Service Manual 8-Cyl TDI (AKF) Engine Mechanics
Service Manual 8-Cyl TDI (AKF) Engine Mechanics
Service Manual 8-Cyl TDI (AKF) Engine Mechanics
Workshop Manual
Audi A8 1994 ➤
8-cyl. TDI engine, mechanics
Engine ID AKF
Edition 02.2005
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.
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 - Cylinder head, valve gear 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.
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.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Rules for cleanliness when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.1 Pulling lock carrier forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2 Exploded view of poly V-belt drive for hydraulic pump, alternator and air conditioner
compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.4 Checking alignment of hydraulic pump and air conditioner compressor pulleys . . . . . . . . 37
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.6 Exploded view of toothed belt guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.7 Exploded view of toothed belt drive for camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.8 Turning engine to TDC - engine in position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.9 Turning engine to TDC - engine removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.10 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.11 Detaching toothed belt from camshaft sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2 Servicing work on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Exploded view of sealing flanges and drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Replacing crankshaft oil seal on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3 Removing and installing front sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4 Removing and installing rear sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.5 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1 Exploded view of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3 Measuring crankshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.4 Measuring crankshaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.1 Exploded view of pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Contents i
Audi A8 1994 ➤
8-cyl. TDI engine, mechanics - Edition 02.2005
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1 Removing and installing lubrication system components . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.1 Exploded view of oil pump, bottom part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.2 Removing and installing bottom part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.3 Removing and installing chain drive for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.5 Exploded view of top part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.6 Removing and installing top part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.7 Exploded view of oil filter bracket with oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.8 Removing and installing oil filter bracket with oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.9 Exploded view of oil retention valves and spray nozzle valve . . . . . . . . . . . . . . . . . . . . . . 159
1.10 Replacing oil retention valves and spray nozzle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.11 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.12 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.13 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.14 Exploded view of crankcase breather components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.15 Checking pressure control valve for crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . 163
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1 Removing and installing cooling system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.1 Exploded view of mechanical coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . 165
1.2 Draining and replenishing coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.3 Removing and installing mechanical coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.4 Removing, installing and checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.5 Exploded view of coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.6 Removing and installing front coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.7 Removing and installing left coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.8 Removing and installing right coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.9 Removing and installing rear coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.10 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.11 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.12 Exploded view of hydraulic fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.13 Removing and installing hydraulic fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.14 Checking radiator fan valve N313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.15 Removing and installing hydraulic pump for power steering and hydraulic fan . . . . . . . . . . 193
1.16 Checking electric radiator fan V7 and actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
ii Contents
Audi A8 1994 ➤
8-cyl. TDI engine, mechanics - Edition 02.2005
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1 Checking charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.1 Notes on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.2 Test requirements for checking turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
1.3 Effects of leakage on inlet and exhaust end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.4 Checking turbocharger and charge pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.5 Connection diagram for charge pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.6 Exploded view of charge pressure control solenoid valves N75 and N274 . . . . . . . . . . . . 226
1.7 Checking charge pressure control solenoid valves N75 and N274 . . . . . . . . . . . . . . . . . . 227
1.8 Checking charge pressure of turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.9 Checking intake manifold pressure sender G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2 Servicing charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
2.2 Exploded view of turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.3 Removing and installing left turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.4 Removing and installing right turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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Contents iii
Audi A8 1994 ➤
8-cyl. TDI engine, mechanics - Edition 02.2005
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
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iv Contents
Audi A8 1994 ➤
8-cyl. TDI engine, mechanics - Edition 02.2005
00 – Technical data
1 Technical data
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1. Technical data 1
Audi A8 1994 ➤
8-cyl. TDI engine, mechanics - Edition 02.2005
3 Contact corrosion
Contact corrosion can occur if use is made of unsuitable con‐
necting elements (bolts, nuts, washers …).
For this reason, only connecting elements with a special surface
coating are fitted. These elements can be recognised from their
greenish colour.
In addition, rubber and plastic parts as well as adhesives are
made of non-conductive material.
In cases of doubt about suitability for re-use, always fit new com‐
ponents.
Caution
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3. Contact corrosion 3
Audi A8 1994 ➤
8-cyl. TDI engine, mechanics - Edition 02.2005
Note
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with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING
– Pull out clip -1- and detach coolant hose from radiator.
– Detach coolant hose -2-.
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Note
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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 cover on left in engine compartment -arrows-.
– Draw off power steering hydraulic fluid from reservoir with
used oil collector and extractor -V.A.G 1782- or -
V.A.G 1358 A- .
Note
– Disengage cable -1- for bonnet at locking lever on left and right
and lay bare.
– Unscrew ATF pipe at top from radiator -arrow-.
Note
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew impactProtected
absorber on left
by copyright. andforright
Copying -arrows-.
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Note
Note
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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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 distributor pipe -1- for hydraulic fluid from inlet hose
-arrow- and attach it to engine using a piece of wire.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Note
– Detach fuel return pipe at T-piece and fuel supply pipe at fuel
filter -arrows-.
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– Prise out cover -1- in scuttle panel trim and slacken off rear
cross-head bolt -rear right arrow-.
– Slacken off the remaining cross-head bolts -arrows-.
– Detach cover for electronics box in plenum chamber.
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Note
Mark position of wires. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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with respect to the correctness of information in this document. Copyright by AUDI AG.
– Release plug contact in plug panel -2- in each case using
ejection tool -VAS 1978/8- from wiring harness repair set -VAS
1978- .
WARNING
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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 heat shield over drive shaft from gearbox on left and
right -arrows-.
– Unscrew drive shaft on left and right from gearbox flange
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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.
– Use puller -T40010- to press joint pin of guide link off tapered
seat on left and right.
– Use a 4 mm Allen key to provide support for joint pin.
– Unscrew nut and take joint pin out of guide link.
– Screw out bolt -arrow- at front exhaust pipe link plate on left
and right.
– Swivel front exhaust pipe link plate to front.
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Note
Note
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– Screw out bottom bolts -arrows- attheengine
with respect to mountings.
correctness of information in this document. Copyright by AUDI AG.
Note
– Screw out the 3 bolts -arrows- at the front right torque reaction
support.
– Carefully raise engine.
Note
WARNING
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
– Screw out bolts -arrows- and detach ATF pipes from gearbox.
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– ScrewProtected
out the 6 bolts -arrows- of the torque converter in the
by copyright. Copying for private or commercial purposes, in part or in whole, is not
openingwith
of respect
the removed starter (to do so,in thisgive crankshaft
Copyright byaAUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness of information document.
further 1/3 turn in each case).
Note
♦ Bolt M12x130
Sequence of operations
• Engine separated from gearbox ⇒ page 22
– Remove drive plate ⇒ page 70 .
– Remove heat shield for turbocharger on left.
– For performing assembly work, attach engine with engine and
gearbox holder -VW 540- and supplementary set for engine
and gearbox holder -VW 540/1 B- to repair stand.
Note
Caution
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Caution
Note
Engine/gearbox attachment
Item Bolt Nm
1, 3, 4, 5, 6 M12x75 65
2 M10x160 65 1)
7, 8, 9 M12x50 65
A Dowel sleeves for centring
1) Bolt strength 10.9
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– Attach front exhaust pipes to engine ⇒ page permitted
249 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.
– Attach ATF pipes ⇒ Automatic gearbox 01L, four-wheel drive;
Rep. Gr. 37 .
– Prior to assembly, always use a thread cutter to remove rem‐
nants of locking compound from tapped holes in flange shaft
of gearbox for propshaft.
– Install propshaft ⇒ Automatic gearbox 01L, four-wheel drive;
Rep. Gr. 39 .
– Fit selector lever cable. Check setting if necessary ⇒ Auto‐
matic gearbox 01L, four-wheel drive; Rep. Gr. 37 .
– Perform stress-free alignment of exhaust system
⇒ page 268 .
– Install guide link, track control link and anti-roll bar connecting
link ⇒ Running gear, front-wheel drive and four-wheel drive;
Rep. Gr. 40 .
– Screw drive shafts to flange shafts of gearbox ⇒ Running
gear, front-wheel drive and four-wheel drive; Rep. Gr. 40 .
Caution
Caution
Note
Tightening torques
Note
Component 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.
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Exceptions:
Coolant drain plug (on right of engine) 10
Coolant drain plug to coolant drain pipe (on left 18
of engine)
Coolant drain plug to front coolant pipe 10
Drive plate to torque converter 65
Oil return pipe to Top part of sump 10
Turbocharger 10
Gearbox support to gearbox 40
ATF pipe to Gearbox 20
Holder 10
Turbocharger 22
Turbocharger holder 22
Holder to mechanical exhaust gas recirculation 22
valve
Front exhaust pipe to turbocharger 25
Torque reaction support to longitudinal mem‐ 42
ber
Engine mounting to subframe 40
Gearbox mounting to subframe 40
Gearbox support to gearbox mounting 40
Heat shield for drive shaft to gearbox 23
Air conditioner compressor to holder 22
ATF pipe to radiator 5
Steering box hydraulic pressure pipe to hy‐ 50
draulic pump
Hydraulic fan hydraulic pressure pipe to hy‐ 50
draulic pump
Clamps for coolant hoses 2
Clamps for air hoses 3,5
13 – Crankshaft group
1 Dismantling and assembling engine
Sequence of operations 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
– On vehicles with auxiliary heater, screw out bolts -arrows- for
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
– Unfasten clips -1- and -2- and detach air duct grille on left and
right.
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.
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.
1.2 Exploded view of poly V-belt drive for hydraulic pump, alternator and air
conditioner compressor
1 - Poly V-belt
❑ Prior to removal, mark
direction with chalk or a
felt-tip pen. Running a
used belt in the opposite
direction could destroy
it.
❑ Check for wear
❑ Removing and installing
⇒ page 36
2 - Cap
❑ Press off with screwdriv‐
er
3 - 22 Nm
4 - 45 Nm
5 - 45 Nm
6 - Alternator
❑ Removing and installing
⇒ Electrical system;
Rep. Gr. 27
7 - Poly V-belt tensioner
❑ Swivel with ring spanner
to slacken off poly V-belt
⇒ page 36
8 - 22 Nm
9 - Vibration damper
❑ With pulley for poly V-
belt
❑ Removing and installing
⇒ page 39
10 - 22 Nm
11 - 22 Nm
12 - Dowel sleeve
❑ 2x
❑ Check for proper attachment in holder
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - Holderpermitted
for hydraulic pump
unless authorised andAG.
by AUDI airAUDI
conditioner
AG does not compressor
guarantee or accept any liability
❑ Pay attention to dowel sleeves ⇒ Item 12 (page 35) on installation
with respect to the correctness of information in this document. Copyright by AUDI AG.
14 - 40 Nm
15 - 22 Nm
16 - Hydraulic pump
❑ For power steering and hydraulic fan
❑ Removing and installing ⇒ page 193
17 - Shims
❑ Various thicknesses
❑ Determine thickness following removal and installation of hydraulic pump or holder for air conditioner
compressor and hydraulic pump
⇒ “1.4 Checking alignment of hydraulic pump and air conditioner compressor pulleys”, page 37
18 - Dowel sleeve
❑ 2x
❑ Check for proper attachment
19 - Pulley
❑ For hydraulic pump
❑ Removing and installing ⇒ page 36
20 - 22 Nm
21 - Air conditioner compressor
❑ After detaching, use a piece of wire for example to attach compressor to longitudinal member. Do not
leave hanging from refrigerant pipes.
❑ Do not unscrew/disconnect refrigerant pipes
❑ Pay attention to dowel sleeves ⇒ Item 18 (page 35) on installation
22 - Idler wheel
❑ For poly V-belt
23 - 22 Nm
24 - Cover
❑ For idler wheel
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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.
Removing and installing pulley for hydraulic pump
• Poly V-belt removed ⇒ page 36
– When slackening off and tightening bolts -arrows-, provide
support with pin wrench -3212- .
• Installation position: Label “front” facing in direction of travel
• Tightening torque 22 Nm
Note
Note
Installing
Install in reverse order; paying attention to the following:
Note
– Position poly V-belt over crankshaft pulley, then over the other
pulleys and finally on tensioning roller.
– Start engine and check belt running.
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. Gr. 50 .
– Install headlights ⇒ Electrical system; Rep. Gr. 94 .
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
– Check headlight adjustment ⇒ Electrical system; Rep. Gr.
94 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note 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.
To avoid damaging the poly V-belt, the alignment of the air con‐
ditioner compressor and hydraulic pump pulleys is to be checked.
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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.
Test sequence
• Poly V-belt removed ⇒ page 36
– Position alignment gauge -3201- on poly V-belt pulley of air
conditioner compressor.
• Poly V-belt pulley of hydraulic pump must be aligned with that
of air conditioner compressor.
Note
– Use shims of 0.5, 1.0 and 1.5 mm thickness to even out dis‐
tance between poly V-belt pulleys for hydraulic pump and air
conditioner compressor. Part no. ⇒ Parts catalogue .
– Then check alignment of poly V-belt pulleys using alignment
gauge -3201- . Repeat adjustment if necessary.
Tightening torque
Component Nm
Pulley to hydraulic pump 22
Installing
Install in reverse order; paying attention to the following:
– On installation, make sure notch -arrow- in vibration damper
is aligned with locking lug on toothed belt sprocket.
Tightening torque
Component Nm
Vibration damper to crankshaft 22
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 - Cap
❑ Press off with screwdriv‐
er
2 - 22 Nm
3 - Vibration damper
❑ With pulley for poly V-
belt
❑ Removing and installing
⇒ page 39
4 - Cap
❑ For lower toothed belt
guard
5 - 10 Nm
6 - Rubber grommet
7 - Cover
8 - Sleeve
❑ Installation position:
Collar facing forwards
9 - Front right toothed Protected
belt by copyright. Copying for private or commercial purposes, in part or in whole, is not
guard 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 - Front left toothed belt
guard
11 - Lower toothed belt guard
❑ To remove, unscrew vi‐
bration damper
12 - 10 Nm
1 - Pivot pin
2 - 45 Nm
3 - Washer
❑ For tensioning roller
4 - 45 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Tensioning roller 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.
6 - Tensioning lever
❑ Fit washer
⇒ Item 32 (page 42)
7 - 70 Nm
8 - Washer
9 - 75 Nm
10 - Camshaft sprocket
❑ For inlet camshaft
❑ For removal and instal‐
lation, detach toothed
belt from camshaft
sprockets ⇒ page 58
❑ Detach using two-arm
puller -T40001- and
claw -T40001/5-
11 - 22 Nm
12 - 10 Nm
13 - Rubber grommet
14 - 10 Nm
15 - Rear right toothed belt
guard
16 - 22 Nm
17 - High-pressure pump
❑ For injection system
Caution
The high-pressure pump
must be filled with fuel
before starting the en‐
gine for the first time. Dry
running of the high-pres‐
sure pump must be avoi‐
ded.
Sequence of operations
– Pull lock carrier forwards ⇒ page 31 .
– Detach engine cover -arrows-.
WARNING
Caution
Note
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unscrew holder for noise insulation -arrows-.
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
A TDC hole can be felt in the crankshaft exactly behind the screw
plug.
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
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Note
Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach fuel pipes -1- and -2- at fuel pre-supply pump. To do
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
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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
Sequence of operations
– Remove right air pipe -arrows-.
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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.
Caution
Note
Note
A TDC hole can be felt in the crankshaft exactly behind the screw
plug.
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
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
Note
Engine in position:
– Turn crankshaft to TDC
⇒ “1.8 Turning engine to TDC - engine in position”, page 43 .
– Remove poly V-belt ⇒ page 36 .
– Unclip wiring harness from fan ring -arrows-.
– Screw out bolts -1 … 4-.
– Set down hydraulic radiator fan with hydraulic pipes 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
on engine. with respect to the correctness of information in this document. Copyright by AUDI AG.
Engine removed:
– Turn crankshaft to TDC
⇒ “1.9 Turning engine to TDC - engine removed”, page 48 .
– Remove top right, top left and lower toothed belt guard
⇒ page 40 .
Note
Note
The toothed belt tensioning element is oil cushioned and can only
be compressed slowly exerting uniform force.
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
Note
– Lay a 4.0 mm Allen key flat between tensioning lever -1- and
piston -2- of tensioning element.
Note
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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
– As a check, screw locking bolt -3242- back into hole in top part
of sump.
Note
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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
– Screw TDC mark screw plug with new oil seal into top part of
sump.
– Install vacuum pump at cylinder head on left ⇒ page 102 .
– Fit poly V-belt ⇒ page 37 .
– Replenish coolant ⇒ page 168 .
Tightening torques
Component Nm
Camshaft sprocket to camshaft 75
Eccentric roller to cylinder block 45
Fuel pre-supply pump to cylinder head 10
Vibration damper to crankshaft sprocket 22
Screw plug in top part of sump 35
Oil filler neck to cylinder head 10
Connecting pipe for Mechanical exhaust gas 22
exhaust gas recircu‐ recirculation valve
lation to Exhaust manifold Protected by10
copyright. Copying for private or commercial purposes, in part or in whole, is not
Air pipe to turbocharger 10 by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.
Top air pipe to Rear air pipe 10
Intake manifold 10
Clamps for coolant hoses 2
Clamps for air hoses 3,5
Removing
Note
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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.
Engine in position:
– Turn crankshaft to TDC
⇒ “1.8 Turning engine to TDC - engine in position”, page 43 .
– Remove poly V-belt ⇒ page 36 .
– Unclip wiring harness from fan ring -arrows-.
– Screw out bolts -1 … 4-.
– Set down hydraulic radiator fan with hydraulic pipes connected
on engine.
Engine removed:
– Turn crankshaft to TDC
⇒ “1.9 Turning engine to TDC - engine removed”, page 48 .
Note
Note
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♦ A small hole is provided in the lower toothed
permitted unlessbelt guard
authorised for AG. AUDI AG does not guarantee or accept any liability
by AUDI
inserting the setting pin -T40011- . with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
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.
Note
Note
– As a check, screw locking bolt -3242- back into hole in top part
of sump.
Note
Note
– Screw TDC mark screw plug with new oil seal into top part of
sump.
– Install vacuum pump at cylinder head on left ⇒ page 102 .
– Fit poly V-belt ⇒ page 37 .
– Replenish coolant ⇒ page 168 .
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
with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Oil seal
❑ For crankshaft
❑ Removing and installing
⇒ page 64
2 - Screw plug - 22.5 Nm
❑ Replace
❑ Only available together
with
⇒ Item 3 (page 63)
3 - Oil seal
❑ Only available together
with ⇒ Item 2 (page 63)
4 - Front sealing flange
❑ Removing and installing
⇒ page 66
5 - Thrust washer
❑ Detach if scored and
turn or replace
⇒ page 64
6 - Gasket
❑ Replace
❑ Before fitting gasket, ap‐
ply thin coat of sealant to
transitions between top
part of sump and cylin‐
der block; sealant ⇒ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Parts catalogue 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.
7 - Rear sealing flange with oil
seal
❑ Removing and installing
⇒ page 69
8 - Fitted pin
❑ Ensure firm attachment in crankshaft
9 - Shim
10 - Drive plate
❑ With sender wheel
❑ Removing and installing ⇒ page 70
11 - Packing plate
12 - 30 Nm + further 90° (1/4) turn
❑ Replace
13 - 10 Nm
14 - Gasket
❑ Replace
❑ Before fitting gasket, apply thin coat of sealant to transitions between top part of sump and cylinder block;
sealant ⇒ Parts catalogue
15 - 10 Nm
Sequence of operations
• Engine in position
– Remove toothed belt ⇒ page 51 .
– Screw out central bolt -2- for crankshaft toothed belt sprocket
-1-.
Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The central boltunless
permitted is slackened off with
authorised by AUDI theAG
AG. AUDI locking
does not bolt -3242-
guarantee or accept any liability
screwed in.
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Screw inner part of oil seal extractor -T40019- out of outer part
by roughly 6 turns and lock with knurled screw.
– Lubricate threaded end of oil seal extractor, fit in position and
screw as far as possible into oil seal whilst exerting firm pres‐
sure.
– Slacken off knurled screw and turn inner part towards crank‐
shaft until oil seal has been extracted.
– Clamp flats of oil seal extractor in a vice and use pliers to re‐
move oil seal.
Note
Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.
– Press in oil seal with thrust piece -T40007- and central bolt.
Note
♦ The thrust washer is turned so that the new oil seal runs on a
new sealing track.
♦ The marked end face of the thrust washer must now be facing
the engine.
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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
2) Replace bolt.
3) 180° corresponds to half a turn.
Removing
• Engine in position
– Place used oil collector and extractor -V.A.G 1782- or -
V.A.G 1358 A- beneath engine and drain off engine oil.
– Remove toothed belt ⇒ page 51 .
– Unscrew tensioning roller for poly V-belt -arrow-.
– Remove cover behind tensioning roller.
– Screw out bolts -arrows- and detach rear left toothed belt
guard.
Note
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-Item 1- can be ignored.
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.
– Screw out central bolt -2- for crankshaft toothed belt sprocket
-1-.
Note
The central bolt is slackened off with the locking bolt -3242-
screwed in.
Note
Installing
Install in reverse order; paying attention to the following:
Note
Note
Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.
– Press in oil seal with thrust piece -T40007- and central bolt.
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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
♦ The thrust washer is turned so that the new oil seal runs on a
new sealing track.
♦ The marked end face of the thrust washer must now be facing
the engine.
Note
Removing
– Remove drive plate ⇒ page 70 .
– Unscrew rear sealing flange -arrow-.
Installing
Install in reverse order; paying attention to the following:
– Clean sealing surfaces before fitting sealing flange.
– Before fitting gasket, apply thin coat of sealant to transitions
between top part of sump and cylinder block ⇒ Parts cata‐
logue .
– Use guide sleeve from installation set for attaching oil seal to
crankshaft.
– Fit drive plate ⇒ page 70 .
Tightening torques
Component Nm
Rear sealing flange to Cylinder block 10
Top part of sump 10
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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.
Removing
• Engine removed ⇒ page 4
• Engine separated from gearbox ⇒ page 22
– Unscrew oil filler neck.
Caution
Note
Note
A TDC hole can be felt in the crankshaft exactly behind the screw
plug.
WARNING
Note
For performing assembly work, attach engine with engine and gearbox holder -VW 540- and supplementary
set for engine and gearbox holder -VW 540/1 B- to repair stand ⇒ page 26 .
1 - Dowel sleeve
❑ 3x
❑ Insert in cylinder block
2 - Chain sprocket
❑ Installation position: La‐
belled side facing for‐
wards
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling chain drive for oil
pump”, page 145
3 - Thrust washer
❑ Detach if scored and
turn or replace
⇒ page 64
❑ Detach from crankshaft
by hand
4 - Crankshaft
❑ Measuring axial clear‐
ance ⇒ page 74
❑ Measuring radial clear‐
ance ⇒ page 74
❑ Do not turn crankshaft
when measuring radial
clearance Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Crankshaft dimensions permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 73 with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Bearing frame
❑ Slacken off bolts in re‐
verse tightening se‐
quence
❑ Tightening sequence
⇒ page 73
6 - Bolt
❑ For bearing frame
❑ Replace
❑ Slacken off in reverse tightening sequence
❑ Tightening sequence and tightening torque ⇒ page 73
7 - Thrust washer
❑ At 5th crankshaft bearing only
❑ Oil grooves face outwards
❑ Pay attention to retainer
Note
Sequence of operations
– Screw on dial gauge with universal dial gauge holder -VW 387-
at cylinder block and position against crank web.
– Press crankshaft by hand towards dial gauge and set dial
gauge to “0”.
– Press crankshaft away from dial gauge and
Protected take reading:
by copyright. Copying for private or commercial purposes, in part or in whole, is not
• As-new axial clearance: 0.090 … 0.251 mm to the correctness 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
Note
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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.
7 - Piston
❑ With combustion chamber
❑ Mark installation position and assignment to cylinder ⇒ page 78
❑ Use chalk or a waterproof felt-tip pen to mark assignment to cylinder at piston crown
❑ Replace piston in the event of cracks at piston crown or skirt
❑ Install using piston ring clamp
❑ Checking piston projection at TDC ⇒ page 79
❑ Piston and cylinder dimensions ⇒ page 80
❑ Checking cylinder bore ⇒ page 78
8 - Piston rings
❑ Offset gap by 120°
❑ Use piston ring pliers for removal and installation
❑ “TOP” mark or label must face piston crown
❑ Checking ring gap ⇒ page 77
❑ Checking side clearance ⇒ page 77
9 - Special bolt - 9 Nm
❑ Replace
10 - Oil spray jet
❑ For piston cooling
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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.
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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
Marking conrods
– Prior to removal, use a coloured pen to mark mutual assign‐
ment of conrod and conrod bearing cap -arrows-.
Note
Note
Note
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♦ The piston projection at TDC is to be checked when installing
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Test sequence
– Set up dial gauge -VAS 6079- with -VW 382/7- and -
VW 385/17- .
– Measure projection for each piston at two locations -1-.
Piston projection over top edge Identification
of cylinder block Holes
0.39 … 0.49 mm 1
0.49 … 0.54 mm 2
0.54 … 0.65 mm 3
Note
The gaskets for the left and right cylinder head are differently
shaped to prevent interchange.
Note
Test sequence
– Remove conrod bearing caps.
– Clean bearing caps and bearing journals.
– Place Plastigage thread corresponding to bearing width on
journal or in bearing shells.
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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
The illustration shows the cylinder head cover for the left cylinder bank.
❑ Replace
14 - 10 Nm
15 - Injector
❑ Removing and installing ⇒ Rep. Gr. 23
16 - O-ring
❑ Replace
❑ Heed installation position: Insert in upper groove of injector
17 - 10 Nm
18 - Hall sender -G40-
❑ Checking ⇒ Rep. Gr. 23
19 - O-ring
❑ Replace
20 - 10 Nm
❑ Replace if damaged or leaking
21 - Half-round gasket
❑ Replace if damaged or leaking
❑ Installation position: Part no. legible from exterior; straight sealing surface on a level with sealing surface
of cylinder head
♦ Puller -T40059-
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
Note
Note
Caution
Caution
Note
Note
Note
– Use torque wrench -V.A.G 1331- with open ring spanner at‐
tachment -V.A.G 1331/8- for tightening injector pipe.
Note
Removing
Note
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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 top air pipe -arrows-.
Note
Note
Note
Caution
Note
Note
Note
Note
– Use torque wrench -V.A.G 1331- with open ring spanner at‐
tachment -V.A.G 1331/8- for tightening injector pipe.
Note
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Note
Note
♦ The illustration shows the cylinder head for the left cylinder bank.
♦ Removing and installing cylinder head cover ⇒ page 84
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Checking
permitted cylinder
unless authorised head
by AUDI for torsion
AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Use bevelled straightedge and feeler gauge to check the cyl‐
inder head for torsion at several locations.
• Permissible torsion: Max. 0.1 mm
Note
The gaskets for the left and right cylinder head are differently
shaped to prevent interchange.
Removing
Note
• Engine in position
– Detach engine cover -arrows-.
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Note
Note
♦ Puller -T40059-
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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.
Sequence of operations
Note
– Unscrew and lift off guide tube for dipstick at cylinder head
-arrow-.
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Caution
Note
Caution
Note
Note
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Note
– Screw out bolts -arrows- and detach rear right toothed belt
guard.
Note
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Note
♦ Puller -T40059-
Sequence of operations
Note
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– Unscrew oil filler neck.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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Caution
Note
Caution
Note
Note
Note
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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 place cylinder head on workbench, as glow plugs could be
damaged.
Note
• The camshafts at both cylinder heads must have been set with
the camshaft retainers -3458- .
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Note
Note
Note
Tightening torques
Component Nm
Coolant pipe to Cylinder head 10
Cylinder block 10
Crankcase breather pipe to cylinder block 10
High-pressure pump to cylinder block 22
Rear toothed belt guard to engine M6 10
M8 22
Turbocharger to exhaust manifold 20 + 90° 11) 12)
Connecting pipe for exhaust gas recirculation 10
to exhaust manifold
Air pipe to turbocharger 10
Guide tube for dipstick to left cylinder head 10
Clamps for coolant hoses 2
Clamps for air hoses 3,5
11) 90° corresponds to a quarter turn.
12) Replace bolts.
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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 - Intake manifold
❑ With charge air cooler
❑ With exhaust gas recir‐
culation system cooler
❑ With 2 intake manifold
flaps
❑ Cannot be dismantled
❑ Removing and installing
⇒ Rep. Gr. 23
2 - Distributor housing
3 - 10 Nm
4 - Injector pipe - 25 Nm
❑ Do not alter shape
5 - Retaining bracket
6 - 22 Nm
7 - 22 Nm
8 - Rail element
❑ With injector pipes
❑ Provide support for con‐
nections at injectors
when unfastening and
tightening unionProtected
nuts forby copyright. Copying for private or commercial purposes, in part or in whole, is not
injector pipes. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Tighten injector pipes to
with respect to the correctness of information in this document. Copyright by AUDI AG.
25 Nm
❑ Do not attempt to bend
injector pipes to a differ‐
ent shape
9 - Connector
❑ For glow plugs
❑ With holder
10 - 22 Nm
11 - Variable intake manifold flap changeover valve -N239-
❑ Checking ⇒ Rep. Gr. 23
12 - 10 Nm
13 - Top air pipe
14 - 10 Nm
15 - Gasket
❑ Replace if damaged
16 - Rear air pipe
❑ Removing and installing ⇒ page 118
17 - O-ring
❑ Replace
❑ Moisten with fuel when fitting
❑ Do not use silicone-based lubricants
Note
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
• Engine in position
– Detach engine cover -arrows-.
– Screw out bolts -1- and -2- for gearbox mountings on left and
right.
Note
Note
Fig. shows right exhaust gas recirculation valve with engine re‐
moved.
– Unscrew nut -2- and detach left part of mounting rail -1- in
-direction of arrow-.
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Installing
Install in reverse order; paying attention to the following:
Note
Note
♦ Fuel canister
Test requirements
• Engine oil temperature min. 30 °C
• Battery voltage min. 12.5 V
Test sequence
Note
Note
– Unscrew union nut -1- at rail element for left cylinder bank.
– Unscrew union nuts -4 ... 7-.
Note
Note
Note
– Use torque wrench -V.A.G 1331- with open ring spanner at‐
tachment -V.A.G 1331/8- for tightening injector pipe.
Note
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Provide support for connections at injectors when tightening un‐
with respect to the correctness of information in this document. Copyright by AUDI AG.
ion nuts for injector pipes.
Note
Note
The illustration shows the cylinder head for the left cylinder bank.
1 - Valve
❑ Checking ⇒ page 140
❑ Valve dimensions
⇒ page 139
2 - Cylinder head
❑ Removing left cylinder
head ⇒ page 103
❑ Removing right cylinder
head ⇒ page 108
❑ Installing cylinder head
⇒ page 113
❑ Valve seats are not to be
reworked
3 - Pressure limiting valve
2.7 bar - 25 Nm
❑ For lubrication points in
cylinder head
4 - Valve stem seal
❑ Replacing ⇒ page 135
5 - Valve spring
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6 - Valve spring plate
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.
7 - Valve cotters
8 - Rocker finger guide
9 - Oil seal
❑ Replacing ⇒ page 130
10 - Outer bearing cap
❑ For inlet camshaft
❑ Prior to installation, ap‐
ply sealant to sealing
surfaces of outer bear‐
ing caps; sealant ⇒
Parts catalogue
❑ Installation sequence ⇒ page 132
11 - Cap nut - 15 Nm
12 - Bearing cap
❑ Installation position ⇒ page 128
❑ Installation sequence ⇒ page 132
13 - 10 Nm
14 - 10 Nm
15 - Cap nut - 15 Nm
16 - Outer bearing cap
❑ For inlet camshaft
❑ Prior to installation, apply sealant to sealing surfaces of outer bearing caps; sealant ⇒ Parts catalogue
❑ Installation sequence ⇒ page 132
17 - Inlet camshaft
❑ Removing and installing ⇒ page 131
❑ Checking axial clearance ⇒ page 129
❑ Check radial clearance with Plastigage
❑ As-new radial clearance: 0.035 … 0.085 mm
❑ Radial clearance wear limit: 0.10 mm
❑ Runout: max. 0.04 mm
18 - Exhaust camshaft
❑ Removing and installing ⇒ page 131
❑ Checking axial clearance ⇒ page 129
❑ Check radial clearance with Plastigage
❑ As-new radial clearance: 0.035 … 0.085 mm
❑ Radial clearance wear limit: 0.10 mm
❑ Runout: max. 0.04 mm
19 - Rocker finger
❑ Mark installation position with coloured pen
20 - Hydraulic valve lifter
❑ Mark installation position with coloured pen
❑ Checking ⇒ page 138
❑ Lubricate contact surface before fitting
21 - Thrust washers
❑ 2x
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Installation position of bearing caps
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.
– Heed numbering of bearing caps -0 … 8-.
Test sequence
– Attach universal dial gauge holder -VW 387- with dial gauge -
VAS 6079- to cylinder head.
Inlet camshaft:
– For measurement, remove rocker fingers and re-install cam‐
shaft with bearing caps at front and rear -top arrows-.
– Move camshaft in direction of arrow -double arrow-.
• Specification: 0.06 … 0.15 mm
• Wear limit 0.30 mm
Exhaust camshaft:
– For measurement, remove rocker fingers and re-install cam‐
shaft with bearing caps at front and rear -bottom arrows-.
– Move camshaft in direction of arrow -double arrow-.
• Specification: 0.06 … 0.15 mm
• Wear limit 0.30 mm
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Sequence of operations
• Engine in position
– Detach toothed belt from camshaft sprockets ⇒ page 58 .
Note
In the event of radial shaft seal leakage, replace oil seals at both
cylinder heads.
– Position inner part of oil seal extractor -2085- flush with outer
part and lock with knurled screw.
– Lubricate threaded end of oil seal extractor -2085- , fit in po‐
sition and screw as far as possible into oil seal whilst exerting
firm pressure.
– Slacken off knurled screw and turn inner part towards cam‐
shaft until oil seal has been extracted.
– Clamp flats of oil seal extractor in a vice and use pliers to re‐
move oil seal.
Note
Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.
Note
Note
Note
Note
Note
Note
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Note
Sealant must not come into contact with the -patterned areas-.
Note
Tightening torques
Component Nm
Bearing cap to cylinder Cap nut 15
head Hexagon nut 10
Hexagon bolt 10
Sequence of operations
• Cylinder head in position
– Remove camshafts ⇒ page 131 .
– Use jointed spanner -3220- to remove all glow plugs.
– Position guide plate -VAS 5161/9- on cylinder head.
– Attach guide plate to cylinder head with knurled screws -
VAS 5161/12- .
– Insert punch -VAS 5161/3- in guide plate and use a plastic-
headed hammer to knock out the seized valve cotters.
– Detach valve stem seals with valve stem seal puller -3364- .
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Proceed as follows if puller -3364- cannot be used on account of
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Note
Note
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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.
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Notepermitted 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
Note
If the hydraulic valve lifters are still noisy, determine defective lifter
as follows:
– Remove cylinder head cover: Left ⇒ page 84 , right
⇒ page 91 .
– Turn crankshaft until cams of cylinder to be tested are facing
upwards.
– Determine clearance between cam and rocker finger.
– Use wooden or plastic wedge to press down rocker finger.
If a 0.20 mm feeler gauge can be inserted between camshaft and
rocker finger:
– Replace hydraulic valve lifter
⇒ “2.4 Removing and installing camshafts ”, page 131 .
Note
Note
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Test sequence
– Insert valve in valve guide.
• End of valve stem must be flush with valve guide.
Note
Note
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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.
17 – Lubrication
1 Removing and installing lubrication
system components
Note
1 - 10 Nm
❑ Tighten diagonally and
in stages
2 - Bottom part of sump
❑ Removing and installing
⇒ page 142
❑ Tighten oil level sender
with spacer to 10 Nm
3 - 10 Nm
4 - Baffle plate
5 - Chain sprocket for oil pump
❑ Installation position: La‐
belling facing rear
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling chain drive for oil
pump”, page 145
6 - 34.5 Nm
7 - Gasket
❑ Before fitting gasket, ap‐
ply thin coat of sealant to
transitions between top
part of sump and cylin‐
der block; sealant ⇒
Parts catalogue
❑ Replace
8 - 10Protected
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
9 - Frontwith
sealing
respect toflange
the correctness of information in this document. Copyright by AUDI AG.
❑ Removing and installing
⇒ page 66
10 - Screw plug - 22.5 Nm
❑ Only available together with oil seal ⇒ Item 11 (page 141)
11 - Oil seal
❑ Only available together with screw plug ⇒ Item 10 (page 141)
12 - Oil seal
❑ For crankshaft
❑ Replacing ⇒ page 64
13 - Thrust washer
❑ Detach if scored and turn or replace ⇒ page 64
❑ Detach from crankshaft by hand
14 - Chain sprocket
❑ Installation position: Labelled side facing forwards
❑ Removing and installing ⇒ “1.3 Removing and installing chain drive for oil pump”, page 145
15 - Drive chain for oil pump
❑ Removing and installing ⇒ “1.3 Removing and installing chain drive for oil pump”, page 145
16 - 10 Nm
17 - Chain tensioner
❑ Secure with setting pin -T40011- before removing
❑ Do not dismantle
❑ Removing and installing ⇒ “1.3 Removing and installing chain drive for oil pump”, page 145
18 - Oil pump
❑ Do not dismantle
❑ With relief valve 5.6 bar
❑ Removing and installing ⇒ page 146
19 - 30 Nm
20 - Oil screen
❑ Clean if contaminated
21 - Inlet connection
22 - Tensioning ring
23 - Return hose
❑ From crankcase breather
24 - Oil seal
❑ Replace
25 - Oil drain plug - 50 Nm
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Installing
Install in reverse order; paying attention to the following:
Note
WARNING
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Note
Removing
– Remove front sealing flange ⇒ page 66 .
– Secure chain tensioner for oil pump with setting pin -T40011- .
– Screw out bolts -arrows- at chain tensioner.
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– Detach chain tensioner. 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.
20 - 10 Nm
21 - Rear sealing flange with oil seal
❑ Oil seal cannot be replaced separately
❑ Removing and installing ⇒ page 69
22 - Gasket
❑ Replace
❑ Before fitting gasket, apply thin coat of sealant to transitions between top part of sump and cylinder block;
sealant ⇒ Parts catalogue
23 - Top part of sump
❑ Removing and installing ⇒ page 148
24 - Gasket
❑ Replace
❑ Before fitting gasket, apply thin coat of sealant to transitions between top part of sump and cylinder block;
sealant ⇒ Parts catalogue
25 - Front sealing flange
❑ Removing and installing ⇒ page 66
26 - 10 Nm
27 - Oil seal
❑ For crankshaft
❑ Removing and installing ⇒ page 64
Installing
Install in reverse order; paying attention to the following:
Note
WARNING
Note
– Fit top part of sump in position and pre-tighten all bolts for top
part of sump/cylinder block diagonally to 5 Nm.
– Tighten bolts -1- for top part of sump/cylinder block diagonally
to 14 Nm.
– Install oil pump ⇒ page 146 .
– Install front sealing flange ⇒ page 66 .
– Install rear sealing flange ⇒ page 69 .
– Fit drive plate ⇒ page 70 .
– Install bottom part of sump ⇒ page 144 .
– Install oil filter bracket with oil cooler ⇒ page 152 .
– Install turbochargers: Left ⇒ page 239 , right ⇒ page 243 .
– Install engine ⇒ page 26 .
– Pour in engine oil and check oil level ⇒ page 161 .
Tightening torques
Component Nm
Top part of sump to cylinder block 14
Holder for hydraulic pump and air conditioner 40
compressor to engine
Hydraulic pump to holder 22
Left engine support to cylinder block 42
Coolant drain pipe to Top part of sump 10
Cylinder block 32,5
Guide tube for dipstick to left cylinder head 10
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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 - Cap - 25 Nm
❑ Before unfastening,
drain off oil at drain plug
⇒ Item 30 (page 152)
❑ Use 36 mm socket
wrench for unfastening
and tightening
2 - O-ring
❑ Replace
3 - Oil filter element
❑ Detach from cap
⇒ Item 1 (page 151)
❑ Replace O-ring
⇒ Item 2 (page 151) on
changing filter
❑ Heed replacement inter‐
vals ⇒ Maintenance ;
Booklet 403
4 - O-ring
❑ Replace
5 - 10 NmProtected 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
6 - Connection
with respect to the correctness of information in this document. Copyright by AUDI AG.
17 - Intermediate pipe
18 - 4 Nm
19 - Oil cooler
❑ With bypass valve 1.45 bar
20 - Bushing
❑ Installation position: Collar facing forwards
21 - Rubber grommet
22 - 10 Nm
23 - Cover
24 - 45 Nm
25 - 45 Nm
26 - 22 Nm
27 - Alternator
28 - Coolant drain plug - 10 Nm
29 - Oil seal
❑ Replace
30 - Oil drain plug -10 Nm
31 - O-ring
❑ Replace
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Removing
• Engine in position
Caution
WARNING
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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
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Leave connector and coolant hoses
permitted connected.
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.
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.
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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
Note
Note
Tightening torques
Component Nm
Oil filter bracket to engine M8 22
M10 45
Oil drain plug to cap 10
Oil pressure switch -F1- to Protected
oil filterbybracket 25or commercial purposes, in part or in whole, is not
copyright. Copying for private
Tensioning roller for poly V-belt to engine 45
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.
Alternator to oil filter bracket M8 22
M10 45
Clamps for coolant hoses 2
Clamps for air hoses 3,5
1.9 Exploded view of oil retention valves and spray nozzle valve
1 - O-ring
❑ Replace
2 - Oil retention valve - 20 Nm
❑ For oil supply to left cyl‐
inder head
3 - Gasket
❑ Replace
4 - Cover
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permitted❑unless
With connection
authorised by AUDI AG. forAUDI AG does not guarantee or accept any liability
with respectcrankcase breather
to the correctness of information in this document. Copyright by AUDI AG.
5 - 10 Nm
6 - Rubber buffer
❑ For intake manifold
7 - Hose
❑ To crankcase breather
8 - Oil retention valve
❑ For oil supply to right
cylinder head
❑ Tighten to 20 Nm
9 - O-ring
❑ Replace
10 - Spray nozzle valve
❑ For piston cooling
❑ Tighten to 20 Nm
Note
Removing
– Remove intake manifold ⇒ Rep. Gr. 23 .
– Detach hose ⇒ Item 7 (page 159) from cover
⇒ Item 4 (page 159) .
– Unscrew cover beneath intake manifold.
– Screw out oil retention valve/spray nozzle valve.
Installing
Install in reverse order; paying attention to the following:
Note
V.A.G 1527 B-
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.
Test conditions
• Oil level OK
Note
Test sequence
– Pull out dipstick, wipe with a clean cloth and re-insert as far as
it will go.
– Then pull out dipstick again and take oil level reading.
Markings on dipstick:
a - Oil is not to be topped up.
b - Oil can be topped up.
c - Oil must be topped up. It is then sufficient for the oil level to be
in area -b- (hatched area).
Note
The oil level must not exceed mark -a- on the dipstick.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 - Hose
2 - 10 Nm
3 - 10 Nm
❑ Self-locking
❑ Apply locking fluid when
fitting; locking fluid ⇒
Parts catalogue
4 - Pressure control valve
❑ For crankcase breather
❑ Checking ⇒ page 163
5 - Holder
6 - Hose
7 - From cylinder block
8 - Pipe
9 - 10 Nm
10 - Air pipe
11 - O-ring
❑ Replace
12 - 10 Nm
13 - Hose
14 - To bottom part of sump
Test condition
• Coolant temperature at least 80 °C
Test sequence
– Pull out dipstick.
– Connect tester for K-Jetronic -V.A.G 1371- to guide tube for
dipstick.
– Start engine and allow it to idle for at least 3 minutes.
– Read crankcase pressure off gauge.
• Specification: Less than 5 mbar Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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19 – Cooling
1 Removing and installing cooling sys‐
tem components
WARNING
Note
Function
The cooling system is made up of a main cooling circuit, a charge
air cooling circuit and a fuel cooling circuit. For function and mode
of operation, refer to ⇒ Self-study programme No. 226 ; 3.3 l V8
TDI engine, mechanics .
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1 - 10 Nm
2 - Sealing ring
❑ Replace
3 - Coolant temperature send‐
er
❑ Tighten to 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
4 - Thermostat housing with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - 22 Nm
6 - O-rings
❑ Replace
7 - Thermostat
❑ Removing and installing
⇒ page 174
❑ Checking ⇒ page 175
❑ Installation position
⇒ page 165
8 - Gasket
❑ Replace
9 - 10 Nm
10 - Mechanical coolant pump
❑ Removing and installing
⇒ page 173
Draining
Note
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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
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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.
– Use hose clamp -3094- to pinch off coolant hose from fuel
cooler to radiator upstream of T-piece.
– Open bleed screw -arrow- at fuel cooler.
– Pour in coolant until it emerges at bleeder hole.
– Detach hose clamp.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Open bleed
permitted screws
unless -1-
authorised by and -2-AUDI
AUDI AG. at intake
AG does manifold.
not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Pour in coolant until it emerges at bleeder holes.
– Close bleed screws.
Note
WARNING
Note
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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.
Installing
Note
– Install thermostat.
• Installation position: Vent valve -arrow- facing upwards
– Install thermostat housing.
– Fit toothed belt (adjust timing) ⇒ page 60 .
– Replenish coolant ⇒ page 168 .
Tightening torques
Component Nm
Thermostat housing to cylinder block 10
Rear toothed belt guard to engine M6 10
M8 22
Clamps for coolant hoses 2
Checking thermostat
– Heat thermostat in water bath.
Start of opening End of opening Opening stroke
approx.
Protected 87 °C
by copyright. Copying for approx. 102 °Cpurposes, inmin.
private or commercial
13)
part or8in mm
14)
whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
13) with
Cannot betochecked
respect the correctness of information in this document. Copyright by AUDI AG.
14) At 95 °C
⇒ page 180
with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - 10 Nm
11 - Coolant temperature
gauge sender -G2- / coolant
temperature sender -G62-
12 - Retaining clip
13 - 10 Nm
14 - 10 Nm
15 - 10 Nm
16 - Left coolant pipe
❑ Removing and installing
⇒ page 178
17 - O-rings
❑ Replace
Note
– Screw out bolts -arrows- and detach rear right toothed belt
guard.
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
ted.
Note
Replace O-rings.
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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
♦ Replace O-rings.
♦ Secure all hose connections with standard clamps ⇒ Parts
catalogue .
Note
Replace O-rings.
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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
Note
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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
Note
♦ Pull catches outwards and press fuel pipes -2- and -4- onto
fuel pre-supply pump connections until they engage
-arrows-.
♦ If the pipe has been fitted properly, the catch will be loosely
positioned in the hose coupling.
♦ -Item 1- and -Item 3- can be ignored.
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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.
Removing
Note
WARNING
– Pull out clip -arrow- and detach coolant hose from radiator.
Note
– Detach both coolant hoses -1- and -2- at bottom right of radi‐
ator.
– Unfasten nut -3- on left and right of radiator by several turns.
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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
Note
Rep. Gr. 37 .
with respect to the correctness of information in this document. Copyright by AUDI AG.
Test condition
• Engine warm
Test sequence
WARNING
1 - Hydraulic pump
❑ For power steering and
hydraulic fan
❑ Removing and installing
⇒ page 193
2 - Sleeve
3 - Sealing ring
❑ Replace
4 - 50 Nm
5 - Radiator fan valve -N313-
❑ Checking ⇒ page 190
6 - Washer
7 - Circlip
8 - Motor for hydraulic fan
❑ Replace if leaking
❑ Unscrew to unscrew fan
ring -Item 15- and fan
impeller -Item 17-
9 - Sealing ring
❑ Replace
10 - Supply pipe
11 - Sealing ring
❑ Replace
12 - 50 Nm
❑ Provide support at hex‐
agon of motor housing
when tightening
13 - Retaining clip
❑ For return hose
14 - Return hose
15 - Fan ring
16 - Spacer
17 - Fan impeller
18 - Special nut with left-hand thread - 21 Nm
19 - 10 Nm
20 - Rubber grommet
21 - Sleeve
22 - 10 Nm
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Removing
Note
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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
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.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Test conditions
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 actuation
– Slacken off cross-head bolts -1- at electronics box in plenum
chamber.
– Unclip plenum chamber cover -2- at front at bulkhead
-arrows-.
– Detach plenum chamber cover.
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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.
– Prise out cover -1- in scuttle panel trim and slacken off rear
cross-head bolt -rear right arrow-.
– Slacken off the remaining cross-head bolts -arrows-.
– Detach cover for electronics box in plenum chamber.
– Check for open circuit and short to earth or positive in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/30-
Contact Socket
-2- 2/14
– Repair wiring if necessary.
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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.
1.15 Removing and installing hydraulic pump for power steering and hydraulic
fan
Removing
Note
WARNING
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– Disconnect vacuum hoses -1 … 3- at charge pressure control
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.
solenoid valves.
– Detach charge pressure control solenoid valves from rubber
mount at heat shield -arrow-.
– Unscrew heat shield for solenoid valves from holder for hy‐
draulic pump and air conditioner compressor -2-.
– Lay bare vacuum pipe -1- at guide tube for dipstick.
– Screw out hexagon socket head bolt for hydraulic pump at
rear.
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– Remove cover onunless
permitted left in engine
authorised compartment
by AUDI -arrows-.
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 top left toothed belt guard ⇒ page 40 .
Note
– Unscrew and lift off guide tube for dipstick at cylinder head
-arrow-.
Note
Note
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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.
Test conditions
• Electric fan fuses OK
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnostic wire -VAS 5051/1- connected,
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” selected; when doing this, the ignition must be switch‐
ed on
Test sequence
Display on -VAS 5051 A-
– In list -1- select function “03 - Final control diagnosis”.
– Keep touching → key until the 3 relays of the electric radiator
fan are consecutively actuated.
• Depending on the relay energised, the electric radiator fan
must run at low, medium or high speed.
– Terminate function “03 - Final control diagnosis” by touching
← key and switch off ignition.
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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 LED flashes:
– Replace electric radiator fan.
If LED does not flash:
– Check power supply and earth connection of electric radiator
fan.
B - If electric radiator fan does not run in one or two speed settings:
– Repeat function “03 - Final control diagnosis”.
– Keep touching → key until the 3 relays of the electric radiator
fan are consecutively actuated.
• The 3 relays of the electric radiator fan must be consecutively
energised (audible in driver's footwell).
– Terminate function “03 - Final control diagnosis” by touching
← key and switch off ignition.
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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
Note
– Remove electric fan by pressing out pin -1- and removing clip.
– Turn electric fan in -direction of arrow- and detach fan.
Installing
Install in reverse order; paying attention to the following:
Note
Test conditions
• Fuse S4 OK (in fuse box, fuse carrier -ST4- - blue)
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnostic wire -VAS 5051/1- connected,
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” selected; when doing this, the ignition must be switch‐
ed on
• Fault memory interrogated
Test sequence
Display on -VAS 5051 A-
– In list -1- select function “03 - Final control diagnosis”.
– Keep touching → key until fuel cooling pump relay -J445- is
actuated.
• The fuel cooling pump relay -J445- (in electronics box in pas‐
senger's footwell) must be energised (click) intermittently and
the fuel cooling pump -V166- must run intermittently (can be
heard at right of engine compartment).
– Terminate function “03 - Final control diagnosis” by touching
← key and switch off ignition.
– Prise out cover -1- in scuttle panel trim and slacken off rear
cross-head bolt -rear right arrow-.
– Slacken off the remaining cross-head bolts -arrows-.
– Detach cover for electronics box in plenum chamber.
Removing
– Remove front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
– Screw out bolts -arrows- of air duct and detach.
– Place drip tray for workshop cranes -VAS 6208- or -V.A.G
1306- beneath engine.
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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
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.
Test conditions
• Pump fuse OK (in relay and fuse carrier in electronics box in
plenum chamber)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Vehicle diagnostic, testing and information
permitted system
unless authorised by AUDI- AG. AUDI AG does not guarantee or accept any liability
VAS 5051 A- with diagnostic with
wire -VAS
respect 5051/1-
to the connected,
correctness of information in this document. Copyright by AUDI AG.
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” selected; when doing this, the ignition must be switch‐
ed on
• Fault memory interrogated
Test sequence
Display on -VAS 5051 A-
– In list -1- select function “03 - Final control diagnosis”.
– Keep touching → key until charge air cooling pump relay -
J536- is actuated.
• The charge air cooling pump relay -J536- (in relay and fuse
carrier in electronics box in plenum chamber) must be ener‐
gised (click) intermittently and the charge air cooling pump -
V188- must run intermittently (can be heard at left of engine
compartment).
– Terminate function “03 - Final control diagnosis” by touching
← key and switch off ignition.
– Prise out cover -1- in scuttle panel trim and slacken off rear
cross-head bolt -rear right arrow-.
– Slacken off the remaining cross-head bolts -arrows-.
– Detach cover for electronics box in plenum chamber.
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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 charge air cooling pump relay -J536- -arrow- out of relay
and fuse carrier in electronics box in plenum chamber.
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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 actuation of charge air cooling pump relay -J536-
– Connect up voltage tester -V.A.G 1527 B- between relay sock‐
et contact -6- and battery positive.
– Repeat function “03 - Final control diagnosis”.
– Keep touching → key until charge air cooling pump relay -
J536- is actuated.
• LED must flash (does not go out completely).
– Terminate function “03 - Final control diagnosis” by touching
← key and switch off ignition.
– Check for open circuit and short to earth or positive in the fol‐
lowing wiring:
Relay socket Test box -V.A.G 1598/30-
Contact Socket
-4- 2/02
– Repair wiring if necessary.
If no fault is found in wire:
– Replace engine control unit.
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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.
Removing
– Remove front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
– Unplug headlight and left turn signal indicator connectors
-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
– Lay bare wires. with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
21 – Turbocharging/supercharging
1 Checking charge air system with tur‐
bocharger
Note
WARNING
Note
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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.
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.
Test condition
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnostic wire -VAS 5051/1- connected,
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” selected; the engine must be idling when doing so
Note
Display on -VAS 5051 A- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Use keypad -2- to enter “033” for “Displaypermitted
group 033” and
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.
confirm by touching Q key.
1 - Enter display group
Note
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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.
3 … mg/S
Protected Intake air mass, right cylinder bank (bank 1), alternating
15) Copying for private or commercial purposes, in part or in whole, is not
by copyright.
• Specification with “Bank 1 on”: 550 … 850 mg/S
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.
• Specification with “Bank 2 on”: 100 … 300 mg/S
4 … mg/S 15) Intake air mass, left cylinder bank (bank 2), alternating
• Specification with “Bank 2 on”: 550 … 850 mg/S
• Specification with “Bank 1 on”: 100 … 300 mg/S
The values for the left and right side must be roughly equal
15) mg/S = Milligrammes/stroke
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Note
Note
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Switch on turbocharger with
tester -V.A.G
respect 1397 A-
to the correctness and set inmeas‐
of information this document. Copyright by AUDI AG.
uring range switch to -I- (absolute pressure).
– Attach measurement hose to connection -I-.
– Connect measurement hose to vacuum hose detached.
Note
1 - Right turbocharger
2 - Left turbocharger
3 - To variable intake manifold
flap changeover valve -N239-
4 - To exhaust gas recircula‐
tion valve -N18- and exhaust
gas recirculation valve 2 -
N213-
5 - Vacuum pump
6 - Brake servo
7 - Vacuum reservoir
❑ Fitting location: In front
left wheel housing be‐
neath liner
8 - Non-return valve
❑ Installation
position (light/dark
side): As shown
9 - Charge pressure control
solenoid valve -N75-
10 - Charge pressure control
solenoid valve 2 -N274-
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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.
1.6 Exploded view of charge pressure control solenoid valves -N75- and -N274-
Note
Installation position: At holder for air conditioner compressor and hydraulic pump
1 - To vacuum pump
2 - Charge pressure control
solenoid valve 2 -N274-
❑ Left cylinder bank:
3 - 5 Nm
4 - Holder
5 - Rubber mount
6 - Charge pressure control
solenoid valve -N75-
❑ Right cylinder bank:
7 - To right turbocharger
8 - To left turbocharger 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.
1.7 Checking charge pressure control solenoid valves -N75- and -N274-
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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
Note
– Use test lead from adapter set to connect contact -2- of sole‐
noid valve to battery positive.
– Connect contact -1- to earth.
• Valve must click.
• Intake must be possible at test hose.
If valve does not open:
– Replace charge pressure control solenoid valve.
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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.
– Prise out cover -1- in scuttle panel trim and slacken off rear
cross-head bolt -rear right arrow-.
– Slacken off the remaining cross-head bolts -arrows-.
– Detach cover for electronics box in plenum chamber.
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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.
– Screw out bolt -arrow-.
– Disengage retainer.
– Detach diesel direct injection system control unit -J248-
-Item 1-. Release and unplug connectors.
– Check for open circuit and short to earth or positive in the fol‐
lowing wiring:
Component Connector Test box -
Contact V.A.G 1598/30-
Socket
Charge pressure -1- 2/21
control solenoid
valve -N75-
Charge pressure -1- 2/19
control solenoid
valve 2 -N274-
– Repair wiring if necessary.
If no fault is found in wire:
– Replace engine control unit.
Note
WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Display on -VAS 5051 A- 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.
– Use keypad -2- to enter “011” for “Display group 011” and
confirm by touching Q key.
1 - Enter display group
Note
Note
Test condition
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnostic wire -VAS 5051/1- connected,
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” selected; the engine must be idling when doing so
Test sequence
– Screw out rear left screw plug at intake manifold and screw in
adapter set -V.A.G 1318/11- .
– Connect turbocharger tester -V.A.G 1397 A- using test hose
-1-.
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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 wiring
– Slacken off cross-head bolts -1- at electronics box in plenum
chamber.
– Unclip plenum chamber cover -2- at front at bulkhead
-arrows-.
– Detach Protected
plenumbychamber cover.
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.
– Prise out cover -1- in scuttle panel trim and slacken off rear
cross-head bolt -rear right arrow-.
– Slacken off the remaining cross-head bolts -arrows-.
– Detach cover for electronics box in plenum chamber.
– Check for open circuit and short to earth or positive in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/30-
Contact Socket
-1- 3/16
-3- 3/14
-4- 3/15
– Repair wiring if necessary.
If no fault is found:
– Replace intake manifold pressure sender.
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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.
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
1 - Turbocharger
❑ Checking ⇒ page 215
❑ Removing and installing
left turbocharger
⇒ page 239
❑ Removing and installing
right turbocharger
⇒ page 243
2 - O-ring
❑ Replace
3 - 10 Nm
4 - Hose
❑ To crankcase breather
5 - Air pipe
❑ Left side of engine: With
connection for crank‐
case breather
6 - Gasket
❑ Replace
7 - ExhaustProtected
manifoldby 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
❑ Removing andtoinstalling
with respect the correctness of information in this document. Copyright by AUDI AG.
left exhaust manifold
⇒ page 266
❑ Removing and installing
right exhaust manifold
⇒ page 267
8 - 20 Nm + further 90° (1/4)
turn
❑ Replace
9 - Oil supply pipe
❑ From cylinder block
10 - Oil seals
❑ Replace
11 - 15 Nm
12 - 15 Nm
13 - Oil seals
❑ Replace
14 - Hose
❑ Pressure side
15 - 10 Nm
16 - Air pipe
17 - O-ring
❑ Replace
18 - Air hose
❑ Intake side
19 - Front exhaust pipe
❑ With starter catalytic converter
❑ Removing and installing left front exhaust pipe ⇒ page 252
❑ Removing and installing right front exhaust pipe ⇒ page 259
20 - 25 Nm
❑ Replace
21 - 22 Nm
22 - Holder
23 - 22 Nm
24 - 10 Nm
25 - Heat shield
26 - 22 Nm
27 - ATF pipes
❑ Heed rules for cleanliness when working on automatic gearbox ⇒ Automatic gearbox 01L, four-wheel
drive; Rep. Gr. 37
28 - Gasket
❑ Replace
29 - 10 Nm
30 - Oil return pipe
❑ To cylinder block
31 - 10 Nm
32 - O-ring
❑ Replace
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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.
– Screw out bolts -arrows- and detach ATF pipes from gearbox.
Note
Note
Seal off oil bore in top part of sump with clean cloths.
Installing
Install in reverse order; paying attention to the following:
Note
Note
Seal off oil bore in top part of sump with clean cloths.
Installing
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
26 – Exhaust system
1 Removing and installing exhaust sys‐
tem components
Note
1 - Centre silencer
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Forms
permitted one
unless unit with
authorised rear
by AUDI AG. AUDI AG does not guarantee or accept any liability
silencer
with respect to as original of information in this document. Copyright by AUDI AG.
the correctness
equipment; can be re‐
placed separately when
performing repair work
❑ Cutting point
⇒ page 252
❑ Stress-free alignment of
exhaust system
⇒ page 268
2 - Rubber mount
❑ Checking pre-tension
⇒ “1.8 Stress-free align‐
ment of exhaust system
”, page 268
3 - Holder
4 - 25 Nm
5 - 25 Nm
❑ Replace
6 - Front exhaust pipe with ox‐
idation catalytic converter and
starter catalytic converter
❑ For right side of vehicle
❑ With decoupling ele‐
ment
❑ Removing and installing
⇒ page 259
❑ Protect against impact
and jolts
❑ To avoid damage, do
not kink decoupling ele‐
14 - 40 Nm
15 - Front right clamp
❑ Before tightening, perform stress-free alignment of exhaust system ⇒ page 268
❑ Installation position: Bolted joint facing left
❑ Installation position of bolt ends ⇒ page 248
❑ Tighten bolted joints evenly
16 - 40 Nm
17 - 40 Nm
18 - Rear left clamp
❑ For separate replacement of centre and rear silencer
❑ Before tightening, perform stress-free alignment of exhaust system ⇒ page 268
❑ Installation position: Bolted joint facing left
❑ Installation position ⇒ page 248
❑ Tighten bolted joints evenly
19 - Rear right clamp
❑ For separate replacement of centre and rear silencer
❑ Before tightening, perform stress-free alignment of exhaust system ⇒ page 268
❑ Installation position: Bolted joint facing right
❑ Installation position ⇒ page 248
❑ Tighten bolted joints evenly
20 - 40 Nm
21 - 25 Nm
22 - 25 Nm
23 - Mounting
❑ Illustration shows left mounting
24 - Rubber mount
❑ Checking pre-tension ⇒ “1.8 Stress-free alignment of exhaust system ”, page 268
25 - Rear silencer
❑ Forms one unit with centre silencer as original equipment; can be replaced separately when performing
repair work
❑ Cutting point ⇒ page 252
❑ Stress-free alignment of exhaust system ⇒ page 268
26 - Holder
❑ With guard
27 - Rubber mount
❑ Checking pre-tension ⇒ “1.8 Stress-free alignment of exhaust system ”, page 268
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Mounting components
Protected for front
by copyright. Copying exhaust
for private pipes
or commercial purposes, in part or in whole, is not
1- Bolt
with-respect
25 Nm
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness of information in this document. Copyright by AUDI AG.
2- Washer
3- Pressure spring
4- Spacer sleeve
5- Spacer sleeve
6- Buffer
7- Link plate
8- Washer
9- Bolt - 25 Nm
Note
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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.
Distance of exhaust pipes from rear axle between centre and rear
silencer
A - Exhaust pipes
B - Rear axle
• Dimension -a- = approx. 27 mm
• Dimension -b- = approx. 24.5 mm
Note
The illustration shows the exhaust pipes from the rear viewed in
direction of travel.
Tailpipe alignment
– Align tailpipes such that distance -a- on left is equal to distance
-a- on right. 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.
Sequence of operations
– Separate exhaust pipes at cutting points marked by a groove
using chain pipe cutter -VAS 6254- .
• Dimension -a- = approx. 240 mm
• Dimension -b- = approx. 200 mm
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
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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.
♦ Replace gaskets and self-locking nuts.
♦ To avoid damage, decoupling element in front exhaust pipe is
not to be kinked by more than 10°.
WARNING
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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 coolant hose -arrow- at top coolant pipe and take it out
of mount on side of engine compartment.
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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
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
Illustration shows engine removed.
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew cross-piece -2- and holder -1- for rear noise insula‐
tion.
Note
Illustration shows
Protected engineCopying
by copyright. removed.
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.
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Note
verter
Special tools and workshop equipment required
Removing
– Detach engine cover -arrows-.
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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
Note
Note
– Unscrew cross-piece -2- and holder -1- for rear noise insula‐
tion.
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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 heat shield for right drive shaft -1- from gearbox
-arrows-.
Note
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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
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.
Mounting components for exhaust system at gearbox
⇒ page 249
Tightening torques
Component Nm
Gearbox support to gearbox 40
Gearbox mounting to gearbox support 40
Gearbox mounting to subframe 40
Front exhaust pipe with oxidation catalytic con‐ 25
verter to turbocharger
Mounting lug for front exhaust pipe to gearbox 25
support
Front exhaust pipe with oxidation catalytic con‐ 25
verter to mounting lug
Drive shaft guard to gearbox 23
Clamp for exhaust pipe 40
Clamps for air hoses 3,5
Note
The illustration shows the exhaust manifold for the left cylinder bank.
1 - Exhaust manifold
❑ Removing and instal‐
ling: Left ⇒ page 266 ,
right ⇒ page 267
2 - 25 Nm
❑ Replace
3 - Gasket
❑ Replace
4 - 10 Nm
5 - Connecting pipe
❑ To mechanical exhaust
gas recirculation valve
6 - Gasket
❑ Replace
7 - 20 Nm + further 90° (1/4)
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
❑ Replace with respect to the correctness of information in this document. Copyright by AUDI AG.
8 - Gasket
❑ Replace
9 - Turbocharger
❑ Removing and instal‐
ling: Left ⇒ page 239 ,
right ⇒ page 243
Note
The exhaust manifolds can only be detached with the engine re‐
moved.
– Unscrew and lift off guide tube for dipstick at cylinder head
-arrow-.
Note
The exhaust manifolds can only be detached with the engine re‐
moved.
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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
Note
Note
Note
position (light/dark with respect to the correctness of information in this document. Copyright by AUDI AG.
side): As shown
7 - To variable intake manifold
flap changeover valve -N239-
and charge pressure control
solenoid valves -N75- and -
N274-
8 - Exhaust gas recirculation
valve 2 -N213-
❑ For left cylinder bank
9 - Exhaust gas recirculation
valve -N18-
❑ For right cylinder bank
Test conditions
• Coolant temperature at least 80 °C
• Vehicle diagnostic, testing and information system -
VAS 5051 A- with diagnostic wire -VAS 5051/1- connected,
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” selected; the engine must be idling when doing so
Test sequence
Display on -VAS 5051 A- :
– From list -1- select function “04 - Basic setting”.
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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
The exhaust gas recirculation valves -N18- and -N213- and the
corresponding wiring are monitored by the engine control unit.
Note
– Use test lead from adapter set to connect contact -2- of sole‐
noid valve to battery positive.
– Connect contact -1- to earth.
• Valve must click.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Disconnect vacuum hose at relevant mechanical exhaust gas with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
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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.
– Prise out cover -1- in scuttle panel trim and slacken off rear
cross-head bolt -rear right arrow-.
– Slacken off the remaining cross-head bolts -arrows-.
– Detach cover for electronics box in plenum chamber.
– Check for open circuit and short to earth or positive in the fol‐
lowing wiring:
Component Connector Test box -
Contact V.A.G 1598/30-
Socket
Exhaust gas recir‐ -1- 2/13
culation valve -N18-
Exhaust gas recir‐ -1- 3/23
culation valve 2 -
N213-
– Repair wiring if necessary.
If no fault is found in wire:
– Replace engine control unit.
Note
Test condition
• Engine stopped
Test sequence
Note
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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.
♦ Fig. shows mechanical exhaust gas recirculation valve for left
cylinder bank.
♦ Top air pipe must be removed for checking mechanical ex‐
haust gas recirculation valve for right cylinder bank.
Note
The illustration shows the exhaust gas recirculation system for the left cylinder bank.
1 - 10 Nm
2 - Gasket
❑ Replace
3 - Gasket
❑ Replace
4 - Intake manifold
5 - Mechanical exhaust gas re‐
circulation valve
❑ Checking ⇒ page 277
❑ Removing and installing
⇒ page 279
6 - 22 Nm
7 - Vacuum hose
❑ To exhaust gas recircu‐
lation valve -N18- or -
N213-
8 - 22 Nm
9 - Connecting pipe
❑ To mechanical exhaust
gas by
Protected recirculation valve
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 - Gasket
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Replace
Note
Note
Note
Replace gaskets.
Tightening torques
Component Nm
Mechanical exhaust gas recirculation valve to 22
intake manifold or connecting pipe
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Top air pipe to Rear air pipe permitted10
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Cylinder head 10with respect to the correctness of information in this document. Copyright by AUDI AG.
Clamps for air hoses 3,5