and thermostat to drain remaining coolant.
Filling

Note

♦ The cooling system is filled all year round with a mixture of

water and antifreeze/corrosion protection agent.
♦ It is important to use only coolant additive Plus -G 012 A8F
A1- (also designated as “G12+”) “meeting specification
TL VW 774 F”. Other coolant additives could seriously impair
in particular the anticorrosion properties. The resulting dam‐
age could lead to loss of coolant and consequently to serious
engine damage.
♦ Coolant additive “G12+” may be mixed with additives “G11”
and “G12”.
♦ “G12+” and coolant additives marked “Conforming with spec‐
ification TL VW 774 F” prevent frost and corrosion damage
and stop scale from forming. Such additives also raise the
boiling point of the coolant. For these reasons the cooling sys‐
tem must be filled all year round with the correct antifreeze and
anticorrosion additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Frost protection is required down to about –25 °C (in countries
with arctic climate: down to about –35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
antifreeze percentage must be at least 40 %.
♦ If greater frost protection is required in very cold climates, the
proportion of “G12+” can be increased, but only up to 60 %
(this gives frost protection to about –40°C). If the antifreeze
percentage exceeds 60%, frost protection is reduced again
and cooling efficiency is also impaired.
♦ Use only clean tap water for mixing coolant.
♦ If radiator, heat exchanger, cylinder head, cylinder head gas‐
ket or cylinder block have been renewed, do not re-use old
coolant.
♦ Contaminated or dirty coolant must not be used again.
♦ To check frost protection level of coolant additive “G12+” you
must use a refractometer -T10007- .
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

1. Removing and installing parts of cooling system 115

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Procedure
– Re-connect coolant hose to radiator -arrow-.
– Tighten drain plug on radiator, if coolant was drained via drain
plug.

– Fit hose connection and thermostat with new O-ring -arrows-.

– Install front noise insulation by locking fasteners -1- and -2-.

– Fill reservoir of -VAS 6096- with at least 10 litres of premixed

coolant (according to recommended ratio):
• “G12+” (40 %) and water (60 %) for frost protection to -25 °C
• “G12+” (50 %) and water (50 %) for frost protection to -35 °C
• “G12+” (60 %) and water (40 %) for frost protection to -40 °C
– Screw adapter for cooling system tester -V.A.G 1274/8- onto
coolant expansion tank.
– Fit cooling system charge unit -VAS 6096- onto adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-. (The vented air
draws along a small amount of coolant, which should be col‐
lected.)
– Close
Protectedboth valves
by copyright. -A- and
Copying -B-or(turn
for private lever
commercial perpendicular
purposes, to di‐
in part or in whole, is not
rection
permittedof flow).
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar.

116 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Open valve -B- (turn lever in direction of flow).

The suction jet pump generates a partial vacuum in the cooling
system.
• The needle on the gauge should move into the green zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on charge unit reservoir -VAS 6091- can fill with
coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump will continue generating a vacuum in the
cooling system.
• The needle on the gauge should remain in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
If the needle does not reach the green zone, repeat the process.
If the vacuum level drops, there is a leak in the cooling system.
– Detach compressed air hose.
– Open valve -A-.
The vacuum in the cooling system causes the coolant to be drawn
out of the reservoir for cooling system charge unit -VAS 6096- ;
the coolingProtected
system is thenCopying
by copyright. filled.for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Detach cooling system
with respect chargeof unit
to the correctness -VAS
information 6096-
in this from
document. expan‐
Copyright by AUDI AG.
sion tank.

– Fit pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .

– Detach rubber seal from plenum chamber cover in direction of

-arrow-.
– Detach plenum chamber cover -1- towards the front.

1. Removing and installing parts of cooling system 117

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Fold back bellows at heat exchanger connection in plenum

chamber.
– Loosen coolant hose going to heat exchanger and pull back
hose until bleeder hole in hose -arrow- is no longer blocked by
the connection.
– Fill up with coolant until it flows out at bleeder hole in coolant
hose.
– Push coolant hose onto connection and secure with hose clip.
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Tighten filler cap on expansion tank.
– Start engine and maintain an engine speed of about 2,000 rpm
for approx. 3 minutes.
– Then allow engine to idle until bottom coolant hose at radiator
becomes hot.

WARNING

Hot steam/hot coolant may escape when opening expansion

tank; cover filler cap with cloth and open carefully.

– Check coolant level.

• The coolant level must be at the MAX marking when the en‐
gine is cold.
• The coolant level can be above the MAX marking when the
engine is warm.
– Switch engine off.
Tightening torque
Component Nm
Hose connection to bracket for ancillaries 10

1.3 Coolant pump and thermostat - exploded view of components

118 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1 - Pulley
2 - 25 Nm
3 - 10 Nm
4 - Coolant pump
❑ Removing and installing
⇒ page 119
5 - O-ring
❑ Renew
6 - O-ring
❑ Renew
7 - Bracket for ancillaries
❑ Removing and installing
⇒ page 30
8 - Thermostat
❑ Removing and installing
⇒ page 120
❑ Checking ⇒ page 121
9 - O-ring
❑ Renew
10 - 10 Nm
11 - Hose connection
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.4 Removing and installing coolant pump

Special tools and workshop equipment required
♦ 2-hole pin wrench -3212-

1. Removing and installing parts of cooling system 119

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Removing
• Front bumper is removed ⇒ General body repairs, exterior;
Rep. Gr. 63 .
• Lock carrier is moved into its service position ⇒ General body
repairs, exterior; Rep. Gr. 50 .
– Remove poly V-belt ⇒ page 27 .
– Remove viscous fan (with pulley) ⇒ page 122 .

Note

The air conditioner poly V-belt remains fitted.

– Drain off coolant ⇒ page 113 .

– Counterhold coolant pump pulley using 2-hole pin wrench
-3212- and unbolt coolant pump pulley from bearing with an 8
mm hexagon key.

– Unbolt coolant pump from bracket for alternator, power steer‐

ing pump and viscous fan -arrow-.
– Remove coolant pump.
Installing
Installation is carried out in the reverse order; note the following:

Note

Renew O-ring.

– Clean and smoothen sealing surface for O-ring as required.

– Install viscous fan ⇒ page 122 .
– Install poly V-belt ⇒ page 29 .
– Fill cooling system ⇒ page 115 .
Tightening torques
Component Nm
Coolant pump to bracket for alternator, power 10
steering pump and viscous fan
Pulley to coolant pump 25

1.5 Removing, installing and checking ther‐

mostat
Removing

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Hot steam/hot coolant may escape when opening expansion

with respect to the correctness of information in this document. Copyright by AUDI AG.

tank; cover filler cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Drain off coolant ⇒ page 113 .

120 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unscrew bolts -arrows- and take out hose connection with O-

ring and thermostat.
Installing
Installation is carried out in the reverse order; note the following:

Note

Renew O-ring.

– Clean and smoothen sealing surface for O-ring as required.

– Fit thermostat with new O-ring into hose connection.
– Install hose connection for thermostat -arrows-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fill cooling system ⇒ pagepermitted
115 . unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Tightening torque
Component Nm
Hose connection to bracket for ancillaries 10
Checking thermostat
– Heat thermostat in water bath.
Starts to open Fully open Opening travel
approx. 87 °C approx. 102 °C 14)
at least 8 mm
14) Cannot be tested.

1.6 Removing and installing coolant pipe

Special tools and workshop equipment required
♦ Hose clip pliers -V.A.G 1921-

Removing
– Release air hose (left-side) at rear air pipe and move hose
clear to one side.
– Unplug electrical connectors -3- and -4-.
– Detach vacuum hose -6-.
– Detach vacuum hose -1- going to mechanical exhaust gas re‐
circulation valve.
– Loosen hose clip -2- to remove air intake hose at intake con‐
necting pipe.
– Unscrew bolt -5- and remove air pipe.

1. Removing and installing parts of cooling system 121

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unclip cover caps.

– Unscrew nuts -arrows- and detach engine cover panel.

– Drain off coolant ⇒ page 113 .

– Detach coolant hose (left-side) from cylinder head and expan‐
sion tank -arrows- and move clear to one side.
– Unplug electrical connector for injection pump and disengage
from retainer.
– Move wiring harness secured to coolant pipe clear.

– Disconnect coolant hose -4- going to oil cooler at coolant pipe.

– Disconnect coolant hose -5- (leading to heat exchanger) from
coolant pipe.
– Loosen hose clip -1- to remove coolant hose going to coolant
pump.
– Unscrew bolt -3- and detach coolant pipe -2- from oil filter
bracket.
Installing
Installation is carried out in the reverse order; note the following:
– Fill cooling system ⇒ page 115 .
Tightening torque
Component Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Coolant
permittedpipe
unlessto oil filter
authorised bracket
by AUDI AG. AUDI AG does not guarantee or accept20 any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.7 Removing and installing viscous fan

Special tools and workshop equipment required
♦ 2-hole pin wrench -3212-

122 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Removing

Caution

Observe notes on procedure for disconnecting the battery ⇒

Electrical system; Rep. Gr. 27 .

– Detach rubber seal from plenum chamber cover in direction of

-arrow-.
– Detach plenum chamber cover -1- towards the front.

– With ignition switched off, disconnect battery earth cable

-arrow-.

– Turn the tensioner in the direction of the -arrow- to slacken the

poly V-belt. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove poly V-belt from alternator pulley. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Release tensioner.

Note

The air conditioner poly V-belt remains fitted.

– Slacken nut -arrow- and remove fuel filter from bracket (fuel
hoses remain connected).

1. Removing and installing parts of cooling system 123

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Counterhold viscous fan pulley using 2-hole pin wrench -3212-

and unbolt viscous fan from bearing with an 8 mm hexagon
key.
– Detach viscous fan from bearing and lay it forwards in radiator
cowl.

– Remove bolts -1- and -2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Remove alternator and lay it aside with wires connected.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Take viscous fan out of radiator cowl.

Installing
Installation is carried out in the reverse order; note the following:
– Place viscous fan in radiator cowl prior to installing alternator.
– To facilitate positioning of alternator, drive back bushes for
securing bolts slightly.
– Install alternator ⇒ Electrical system; Rep. Gr. 27
– Install viscous fan.
– Connect battery and observe notes on procedures required
after connecting battery ⇒ Electrical system; Rep. Gr. 27 .
– Install poly V-belt ⇒ page 29 .
Tightening torques
Component Nm
Fan to viscous coupling 9 15)
Viscous coupling to pulley 28 16)
Viscous fan to bearing 45
Alternator to bracket 25
15) Renew self-locking bolts.
16) Renew ribbed bolt.

1.8 Removing and installing bearing for viscous fan in bracket

124 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

equipment required
♦ 2-hole pin wrench -3212-
♦ Assembly tool -3301-
♦ Assembly tool -3350-
♦ Viscous fan fitting tool
-3367-

Removing
• Front bumper is removed ⇒ General body repairs, exterior;
Rep. Gr. 63 .
• Lock carrier is moved into its service position ⇒ General body
repairs, exterior; Rep. Gr. 50 .
– Turn the tensioner in the direction of the -arrow- to slacken the
poly V-belt.
– Remove poly V-belt from alternator pulley.
– Release tensioner.

Note

The air conditioner poly V-belt remains fitted.

1. Removing and installing parts of cooling system 125

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Slacken nut -arrow- and remove fuel filter from bracket (fuel
hoses remain connected).

– Counterhold viscous fan pulley using 2-hole pin wrench -3212-

and unbolt viscous fan from bearing with an 8 mm hexagon
key.
– Remove viscous fan from bearing.

– Use angled circlip pliers to remove circlip -arrow- from bearing

bush.

– Pull viscous fan bearing out of bracket using nut from assem‐
bly tool -3301- , bolt -3367/3- and assembly tool -3350- .

126 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Installing
Installation is carried out in the reverse order; note the following:
– Press viscous fan bearing in, using viscous fan fitting tool
-3367/1- , -3367/2- and -3367/3- with nut from assembly tool
-3301- .

– Use angled circlip pliers to install circlip -arrow- in bracket for

viscous fan.
– Install viscous fan.
– Install poly V-belt ⇒ page 29 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. Gr.
50 .
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
Tightening torque
Component Nm
Viscous fan to bearing 45

1.9 Removing and installing radiator

1. Removing and installing parts of cooling system 127

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

equipment required
♦ Used oil collection and ex‐
traction unit -V.A.G 1782-
♦ Hose clip pliers -V.A.G
1921-
♦ Drip tray for workshop hoist
-VAS 6208- or drip tray -
V.A.G 1306-

Removing
– Remove front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
– Remove air duct in front of charge air cooler -arrows-.

WARNING

Hot steam/hot coolant may escape when opening expansion

tank; cover filler cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

128 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unclip ambient temperature sensor -G17- from bracket.

– Unscrew bolts -arrows- and move cooling pipe for power steer‐
ing clear; hydraulic fluid system remains closed.

– Place drip tray -V.A.G 1306- or drip tray for workshop hoist -
VAS 6208- under engine.
– Turn drain plug -arrow- on radiator anticlockwise and drain
coolant (attach hose to connection if necessary).

– Pull off retaining clip for coolant hose (bottom) -arrow- and re‐
move coolant hose from radiator.

– Remove top coolant hose at radiator.

– Unscrew bolts -arrows-.
– Remove air ducts -1- and -2-.

1. Removing and installing parts of cooling system 129

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Vehicles with automatic gearbox:

Note

Note the rules for cleanliness when working on the automatic

gearbox ⇒ Automatic gearbox 01N; Rep. Gr. 37 .

– Place used oil collection and extraction unit -V.A.G 1782- un‐
der engine.
– Remove ATF pipes (top -arrow- and bottom) from radiator: ⇒
Automatic gearbox 01N; Rep. Gr. 37 .
– Tie ATF pipes up onto longitudinal member to prevent fluid
escaping.

All models:
– Remove the left and right-hand air ducts from the radiator.
– Unplug electrical connector -1-byat
Protected low pressure
copyright. switch
Copying for private for air purposes, in part or in whole, is not
or commercial
conditioner -F73- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Release both retaining pins -2- and pull out to side -arrows-.

WARNING

The air conditioner refrigerant circuit must not be opened.

– Detach both brackets -3- and pull condenser upwards out of

bracket

Note

To prevent damage to the condenser and refrigerant pipes/hoses,

ensure that the pipes and hoses are not stretched, kinked or bent.

– Pivot condenser downwards with pipes/hoses attached.

130 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Release two retaining pins for radiator and pull out upwards
-arrows-.
– Swivel radiator forwards and lift off.
Installing
Installation is carried out in the reverse order; note the following:
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
– Fill cooling system ⇒ page 115 .

Note

The coolant in the entire system must be changed if the radiator

is renewed.

Vehicles with automatic gearbox:

– Secure the ATF pipes ⇒ Automatic gearbox 01N; Rep. Gr.
37 .
– Check ATF level ⇒ Automatic gearbox 01N; Rep. Gr. 37
Tightening torques
Component Nm
Condenser to radiator 10
Air cowls to radiator 2

1.10 Checking cooling system for leaks

1. Removing and installing parts of cooling system 131

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

equipment required
♦ Cooling system tester -
V.A.G 1274-
♦ Adapter for cooling system
tester -V.A.G 1274/8-
♦ Adapter for cooling system
tester -V.A.G 1274/9-

Test requirement
• Engine must be warm.
Test sequence

WARNING

Hot steam/hot coolant may escape when opening expansion

tank; cover filler cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Attach cooling system tester -V.A.G 1274- with adapter -
V.A.G 1274/8- to expansion tank.
– Use hand pump on cooling system tester to create a pressure
of approx. 1.0 bar.
If the pressure drops:
– Trace leak and repair.

132 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Checking pressure relief valve in filler cap

– Attach cooling system tester -V.A.G 1274- with adapter -
V.A.G 1274/9- to filler cap.
– Use hand pump on cooling system tester to create pressure.
• The pressure relief valve should open at pressure of 1.4 ... 1.6
bar.
If the relief valve does not open as described:
– Renew filler cap.

1. Removing and installing parts of cooling system 133

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

21 – Turbocharging/supercharging
1 Checking charge air system with tur‐
bocharger

Note

♦ Observe rules for cleanliness ⇒ page 149 .

♦ Renew gaskets, seals and self-locking nuts.
♦ Charge air system must be free of leaks.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use lubricant.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

1.1 Safety precautions

Note the following if testers and measuring instruments have to
be used during a road test:

WARNING

♦ Test equipment must always be secured on the rear seat

and operated from that position by a second person.
♦ If test and measuring instruments are operated from front
passenger's seat and the vehicle is involved in an acci‐
dent, the person sitting in this seat could be seriously
injured when the airbag is triggered.

1.2 Requirements for turbocharging check

• Coolant temperature at least 85 °C.
• Fault memory of engine control unit interrogated.
• Exhaust gas recirculation system OK, checking ⇒ page 170 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

If there is a fault in the exhaust gas recirculation, it is not possible

to achieve reliable values when checking exhaust turbocharging.

• No leaks in the intake and exhaust systems. Effects of leaks

⇒ page 134 .
• Vacuum pipe to charge pressure regulating valve not obstruc‐
ted, loose or leaking.
• No faults on engine or injection system (e.g. compression
pressure or injectors).

1.3 Effects of leaks in the intake and ex‐

haust systems
A - Leaks after air mass meter -G70-
Possible causes of trouble:

134 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1- Connecting hose between air mass meter -G70- and turbo‐

charger
2- Connecting hose to crankcase breather
Effect: Loss of power
B - Leaks after turbocharger (intake side)
Possible causes of trouble:
1- Hoses connecting air intake pipe in lock carrier to turbo‐
charger or charge air cooler
2- Air intake hoses and pipes between charge air cooler and
intake manifold
3- Charge air cooler
4- Gasket below intake manifold pressure sender -G71- and
intake manifold temperature sender -G72- .
5- Gasket between inlet connection flange and intake manifold
6- Gasket between intake manifold and cylinder head
Effect: inadequate charge pressure
C - Leaks after turbocharger (exhaust side)
Possible causes of trouble:
1- Components of exhaust gas recirculation system
2- Connection between turbocharger and exhaust manifold
3- Connection between exhaust manifold and cylinder head
Effect: inadequate charge pressure; possible smell of exhaust
gas, traces of soot in engine compartment

1.4 Checking turbocharger and charge

pressure
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1-

1. Checking charge air system with turbocharger 135

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

♦ Hand-operated vacuum pump -V.A.G 1390-

Test requirements
• All hoses, pipes and wiring are checked for tight fit and leak‐
ages.
• No leaks in the intake and exhaust systems.
• No faults in engine or injection system, e.g compression pres‐
sure or injectors.
• Coolant temperature at least 80 °C.
• Fault memory interrogated.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Test sequence
with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

To avoid accident risks when road testing the vehicle with test
equipment, always observe the relevant safety precautions
⇒ page 134 .

• Vehicle diagnostic, testing and information system -

VAS 5051 A- with diagnosis lead -VAS 5051/1- is connected;
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” is selected. Engine must be idling.
Display on -VAS 5051 A- :
– From list -1- select diagnostic function “04 - Basic setting”.

136 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Display on -VAS 5051 A- :

1 - Enter display group (highest possible entry = 255)
– Use keypad -2- to enter “11” for “Display group number 011”
and confirm by touching the Q key.

Display on -VAS 5051 A- :

– Activate basic setting by touching Activate key -A-.
• The engine speed is increased to 1380
Protected by copyright. rpmfor...
Copying 1420
private rpm. purposes, in part or in whole, is not
or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• The vacuum unit for charge pressure
with respect controlofisinformation
to the correctness actuated indocument.
in this in‐ Copyright by AUDI AG.
tervals.
– Compare displays in zones -2- and -3-.

Display zones Explanatory notes

2 … Activation of charge pressure control solenoid valve -N75- alternating between
• “Off”
• “On”

3 ... mbar Intake manifold pressure (charge pressure) alternating between

• Specification for status “off”: approx. ambient pressure
• Specification for status “on”: 100 ... 200 mbar above ambient pressure

– Unscrew bolts -arrows-.

– Remove air ducts -1- and -2-.

1. Checking charge air system with turbocharger 137

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– In addition, check whether the turbocharger actuating rod

moves -arrows-.
– End function “04 - Basic setting” by pressing the ← key.
If the specified value in display zone “3” is not achieved, or if the
operating rod on the turbocharger does not move smoothly:
– Check linkage and vacuum unit for charge pressure control
⇒ page 139 .

– Continue the test as follows:

Display on -VAS 5051 A-
– From the list -1- select diagnostic function “08 - Read meas‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

ured value block”.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Display on -VAS 5051 A-

– Use keypad -2- to enter “011” for “Display group number 011”
and confirm by touching the Q key.
1 - Enter display group
– Engage third gear or move selector lever to position 2 and
accelerate at full throttle (without kickdown) from 2000 rpm.
Observe rev counter (2nd mechanic required).
– The 2nd mechanic must press keypad “Print out - store test
result” on -VAS 5051 A- at an engine speed of approx. 3000
rpm.

138 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

• Specification in display zone -1- (engine speed): approx. 3000

rpm
• Specification in display zone -3- (actual charge pressure):
800 ... 2200 mbar.
– Press the ← button to exit from the function “08 - Read meas‐
ured value block”.
– Press “06 - End output”.
– Switch off ignition.
If charge pressure is not within the specified range:
– Check charge air system for leaks.
– Check linkage and vacuum unit for charge pressure control
⇒ page 139 .
– Check intake manifold pressure sender -G71- ⇒ page 145 .
– Check charge pressure control solenoid valve -N75-
⇒ page 142 .
If all the above items are OK, but the charge pressure is too low:
– Renew turbocharger ⇒ page 151 .
Checking linkage and vacuum unit for charge pressure control
Problems with linkage/vacuum unit for charge pressure control
result in the following faults:
1- Not achieving the specified charge pressure values.
2- Loss of power.
3- Uneven power delivery at part throttle
4- Jolts when throttle is opened or closed.
• Check that all vacuum hoses are fitted and not leaking
⇒ page 140 .
• Vacuum must be available in vacuum reservoir. Run engine
for a short period of time to build up vacuum if necessary.
• Air duct (right-side) in engine compartment removed.
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1- is connected;
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” is selected. When doing this, the ignition must be
switched on.

Display on -VAS 5051 A-

– From the menu -1- select the diagnostic function “03 - Final
control diagnosis”. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Press the button → until the charge pressure control solenoid
with respect to the correctness of information in this document. Copyright by AUDI AG.
valve -N75- is actuated.
• Solenoid valve for charge pressure control -N75- should op‐
erate audibly.

1. Checking charge air system with turbocharger 139

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Also observe linkage at turbocharger.

• Simultaneously, the linkage rod of the vacuum unit for charge
pressure control on the turbocharger should move back and
forth (at least 3 ... 4 times until the vacuum supply in the res‐
ervoir is exhausted).
If linkage does not move because the solenoid valve is not work‐
ing:
– Check charge pressure control solenoid valve -N75-
⇒ page 142 .

If linkage does not move, even though solenoid valve is working:

– Disconnect hose -arrow- from vacuum unit for charge pres‐
sure control.

– Connect hand-operated vacuum pump -V.A.G 1390- to charge

pressure regulating valve and check that linkage moves freely
between both end stops.

Note

Observe the movement of the linkage over the complete range of

travel. It should move steadily and smoothly.

If the specified values are not achieved or if the linkage does not
move smoothly:
– Renew turbocharger ⇒ page 151 .

1.5 Hose connection diagram for charge pressure control

140 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1 - To exhaust gas recircula‐

tion valve -N18-
2 - Vacuum connection for air
conditioning system
❑ With cap for vehicles
without air conditioning
system
3 - Vacuum hose for brake ser‐
vo
4 - Exhauster pump
5 - Vacuum unit for charge
pressure control
6 - Vacuum hose
❑ To vacuum reservoir
7 - Vent pipe
❑ Between charge pres‐
sure control solenoid
valve -N75- and air
cleaner
8 - Solenoid valve for charge
pressure control -N75-
9 - Vacuum reservoir
10 - Vacuum hose
❑ From solenoid valve for
charge pressure control
-N75- to vacuum unit for
charge pressure control
11 - Vacuum hose
❑ Between charge pres‐
sure control solenoid
valve -N75- and non-re‐
turn valve
12 - Non-return valve
❑ White connection facing charge pressure control solenoid valve -N75- ⇒ Item 8 (page 141) and vacuum
reservoir
13 - Vent pipe
❑ To air cleaner
14 - Vent pipe
❑ From exhaust gas recirculation valve -N18-

1. Checking charge air system with turbocharger 141

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1.6 Checking solenoid valve for charge pressure control -N75-

Special tools and workshop

equipment required
♦ Hand-held multimeter -
V.A.G 1526 A- or -V.A.G
1526 B-
♦ Voltage tester -
V.A.G 1527 B-
♦ Auxiliary measuring set -
V.A.G 1594 A- or -V.A.G
1594 C-
♦ Test box -V.A.G 1598/22-
for vehicles to 06.1999
♦ Test box -V.A.G 1598/31-
for vehicles from 07.1999
♦ Vehicle diagnosis, testing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
and information system - with respect to the correctness of information in this document. Copyright by AUDI AG.
VAS 5051 A- with diagnosis
lead -VAS 5051/1-

Test sequence
– Unscrew bolts -arrows-.
– Remove air ducts -1- and -2-.

142 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Checking internal resistance

– Switch off ignition.
– Disconnect electrical connector at charge pressure control
solenoid valve -N75- .
– Connect hand-held multimeter -V.A.G 1526 A- or -V.A.G 1526
B- between contacts 1 and 2 of charge pressure control sole‐
noid valve -N75- to measure resistance.
• Specification: 14 ... 20 Ω
If specification is not obtained:
– Renew charge pressure control solenoid valve -N75- .

Checking voltage supply

– Connect hand-held multimeter -V.A.G 1526 A- or -V.A.G 1526
B- between contact -1- and earth to measure voltage.
– Switch on ignition.
• Specification: approx. battery voltage
If specification is not obtained:
– Check for open circuit in wiring (see current flow diagram) and
repair if necessary.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Checking activation
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1- is connected;
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” is selected. When doing this, the ignition must be
switched on.
– Connect voltage tester -V.A.G 1527 B- between contacts -1-
and -2-.

1. Checking charge air system with turbocharger 143

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Display on -VAS 5051 A-

– From the menu -1- select the diagnostic function “03 - Final
control diagnosis”.
– Press the button → until the charge pressure control solenoid
valve -N75- is actuated.
• LED should flash slowly.

Note

Voltage testers with a low current draw do not go out completely

between activation signals from engine control unit, but continue
to glow slightly and become distinctly brighter on activation.

– Press the ← key to exit from function “03 - Final control diag‐
nosis”.
– Press “06 - End output”.
– Switch off ignition.
If LED does not react as described:

Vehicles to 06.1999:
– Connect test box -V.A.G 1598/22- to connectors of wiring har‐
ness; do not connect engine control unit. Connect earth clip of
test box to earth (not shown in illustration) ⇒ Rep. Gr. 23 .

Caution

To prevent damage to electronic components,

Protected byselect
copyright.appro‐
Copying for private or commercial purposes, in part or in whole, is not

priate measuring range before connectingwithmeasuring leads of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness
and observe test requirements.

– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/22-
Contact Socket
-2- 15
– Repair wiring connection if necessary.

Vehicles from 07.1999:

– Connect test box -V.A.G 1598/31- to connectors of wiring har‐
ness; do not connect engine control unit. Connect earth clip of
test box to earth (not shown in illustration) ⇒ Rep. Gr. 23 .

Caution

To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads
and observe test requirements.

144 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/31-
Contact Socket
-2- 62
– Repair wiring connection if necessary.

1.7 Checking
permitted unless intake
authorised bymanifold pressure sender
does not guarantee -G71-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
AUDI AG. AUDI AG or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop

equipment required
♦ Hand-held multimeter -
V.A.G 1526 A- or -V.A.G
1526 B-
♦ Auxiliary measuring set -
V.A.G 1594 A- or -V.A.G
1594 C-
♦ Test box -V.A.G 1598/22-
for vehicles to 06.1999
♦ Test box -V.A.G 1598/31-
for vehicles from 07.1999
♦ Vehicle diagnosis, testing
and information system -
VAS 5051 A- with diagnosis
lead -VAS 5051/1-

1. Checking charge air system with turbocharger 145

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

♦ Fitting location of intake manifold pressure sender -G71-

-arrow-: in rear air intake pipe.
♦ The intake manifold pressure sender -G71- is combined as
one unit with intake manifold temperature sender -G72- .

Test sequence
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1- is connected;
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” is selected. When doing this, the ignition must be
switched on.

Display on -VAS 5051 A-

– From the list -1- select diagnostic function “08 - Read meas‐
ured value block”.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Display on -VAS 5051 A-

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Use keypad -2- to enter “010” for “Display group number 010”
and confirm by touching the Q key.
1 - Enter display group

Display on -VAS 5051 A-

– Compare display in zones -2- and -3-.
• Specification: The pressures should be the same; tolerance:
± 30 mbar.
If specification is not obtained:
– Use current flow diagram to check wiring.
– Press the ← button to exit from the function “08 - Read meas‐
ured value block”.
– Press “06 - End output”.
– Switch off ignition.

146 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Checking wiring
Vehicles to 06.1999:
– Connect test box -V.A.G 1598/22- to connectors of wiring har‐
ness; do not connect engine control unit. Connect earth clip of
test box to earth (not shown in illustration) ⇒ Rep. Gr. 23 .

Caution

To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads
and observe test requirements.

– Unplug electrical connector -arrow- at charge air pressure

sender -G71- .

– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/22-
Contact Socket
-1- 1, 25 or 27
-3- 39
-4- 40
– Repair wiring connection if necessary.
If no fault is found:
– Renew the unit containing charge air pressure sender -G71- /
intake air temperature sender -G72- .

Vehicles from 07.1999:

– Connect test box -V.A.G 1598/31- to connectors of wiring har‐
ness; do not connect engine control unit. Connect earth clip of
test box to earth (not shown in illustration) ⇒ Rep. Gr. 23 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Cautionof information in this document. Copyright by AUDI AG.
with respect to the correctness

To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads
and observe test requirements.

1. Checking charge air system with turbocharger 147

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Unplug electrical connector -arrow- at charge air pressure

sender -G71- .

– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/31-
Contact Socket
-1- 52
-3- 31
-4- 71
– Repair wiring connection if necessary.
If no fault is found:
– Renew the unit containing charge air pressure sender -G71- /
intake air temperature sender -G72- .

148 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2 Servicing charge air system with tur‐

bocharger

2.1 Rules for cleanliness

When working on the turbocharger, pay careful attention to the
following “5 rules”:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air if
Protectedthis can beCopying
by copyright. avoided. Doornot
for private move purposes,
commercial the vehicle
in part unless absolutely
or in whole, is not
necessary.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.2 Turbocharger - exploded view of components

2. Servicing charge air system with turbocharger 149

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1 - Bracket
2 - 20 Nm
3 - Turbocharger
❑ Checking ⇒ page 135
❑ Removing and installing
⇒ page 151
4 - Gasket
❑ Renew
5 - Catalytic converter
6 - 25 Nm
❑ Renew
7 - Seal
❑ Renew
8 - Screw connection
❑ Garret version: tighten
to 23 Nm
❑ KKK version: tighten to
40 Nm
9 - Hose
❑ From charge pressure
control solenoid valve -
N75-
10 - Oil supply pipe
❑ Tighten union nut to 22
Nm
11 - 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
12 - To oil filter bracket with respect to the correctness of information in this document. Copyright by AUDI AG.

13 - Bracket
14 - 10 Nm
15 - Exhaust manifold
❑ Removing and installing ⇒ page 162
16 - 25 Nm
❑ Renew
❑ Coat thread and contact surface of bolt head with high-temperature paste.
❑ High-temperature paste ⇒ Parts catalogue
17 - Intake manifold
❑ Removing and installing ⇒ page 77
18 - Gasket
❑ Renew
❑ Note installation position
19 - 22 Nm
20 - Gasket
❑ Renew
❑ Note installation position
21 - Bracket
❑ For heat shield ⇒ Item 24 (page 151)

150 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

22 - Washer
23 - 25 Nm
❑ Renew
24 - Heat shield
❑ Engage in bracket ⇒ Item 21 (page 150)
25 - 25 Nm
❑ Renew
26 - Gasket
❑ Renew
27 - Oil return pipe
❑ To cylinder block
❑ Tighten banjo bolt to 30 Nm
28 - Seal
❑ Renew
29 - Banjo bolt, 30 Nm
30 - 15 Nm
31 - 40 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.3 Removing and
permitted unless installing
authorised turbocharger
by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing

Note

All cable ties which are released or cut open when removing must
be fitted in the same position when installing.

– Vehicles with auxiliary heater: remove bolts -arrows- securing

exhaust pipe for auxiliary/additional heater to noise insulation.

– Release quick-fasteners -1- and -2- and take off front noise
insulation. Leave rear noise insulation in position.

2. Servicing charge air system with turbocharger 151

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.

– Loosen securing bolts of tensioning roller for air conditioner

compressor poly V-belt -arrows-.
– Remove poly V-belt.

WARNING

The air conditioner refrigerant circuit must not be opened.

– Unbolt air conditioner compressor from bracket.

– Tie up air conditioner compressor to vehicle, with lines attach‐
ed. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Disconnect air intake hose from turbocharger
with respect to(bottom)
the correctness of information in this document. Copyright by AUDI AG.
-arrows-.

– Remove bolt -1- from noise insulation cover above drive shaft
(right-side).
– Disengage hook -2- and detach noise insulation.

– Remove bracket for turbocharger -arrows-.

152 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach oil return pipe at cylinder block -arrow-.

– Unscrew turbocharger/exhaust manifold securing nut (acces‐
sible from below).

– Unclip cover caps.

– Unscrew
Protected nuts
by copyright. -arrows-
Copying and
for private detachpurposes,
or commercial enginein cover
part or inpanel.
whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew bolts -arrows-.

– Remove air ducts -1- and -2-.

– Disconnect breather hose -3- from air cleaner housing.

2. Servicing charge air system with turbocharger 153

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Disconnect air intake hose from turbocharger -arrows-.

– Remove exhaust gas recirculation pipe with mechanical ex‐

haust gas recirculation valve -arrows-.
– Move exhaust gas recirculation pipe with mechanical exhaust
gas recirculation valve clear to one side (vacuum hose -1- re‐
mains connected).

– Detach heat shield from exhaust manifold -arrows-.

– Remove oil supply pipe bracket from exhaust manifold.

154 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Detach vacuum hose -2- from vacuum unit for charge pressure
control.
– Unscrew bolt -1- from bracket for oil supply pipe.
– Unscrew oil supply pipe -3- at turbocharger.
– Unscrew nuts securing turbocharger to catalytic converter
-arrows-.
– Unscrew top turbocharger securing nut from exhaust manifold.
– Detach turbocharger.
Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Renew seals, gaskets and self-locking nuts.

♦ Pay attention to installation position of exhaust manifold/tur‐
bocharger gasket.
♦ Fill turbocharger with engine oil at connection for oil supply
pipe.
♦ Charge air system must be free of leaks.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Fit all cable ties in the original position when installing.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

– Install exhaust system and align it free of stress

⇒ page 165 .
– Install poly V-belt ⇒ page 29 .
– Check oil level ⇒ page 109 .

Note

After installing turbocharger, allow engine to idle for approx. 1 mi‐

nute and do not rev up immediately to ensure turbocharger is
supplied with oil.

2. Servicing charge air system with turbocharger 155

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Tightening torques
Component Nm
Turbocharger to exhaust manifold 25 17) 18)
Turbocharger to catalytic converter 25 17)
Bracket for turbocharger to turbocharger 20
Bracket for turbocharger to cylinder block 40
Oil return pipe to cylinder block 30
A/C compressor to bracket 25
Oil supply pipe to turbocharger 22
Oil supply pipe to bracket 10
Connecting pipe for exhaust gas recirculation to 25
exhaust manifold
Mechanical exhaust
Protected by copyright. Copyinggas recirculation
for private or commercial valve to in part or in whole,
purposes, 25 is not
intake
permittedconnecting
unless authorisedpipe
by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Heat shield to exhaust manifold 25
Hose clips for air hoses 3.5
17) Renew nuts.
18) Coat thread and contact surface of bolt head with high-temperature paste;
High-temperature paste ⇒ Parts catalogue .

2.4 Charge air cooler - exploded view of components

156 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1 - Air duct
❑ For charge air cooler
2 - Air intake hose
❑ To lock carrier
3 - Air intake hose
❑ To air pipe
4 - O-ring
❑ Renew if damaged
5 - Charge air cooler
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Different
permitted unless authorised byversions
AUDI AG. AUDI possi‐
AG does not guarantee or accept any liability
with respect toble ⇒ Partsof catalogue
the correctness information in this document. Copyright by AUDI AG.

❑ Removing and installing

⇒ page 157
6 - Retainer
7 - Bracket for charge air cooler
8 - Rubber grommet
9 - Bracket for refrigerant lines
10 - 10 Nm

2.5 Removing and installing charge air cool‐

er
Removing
– Remove air intake hose from charge air cooler -arrow-.

2. Servicing charge air system with turbocharger 157

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Remove front bumper ⇒ General body repairs, exterior; Rep.

Gr. 63 .
– Remove air duct in front of charge air cooler -arrows-.

– Detach bottom air intake hose -arrow- going to charge air

cooler from charge air cooler.
– Disengage charge air cooler and take out from underneath.
Installing
Installation is carried out in the reverse order; note the following:

Note

♦ Charge air system must be free of leaks.

♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

– Install front bumper ⇒ General body repairs, exterior; Rep.

Gr. 63 .
Tightening torque
Component Nm
Hose clips for air hoses 3.5

158 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

26 – Exhaust system
1 Removing and installing parts of ex‐
haust system

Note

♦ Do not bend the flexible joint (de-coupling element) in the ex‐

haust system more than 10°, otherwise it could be damaged.
♦ Renew gaskets and self-locking nuts.
♦ After working on the exhaust system, ensure that the system
is not under stress and that it has sufficient clearance from the
body. If necessary, loosen clamp and align silencers and ex‐
haust pipe so that sufficient clearance is maintained to the
body at all points and the mountings are evenly loaded.
♦ Use screwdriver to unfasten and tighten lock washers for heat
shields. Tightening torque: 2 Nm

1.1 Exhaust system - exploded view of components

1 - 25 Nm
❑ Renew
2 - Gasket
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renew
with respect to the correctness of information in this document. Copyright by AUDI AG.

3 - Bolt
4 - 25 Nm
❑ Renew
5 - Turbocharger
6 - Gasket
❑ Renew
7 - Catalytic converter
❑ With flexible joint
❑ Do not bend flexible joint
more than 10° - other‐
wise it can be damaged
❑ Protect against knocks
and impact
❑ Removing and installing
⇒ page 163
8 - Front exhaust pipe
❑ Removing and installing
⇒ page 163
9 - Clamp (front)
❑ Align exhaust system so
it is free of stress before
tightening clamp
⇒ page 165
❑ Tighten bolt connec‐
tions evenly.
❑ Installation position: bolt

1. Removing and installing parts of exhaust system 159

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

connection facing to the

left.
❑ Installation position of bolts ⇒ page 160
10 - 40 Nm
11 - Mounting
❑ Renew if damaged
12 - Mounting
❑ Renew if damaged
13 - 25 Nm
14 - Rear silencer
❑ Combined in one unit with centre silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting location ⇒ page 161
❑ Align exhaust system so it is free of stress ⇒ page 165
15 - 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
16 - Clamp (rear) with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For separate replacement of centre and rear silencers
❑ Align exhaust system so it is free of stress before tightening clamp ⇒ page 165
❑ Installation position ⇒ page 161
❑ Tighten bolt connections evenly.
❑ Installation position ⇒ page 161
❑ Tighten bolt connections evenly.
17 - 40 Nm
18 - 25 Nm
19 - Mounting
❑ Renew if damaged
20 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting location ⇒ page 161
❑ Align exhaust system so it is free of stress ⇒ page 165

Installation position of front clamp

– Install clamp so that the bolt ends do not protrude beyond bot‐
tom of clamp.
• Bolt connection faces to left.

160 Rep. Gr.26 - Exhaust system

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Installation position of rear clamp

• -α- = 25 … 35°.
• Bolt heads -arrow- face fuel tank -1-.

1.2 Separating centre and rear silencers

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on circumference
of exhaust pipe.

Special tools and workshop equipment required

♦ Chain-type pipe cutter -VAS 6254-
Procedure
– Cut through exhaust pipe at a right angle at cutting point
-arrow- using chain-type pipe cutter -VAS 6254- .

– When reassembling, position the clamp -1- centrally over the

cutting point. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Removing and installing parts of exhaust system 161

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Install clamp so that bolt heads -arrow- face fuel tank -1-.
• -α- = 25 … 35°.
– Align exhaust system free of stress ⇒ page 165 .
– Tighten bolt connections on clamp evenly to 40 Nm.

1.3 Removing and installing exhaust mani‐

fold
Removing
– Remove turbocharger ⇒ page 151 .
– Loosen nuts on clamp -arrows-.
– Push the clamp back in order to separate the exhaust system.
– Move catalytic converter with front exhaust pipe aside or to‐
wards front.

– Unscrew all nuts -arrows- on exhaust manifold.

– Detach washers, heat shield bracket (where fitted) and ex‐
haust manifold. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.

Installation is carried out in the reverse order; note the following:

Note

Renew gaskets and self-locking nuts.

– Install turbocharger ⇒ page 155 .

– Install catalytic converter together with front exhaust pipe.
– Align exhaust system free of stress ⇒ page 165 .
Tightening torques
Component Nm
Exhaust manifold to cylinder head 25 19)
Heat shield to exhaust manifold 25
Bracket for oil supply pipe to exhaust manifold 25
19) Renew self-locking nuts.

162 Rep. Gr.26 - Exhaust system

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

1.4 Removing and installing catalytic con‐

verter with front exhaust pipe
Removing
– Release quick-release fasteners -2- and -3- and detach rear
section of noise insulation.

– Loosen nuts on clamp -arrows-.

– Push the clamp back in order to separate the exhaust system.

– Unscrew bolts -arrows-.

– Remove air ducts -1- and -2-.
– Remove air intake duct going to air cleaner.

1. Removing and installing parts of exhaust system 163

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Disconnect breather hose -3- from air cleaner housing.

– Unscrew nuts securing turbocharger to catalytic converter

-arrows-.
– Raise vehicle approx 550 mm, measured at bottom edge of
bumper.

164 Rep. Gr.26 - Exhaust system

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Note

Do not bend the flexible joint (de-coupling element) in the exhaust

system more than 10°, otherwise it could be damaged.

– Turn front exhaust pipe to left slightly, at the same time lifting
it slightly.
– To prevent damage, place a cloth over the lock carrier at the
front right.
– Place catalytic converter flexible joint on cloth.
– To separate flange connection, unscrew nuts -arrows-.
– Take out catalytic converter and front exhaust pipe separately.
Installing
Installation is carried out in the reverse order; note the following:

Note

Renew gaskets and self-locking nuts.

– Align exhaust system free of stress ⇒ page 165 .

Tightening torques Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Component Nmof information in this document. Copyright by AUDI AG.
with respect to the correctness

Catalytic converter to turbocharger 25 20)

Front exhaust pipe to catalytic converter 25
Clamp 40
20) Renew self-locking nuts.

1.5 Stress-free alignment of exhaust system

Vehicles without clamp between centre silencer and rear silencer
• The exhaust system must be aligned when it is cool.
– Loosen bolt connections of front clamp ⇒ Item 9 (page 159) .
– Push exhaust system towards front of vehicle -arrow-, so that
rubber mounting (right-side) for centre silencer is preloaded
by dimension -a- = 5 ... 9 mm.
– Tighten bolts on front clamp ⇒ Item 9 (page 159) evenly to
40 Nm.
– Align tailpipes ⇒ page 166 .

1. Removing and installing parts of exhaust system 165

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Vehicles with clamp between centre silencer and rear silencer

• On vehicles with clamp fitted between centre silencer and rear
silencer, it is also necessary to align the centre silencer.
– Loosen bolts for front clamp ⇒ Item 9 (page 159) and rear
clamp ⇒ Item 16 (page 160) .
– Push front section of exhaust system towards front of vehicle
-arrow-, so that rubber mounting (right-side) for centre silencer
is preloaded by dimension -a- = 5 ... 9 mm.
– Tighten bolts on front clamp ⇒ Item 9 (page 159) evenly to
40 Nm.

– Push rear section of exhaust system towards front of vehicle

-arrow-, so that rear rubber mounting for rear silencer is pre‐
loaded by dimension -a- = 12 mm.
– Tighten bolts on rear clamp ⇒ Item 16 (page 160) evenly to
40 Nm.

Aligning tailpipes
– Align rear silencer so that there is an equal distance -a- and
-b- between the cut-out in the bumper and the pipe ends.
– If necessary, loosen mounting for rear silencer to adjust the
tailpipes.

1.6 Checking exhaust system for leaks

– Start engine and run at idling speed.
– Plug tailpipes during leak test (e.g. with cloth or plug).
– Listen for leaks at connection points between cylinder head/
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

exhaust manifold, exhaust manifold/turbocharger and turbo‐ of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness
charger/catalytic converter etc.
– Repair any leaks that are found.

166 Rep. Gr.26 - Exhaust system

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2 Exhaust gas recirculation system

2.1 Exhaust gas recirculation system - exploded view of components

1 - 25 Nm
2 - Bracket
❑ For oil supply pipe going
to turbocharger
3 - Connecting pipe
❑ When installing, first
tighten all bolted con‐
nections
Protected by copyright. lightly
Copying (compo‐
for private or commercial purposes, in part or in whole, is not
nents must just still
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

move in relation to each

with respect to the correctness of information in this document. Copyright by AUDI AG.

other). Only then should

joints be tightened, with‐
out straining
4 - 25 Nm
5 - Gasket
❑ Renew
6 - Intake manifold
❑ Removing and installing
⇒ page 77
7 - Mechanical exhaust gas re‐
circulation valve
❑ Checking ⇒ page 169
❑ Checking exhaust gas
recirculation system
⇒ page 170
8 - Exhaust manifold
❑ Removing and installing
⇒ page 162
9 - Gasket
❑ Renew

2. Exhaust gas recirculation system 167

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2.2 Hose connection diagram for exhaust gas recirculation

1 - Rear air pipe

2 - Vacuum connection for air
conditioning system
❑ With cap for vehicles
without air conditioning
system
3 - From brake servo
4 - Vacuum unit for charge
pressure control
5 - Exhauster pump for brake
servo
6 - Vent pipe
❑ To charge pressure
control
7 - Vent pipe
❑ To air cleaner
8 - Mechanical exhaust gas re‐
circulation valve
9 - Exhaust gas recirculation
valve -N18-
❑ Fitting location: on rear
of air pipe
❑ Checking ⇒ page 171

168 Rep. Gr.26 - Exhaust system

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2.3 Checking mechanical exhaust gas recir‐

culation valve

Note

♦ The exhaust gas recirculation system is actuated from the die‐

sel direct injection system control unit -J248- via the exhaust
gas recirculation valve -N18- and the mechanical exhaust gas
recirculationProtected
valve.by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The tapered plunger
with respectintothe mechanical exhaustin thisgas recircula‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
the correctness of information document. Copyright by AUDI AG.
tion valve varies the opening cross section according to valve
travel.
♦ Pulsed actuation makes it possible to obtain any required
valve position.
♦ The exhaust gas recirculation is switched off after approx. 10
minutes at idling speed.
♦ Restart engine or briefly increase engine speed above 1500
rpm when longer checks are necessary. Then repeat meas‐
urement.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.

Special tools and workshop equipment required

♦ Hand-operated vacuum pump -V.A.G 1390-

Test sequence
– Detach vacuum hose at mechanical exhaust gas recirculation
valve.
– Connect hand vacuum pump -V.A.G 1390- to valve.
– Create vacuum with hand-operated vacuum pump.
• The diaphragm rod must move in direction of vacuum con‐
nection.

Note

The movement of the diaphragm rod in the exhaust gas recircu‐

lation valve can be observed through the opening -arrow-.

– Detach hose of hand pump at exhaust gas recirculation valve.

• The closing of the valve should be clearly audible. The dia‐
phragm rod should move towards intake manifold

2. Exhaust gas recirculation system 169

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

2.4 Checking exhaust gas recirculation

Checking of exhaust gas recirculation is done with the vehicle
diagnosis, testing and information system -VAS 5051 A- under
the function “basic setting”. The EGR valve is pulsed every 10
seconds, so that the extreme values for the EGR ( air mass meter
-G70- ) can be read.
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1-

Test requirement
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1- is connected;
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” is selected. Engine must be idling.
• Coolant temperature at least 80 °C.
Test sequence
Display on -VAS 5051 A- :
– From the selection menu -1- select diagnostic function “04 -
Basic setting”.

Display on -VAS 5051 A- :

– Use keypad -2- to enter “003” for “Display group number 003”
and confirm
Protected by touching
by copyright. Copying forthe Q orkey.
private commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1 - Enter display group
with respect to the correctness of information in this document. Copyright by AUDI AG.

170 Rep. Gr.26 - Exhaust system

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Activate basic setting by touching Activate key -A-.

Display on -VAS 5051 A- :
– Check display in zones -2- and -3-.

Display zones Explanatory notes

2 … Activation of exhaust gas recirculation valve -N18- alternating every 10 seconds
between
• “EGR active”
• “EGR not active”

3 … mg/H 21) Intake air mass, alternating every 10 seconds

• Specification for status “EGR active”: 180 ... 280 mg/H
• Specification for status “EGR not active”: above 370 mg/H

21) mg/H = milligrammes/stroke

Note

If display zone 3 constantly indicates 550 mg/H, possible causes

can be a sticking mechanical exhaust gas recirculation valve or a
defective air mass meter. If the latter applies, check whether a
corresponding fault is stored in the fault memory ⇒ Rep. Gr. 01 .

– End function “04 - Basic setting” by pressing the ← key.

– Press “06 - End output”.
– Switch off ignition.
If the specifications are not obtained:
– Check mechanical exhaust gas recirculation valve
⇒ page 169 .
– Check vacuum hose connections ⇒ page 168 .
– Check exhaust gas recirculation valve -N18- ⇒ page 171 .

2.5 Checking exhaust gas recirculation valve -N18-

2. Exhaust gas recirculation system 171

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Special tools and workshop

Checking internal resistance

– Protected
Unplugbyelectrical connector
copyright. Copying for private at exhaustpurposes,
or commercial gas recirculation valve
in part or in whole, is not
-N18-
permitted .unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Connect hand-held multimeter -V.A.G 1526 A- or -V.A.G 1526
B- to valve to measure resistance.
• Specification: 14 ... 20 Ω

Note

At room temperature the resistance is in the lower tolerance

range; at operating temperature it is in the upper tolerance range.

If specification is not obtained:

– Renew exhaust gas recirculation valve -N18- .

172 Rep. Gr.26 - Exhaust system

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

Checking voltage supply

– Connect hand-held multimeter -V.A.G 1526 A- or -V.A.G 1526
B- to contact -1- and earth to measure voltage.
– Switch on ignition.
• Specification: approx. battery voltage
If specification is not obtained:
– Check for open circuit in wiring (see current flow diagram) and
repair if necessary.

Checking activation
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1- is connected;
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” is selected. When doing this, the ignition must be
switched on.
– Connect voltage tester -V.A.G 1527 B- between contacts -1-
and -2-.

Display on -VAS 5051 A- :

– From the menu -1- select the diagnostic function “03 - Final
control diagnosis”.
– Press the button → repeatedly until the exhaust gas recircu‐
lation valve -N18- is actuated.
• LED should flash slowly.

Note

Voltage testers with a low current draw do not go out completely

between activation signals from engine control unit, but continue
to glow slightly and become distinctly brighter on activation.

– Press the ← key to exit from function “03 - Final control diag‐
nosis”.
– Press “06 - End output”.
– Switch off ignition.
If LED does not react as described:

Caution

To prevent damage to electronic components, select appro‐

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
priate measuring with
range
respectbefore connecting
to the correctness measuring
of information leads
in this document. Copyright by AUDI AG.
and observe test requirements.

2. Exhaust gas recirculation system 173

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005

– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/22-
Contact Socket
-1- 2 or 28
-2- 29
– Repair wiring connection if necessary.

Vehicles from 07.1999:

– Connect test box -V.A.G 1598/31- to connectors of wiring har‐
ness; do not connect engine control unit. Connect earth clip of
test box to earth (not shown in illustration) ⇒ Rep. Gr. 23 .

Caution

To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads
and observe test requirements.

– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/31-
ProtectedContact Socketin part or in whole, is not
by copyright. Copying for private or commercial purposes,

-1-to the correctness of information in this document.

1 or 2Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect
-2- 61
– Repair wiring connection if necessary.

174 Rep. Gr.26 - Exhaust system

Audi A6 Electrical Wiring Manual: Available January 2003
No ratings yet
Audi A6 Electrical Wiring Manual: Available January 2003
1 page
Fuses and Circuit Brakers
No ratings yet
Fuses and Circuit Brakers
43 pages
Jhon Deere (CTM385 Electronic Fuel System)
100% (8)
Jhon Deere (CTM385 Electronic Fuel System)
1,344 pages
The Audi A6: Pricing and Specification Guide
100% (3)
The Audi A6: Pricing and Specification Guide
68 pages
Audi Allroad Owners Manual OCR
100% (1)
Audi Allroad Owners Manual OCR
306 pages
Audi Ars Engine Wiring Diagram
No ratings yet
Audi Ars Engine Wiring Diagram
17 pages
Service Manual 8-Cyl TDI (AKF) Engine Mechanics
No ratings yet
Service Manual 8-Cyl TDI (AKF) Engine Mechanics
285 pages
Schema Montare Cruise Control CC A6 AKE 2002
No ratings yet
Schema Montare Cruise Control CC A6 AKE 2002
1 page
Audi A6 No. 802 / 1: Fuses
100% (1)
Audi A6 No. 802 / 1: Fuses
73 pages
Audi B5 RS4 V6BiTurbo Engine Part Numbers
100% (1)
Audi B5 RS4 V6BiTurbo Engine Part Numbers
62 pages
A6 C7
0% (1)
A6 C7
4 pages
Audi A6/A6 Avant: Quick Reference Guide
No ratings yet
Audi A6/A6 Avant: Quick Reference Guide
8 pages
Service: Radio Installation Instructions
No ratings yet
Service: Radio Installation Instructions
69 pages
Audi A6 C5 AirConditioner ElectricalTesting
100% (1)
Audi A6 C5 AirConditioner ElectricalTesting
189 pages
Audi A6 (C5 - 4B) - Bakım - Ücretsiz Alın
No ratings yet
Audi A6 (C5 - 4B) - Bakım - Ücretsiz Alın
155 pages
Manual For Loadmate Electric Chain Hoist Wiring Diagrams For Crane Applications
No ratings yet
Manual For Loadmate Electric Chain Hoist Wiring Diagrams For Crane Applications
30 pages
SM 77.c
No ratings yet
SM 77.c
713 pages
JCB Rough Terrain Forklift 930 940 950 Brochure PDF
100% (3)
JCB Rough Terrain Forklift 930 940 950 Brochure PDF
16 pages
Mahindra 8000 9500 4WD Series Brochure Web PDF
50% (2)
Mahindra 8000 9500 4WD Series Brochure Web PDF
6 pages
SM 7
No ratings yet
SM 7
237 pages
Audi A6 2005 2011 Body Repairs Interior Eng
100% (1)
Audi A6 2005 2011 Body Repairs Interior Eng
637 pages
Audi A6 Qu (1) - 3.0 Tdi
No ratings yet
Audi A6 Qu (1) - 3.0 Tdi
4 pages
Audi Navigation Plus Installation - Phase 1 (A6/S6/RS6/allroad)
No ratings yet
Audi Navigation Plus Installation - Phase 1 (A6/S6/RS6/allroad)
84 pages
Service: Wheel and Tire Guide
No ratings yet
Service: Wheel and Tire Guide
113 pages
Rear Final Drive 0BD
No ratings yet
Rear Final Drive 0BD
62 pages
MTM Tuning A4b5110
No ratings yet
MTM Tuning A4b5110
3 pages
Communication PDF
100% (2)
Communication PDF
347 pages
Audi A6 4B
No ratings yet
Audi A6 4B
8 pages
34-18 Transmission Remove & Install
No ratings yet
34-18 Transmission Remove & Install
21 pages
Service: Audi A6 1998
100% (1)
Service: Audi A6 1998
77 pages
AUDI A6 Schemat Centralka-Alarm
50% (2)
AUDI A6 Schemat Centralka-Alarm
20 pages
Audi - US A6 - 2013 PDF
No ratings yet
Audi - US A6 - 2013 PDF
23 pages
Airbag, Servicing: Just A Test
No ratings yet
Airbag, Servicing: Just A Test
13 pages
Electrical System
No ratings yet
Electrical System
404 pages
SM 81
100% (2)
SM 81
191 pages
Camshaft and Camshaft Adjusters Removing and Installing
No ratings yet
Camshaft and Camshaft Adjusters Removing and Installing
9 pages
Audi A6 C5 - Demontaż Świateł
100% (1)
Audi A6 C5 - Demontaż Świateł
20 pages
Service: Fitting Instructions: Retrofitting Key-Operated Switch To Deactivate Airbag On Front Passenger Side
No ratings yet
Service: Fitting Instructions: Retrofitting Key-Operated Switch To Deactivate Airbag On Front Passenger Side
91 pages
Audi Allroad Compressor Strip & Repair How To
100% (2)
Audi Allroad Compressor Strip & Repair How To
5 pages
Audi A4 Avant 95-01 Service & Repair Manual - Fuel System
No ratings yet
Audi A4 Avant 95-01 Service & Repair Manual - Fuel System
222 pages
48-71 Steering Column Remove & Install PDF
100% (1)
48-71 Steering Column Remove & Install PDF
14 pages
Audi Engine Code - How To Find Your Audi Engine Code (A8)
No ratings yet
Audi Engine Code - How To Find Your Audi Engine Code (A8)
4 pages
Oettinger Audi A4 B6 8E
100% (1)
Oettinger Audi A4 B6 8E
2 pages
2012 Audi A4 s4 Manual
100% (1)
2012 Audi A4 s4 Manual
310 pages
00-1 Transmission Id
No ratings yet
00-1 Transmission Id
6 pages
2,8 L Fuel Injection Engine (142 KW - Motronic - 6-Cylinder) 2.4 L Fuel Injection Engine (121 KW - Motronic - 6-Cylinder) Engine Code ACK, ALG/AGA, AJG, ALF, ALW
No ratings yet
2,8 L Fuel Injection Engine (142 KW - Motronic - 6-Cylinder) 2.4 L Fuel Injection Engine (121 KW - Motronic - 6-Cylinder) Engine Code ACK, ALG/AGA, AJG, ALF, ALW
27 pages
Pwglist PDF
No ratings yet
Pwglist PDF
32 pages
A0059182920-6-Speed Manual Gearbox 02X Four-Wheel Drive
No ratings yet
A0059182920-6-Speed Manual Gearbox 02X Four-Wheel Drive
250 pages
39-64 Final Driveshaft Service
No ratings yet
39-64 Final Driveshaft Service
19 pages
Vehicle List Software Flex ECU OBD Bench Ver.4.3.0.0
100% (2)
Vehicle List Software Flex ECU OBD Bench Ver.4.3.0.0
134 pages
Audi Coolant
No ratings yet
Audi Coolant
15 pages
SM 57
50% (2)
SM 57
373 pages
Manual Eléctrico Audi
No ratings yet
Manual Eléctrico Audi
110 pages
642 Engine Oil and Filter Change
No ratings yet
642 Engine Oil and Filter Change
2 pages
Audi A4-7
No ratings yet
Audi A4-7
532 pages
Audi A6 2.7t Component Location
No ratings yet
Audi A6 2.7t Component Location
3 pages
C6 (Typ 4F, 2004-Present)
No ratings yet
C6 (Typ 4F, 2004-Present)
7 pages
Audi A4 Quattro 3.0 Liter 6-Cyl. 5V Fuel Injection & Ignition
100% (1)
Audi A4 Quattro 3.0 Liter 6-Cyl. 5V Fuel Injection & Ignition
259 pages
Caractere Audi A6 (C6) Product Sheet
No ratings yet
Caractere Audi A6 (C6) Product Sheet
1 page
The Mercedes 219, 220 Ponton
From Everand
The Mercedes 219, 220 Ponton
Bernd S. Koehling
No ratings yet
A0059005420-6-Cylinder Diesel Direct Injection Engine (TDI) Mechanics
No ratings yet
A0059005420-6-Cylinder Diesel Direct Injection Engine (TDI) Mechanics
288 pages
Reparatie motor 1.8 AJP Aud A6
No ratings yet
Reparatie motor 1.8 AJP Aud A6
175 pages
A0058007520-4-Cylinder Direct Injection Engine (1 6 LTR 4-Valve) Mechanics
No ratings yet
A0058007520-4-Cylinder Direct Injection Engine (1 6 LTR 4-Valve) Mechanics
176 pages
Manual audi 1 Resistência
No ratings yet
Manual audi 1 Resistência
231 pages
1z Aff Afn Ahh Ahu Avg
No ratings yet
1z Aff Afn Ahh Ahu Avg
266 pages
Rtn09 Endtruck Us
No ratings yet
Rtn09 Endtruck Us
1 page
GES Drive Manual: Installation Operation & Maintenance
No ratings yet
GES Drive Manual: Installation Operation & Maintenance
11 pages
Rtl09 Endtruck Us
No ratings yet
Rtl09 Endtruck Us
1 page
End Truck Rt/Rs Manual: Installation Operating Maintenance & Spare Parts
No ratings yet
End Truck Rt/Rs Manual: Installation Operating Maintenance & Spare Parts
29 pages
SSP 040 Automatic Gearbox 001 Fabia
No ratings yet
SSP 040 Automatic Gearbox 001 Fabia
46 pages
RM Kit Assembly Manual 2
No ratings yet
RM Kit Assembly Manual 2
120 pages
CMXC 022 Upgrade Kit Manual
No ratings yet
CMXC 022 Upgrade Kit Manual
55 pages
Every Second One in The World Drives Automatic!
100% (1)
Every Second One in The World Drives Automatic!
54 pages
096, 097, 098 Remanufactured Valve Body: Internal Manual Linkage Adjustment
No ratings yet
096, 097, 098 Remanufactured Valve Body: Internal Manual Linkage Adjustment
1 page
b5 Front Door
No ratings yet
b5 Front Door
31 pages
SM 47.c
No ratings yet
SM 47.c
84 pages
Crane Wheel Systems Sra / SRN
100% (1)
Crane Wheel Systems Sra / SRN
28 pages
C1 30 - 3 EN Crane Wheel Systems
No ratings yet
C1 30 - 3 EN Crane Wheel Systems
16 pages
Deutz F6L914 - 02931400 - 04234638 - 04236676 - Deutz 914 Series - Construction and Industrial Diesel Engine - 62-85kW - Engine Family
No ratings yet
Deutz F6L914 - 02931400 - 04234638 - 04236676 - Deutz 914 Series - Construction and Industrial Diesel Engine - 62-85kW - Engine Family
8 pages
The Cetane Index Is A Figure Which Denotes The Quality of A Diesel Fuel
No ratings yet
The Cetane Index Is A Figure Which Denotes The Quality of A Diesel Fuel
4 pages
EGS240-6 EGS240B-6 EGS240BS-6: Diesel Generator Set
No ratings yet
EGS240-6 EGS240B-6 EGS240BS-6: Diesel Generator Set
3 pages
RAVO Catalogue Service & Wear Kits 2013
No ratings yet
RAVO Catalogue Service & Wear Kits 2013
13 pages
Man l35mc6
No ratings yet
Man l35mc6
375 pages
Fuel Injection ATD
No ratings yet
Fuel Injection ATD
104 pages
Difference Between Toyota Hilux Vigo G and Toyota Hilux Vigo e
100% (1)
Difference Between Toyota Hilux Vigo G and Toyota Hilux Vigo e
37 pages
Dictionary For The Petroleum Industry.
100% (5)
Dictionary For The Petroleum Industry.
242 pages
Gpu400 120
No ratings yet
Gpu400 120
2 pages
01.401.01DSEN.04 Data Sheet IF05-Series
No ratings yet
01.401.01DSEN.04 Data Sheet IF05-Series
2 pages
Lubricant Market Statistics 2023 Q2 ED1
No ratings yet
Lubricant Market Statistics 2023 Q2 ED1
23 pages
BMW 1 Series (F40)基础配置
No ratings yet
BMW 1 Series (F40)基础配置
18 pages
Specification of CAT 330D Caterpillar
No ratings yet
Specification of CAT 330D Caterpillar
24 pages
Operation Maintanance Manual For HVWS System
No ratings yet
Operation Maintanance Manual For HVWS System
17 pages
ENERGY EFFICIENCY OF A CAR ENGINE Final Assessment
No ratings yet
ENERGY EFFICIENCY OF A CAR ENGINE Final Assessment
11 pages
Dresser Rand Catalog
No ratings yet
Dresser Rand Catalog
12 pages
02wged PDF
0% (1)
02wged PDF
284 pages
Service Bulletin A - 2.2: Technical Information To All The Owners of Sulzer A - Type Diesel Engines 30.11.94
No ratings yet
Service Bulletin A - 2.2: Technical Information To All The Owners of Sulzer A - Type Diesel Engines 30.11.94
9 pages
FF Pumps
No ratings yet
FF Pumps
7 pages
2506a-E15tag3&4 Tpd1581e7
No ratings yet
2506a-E15tag3&4 Tpd1581e7
14 pages
08DDECVI47REV
100% (1)
08DDECVI47REV
4 pages
Drawing qsk45 Well Servicing
No ratings yet
Drawing qsk45 Well Servicing
4 pages
Portables
No ratings yet
Portables
16 pages
ADS Disaster Relief Catalog
No ratings yet
ADS Disaster Relief Catalog
17 pages
DS DC-7 Digital-Speed-Control e
No ratings yet
DS DC-7 Digital-Speed-Control e
2 pages
DE08 Engine Manual
100% (7)
DE08 Engine Manual
80 pages
New 7 Series: Bucket Selection Guide Supplemental Specifications
No ratings yet
New 7 Series: Bucket Selection Guide Supplemental Specifications
6 pages