07-6-Cyl. TDI Engine, 3.0 Ltr. 4-Valve Common Rail (EA 897 - Gen. II)

Service
Workshop Manual
Audi Q5 2017 ➤
6-cylinder TDI engine, 3.0 ltr. 4-valve common rail (EA
897 - Gen. II)
Engine ID
DCP DCP
C E
Edition 08.2018
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2018 Audi AG, Ingolstadt D4B806BCE78

Audi Q5 2017 ➤
6-cylinder TDI engine, 3.0 ltr. 4-valve common rail (EA 897 - Gen. II) - Edition 08.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.1 Exploded view - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.8 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.9 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1 Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Exploded view - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Exploded view - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.5 Removing and installing seals for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2 Removing and installing cam actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4 Measuring radial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Contents i
Audi Q5 2017 ➤
4.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.6 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.4 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 62
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.1 Exploded view - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.5 Removing and installing oil temperature sender G8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.6 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.7 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.8 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 66
4.9 Removing and installing oil temperature sender 2 G664 . . . . . . . . . . . . . . . . . . . . . . . . . . 67
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Exploded view - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.3 Exploded view - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.4 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.5 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 83
2.9 Removing and installing temperature sender for engine temperature regulation G694 . . 83
2.10 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4 Radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.1 Exploded view - radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2 Exploded view - auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.4 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
ii Contents
Audi Q5 2017 ➤
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.5 Removing and installing charge air temperature sender after charge air cooler G811 . . . . 115
2.6 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.3 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2 Removing and installing intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3 Removing and installing intake manifold (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.4 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.5 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5 Injectors/high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.3 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.4 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.5 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.6 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 130
5.7 Checking restrictor in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.9 Removing and installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.10 Removing and installing high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.2 Removing and installing fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
6.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
6.4 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 136
6.5 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.6 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 139
6.7 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 139
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.3 Removing and installing NOx senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.4 Removing and installing particulate sensor G784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
9.1 Exploded view - engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
9.2 Removing and installing engine/motor control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . 150
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Contents iii
Audi Q5 2017 ➤
1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.4 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Exploded view - emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Removing and installing emission control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.3 Removing and installing trap catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.4 Removing and installing exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3 SCR (selective catalytic reduction) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.1 Exploded view - reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.2 Exploded view - control unit for SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.3 Exploded view - delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.4 Exploded view - reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.5 Releasing pressure in SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.6 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.7 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.8 Removing and installing injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 171
3.9 Removing and installing control unit for reducing agent metering system J880 . . . . . . . . 171
3.10 Removing and installing pump for reducing agent V437 . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.11 Removing and installing pressure sender for reducing agent metering system G686 . . . . 174
3.12 Removing and installing connection for SCR supply line . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 182
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.3 Removing and installing exhaust gas recirculation control motor 2 V339 . . . . . . . . . . . . . . 188
5.4 Removing and installing exhaust gas recirculation temperature sensor G98 . . . . . . . . . . 189
6 Exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
6.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
6.2 Removing and installing exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
iv Contents
Audi Q5 2017 ➤
00 – Technical data
1 Identification
(ARL005971; Edition 08.2018)
All information can be found in ⇒ Servicing 6-cylinder TDI engine,
common rail; Rep. gr. 00 ; Identification .
1. Identification 1
Audi Q5 2017 ➤
2 Safety precautions
common rail; Rep. gr. 00 ; Safety precautions .
2 Rep. gr.00 - Technical data

Audi Q5 2017 ➤
3 Repair instructions
common rail; Rep. gr. 00 ; Repair instructions .
3. Repair instructions 3
Audi Q5 2017 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 4
⇒ “1.2 Separating engine and gearbox”, page 18
⇒ “1.3 Securing engine to engine and gearbox support”,
page 26
⇒ “1.4 Installing engine”, page 29
1.1 Removing engine

Special tools and workshop equipment required
♦ Hook - 10-222A/20-
♦ Removal lever - 80-200-
♦ Engine bung set - VAS 6122-
4 Rep. gr.10 - Removing and installing engine

Audi Q5 2017 ➤
♦ Scissor-type assembly platform - VAS 6131 B-
♦ Support set for Audi - VAS 6131/10-
♦ Adapter -VAS 6131/11-1- from support set, Audi A8 >2002 -

VAS 6131/11- (not illustrated)
♦ Adapter (2x) -VAS 6131/13-2- from support set, Audi Q7
>2005 - VAS 6131/13-
♦ Coolant collecting system - VAS 5014- or drip tray for work‐

shop hoist - VAS 6208-
1. Removing and installing engine 5

Audi Q5 2017 ➤
♦ Hose clip pliers - VAS 6362-
♦ Ball joint ejector - VAS 251 805-
♦ Wrench, 21 mm - T40263-

Audi Q5 2017 ➤
♦ Adapter - T40314-
♦ Ball joint puller (tool currently being developed)

♦ Stepladder (commercially available)
Procedure
Note
♦ The engine is removed from underneath together with the

gearbox and subframe (with lock carrier installed).
♦ Fit cable ties in the same locations when installing.
♦ Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 00 ; Repair instructions; Rules for
cleanliness .
♦ All bolts on running gear components with bonded rubber
bushes must be tightened with suspension in unladen position
(vehicle unladen) on vehicles with coil springs or in reference
position on vehicles with air suspension.
♦ Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension compo‐
nents with bonded rubber bushes must be brought into a
position corresponding to the normal position while driving
(unladen position/reference position). Otherwise, the bush
would be subject to torsion loading and its service life short‐
ened.
– Before starting work, determine unladen position ⇒ Running

gear, axles, steering; Rep. gr. 00 ; Repair notes; Lifting sus‐
pension to unladen position (vehicles with coil springs) or
determine reference position ⇒ Running gear, axles, steering;
Rep. gr. 00 ; Repair notes; Lifting suspension to unladen po‐
sition (vehicles with air suspension) .
– Bring front wheels into straight-ahead position.
Note
The electromechanical parking brake must be released before

disconnecting the battery, so that the propshaft can be turned
during removal.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .

Audi Q5 2017 ➤
WARNING
The cooling system is under pressure when the engine is hot.

Risk of scalding due to hot steam and hot coolant.
Danger of scalding skin and other parts of the body.
• Put on protective gloves.
• Put on safety goggles.
• Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
– Release fastener -arrow- and open filler cap -1- on coolant

expansion tank.
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front) .
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres .
– Remove wheel spoilers (left and right) and wheel housing liner
(front right) ⇒ General body repairs, exterior; Rep. gr. 66 ;
Wheel housing liners; Removing and installing wheel housing
liner (front) .
– Remove noise insulation panels ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– Remove propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
– Place collector tank from coolant collecting system -VAS

5014- or drip tray for workshop hoist - VAS 6208- underneath.
– Release hose clip -1- and drain off coolant.
– Lift retaining clip -2- and disconnect coolant hose from radiator
(bottom right).
– Release hose clip -1-, disconnect coolant hose from ATF cool‐
er and drain off coolant.
– Lift retaining clip -2- and disconnect coolant hose.

Audi Q5 2017 ➤
– Carefully pull engine cover panel off retaining pins one after
another -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
– Remove bolts -arrows- and detach air duct -1-.
– Release hose clips -arrows- and detach air pipe -1-.
– Unplug electrical connector -2- for air mass meter - G70- .

– Move fuel hoses -3- clear and press to one side.
– Lift off air cleaner housing -1- and detach.

Audi Q5 2017 ➤
– Disconnect fuel hoses -1, 2, 3- ⇒ Fuel supply system; Rep.

gr. 20 ; Plug-in connectors; Disconnecting plug-in connectors .
– Move coolant hoses clear and tie up to right side.
– Seal off open lines and connections with plugs (thoroughly
cleaned) from engine bung set - VAS 6122- .
– Move electrical connector -arrow- clear and unplug.
– Release fastener -arrow B- and open terminal 30 wiring junc‐

tion - TV2- -item 1- -arrow A-.
– Remove nut -2- and move B+ wire clear.
– Move wiring duct clear at top.
– Detach terminal 30 wiring junction - TV2- and move to one side
with wiring connected ⇒ Electrical system; Rep. gr. 97 ; Relay
carriers, fuse carriers, electronics boxes; Overview of fitting
locations - relay carriers, fuse carriers, electronics boxes .
– Release hose clip -arrow- and disconnect coolant hose from

coolant pipe (front).

Audi Q5 2017 ➤
– Loosen hose clip -arrow- and disconnect air hose from throttle
valve module - J338- .
– Lift retaining clip -2- and disconnect coolant hose (top left) from
bracket for air conditioner compressor.
– Unplug electrical connector -2-.

– Unscrew nuts -arrows-, detach and move clear control unit for
NOx sender - J583- -item 1-, and place it on engine.
– Release fastener -arrow- and disconnect vacuum hose -1-,

taking care not to damage it.

Audi Q5 2017 ➤
– Detach electrical connectors -2- from bracket, unplug and

move electrical wiring clear.
– Remove bolts -arrows- and detach engine control unit - J623-
-item 1-.
– Unplug electrical connector “K” -arrow-.

– Place engine control unit - J623- on engine and secure to pre‐
vent it from dropping.
– Detach electrical connector -3- from bracket, unplug and move

electrical wire clear.
– Loosen nut -arrow- a few turns, move electrical connector
-2- clear and unplug.
– Remove nut -1- and move earth wires clear.
– Remove nut -arrow- and move earth wires clear.

Audi Q5 2017 ➤
– Release hose clip -arrow- and detach air hose from air pipe.
– Unplug electrical connector -2- for electrohydraulic engine

mounting solenoid valve on both sides and move wiring clear.
– If you intend to secure engine to engine and gearbox support
in a later step, unscrew bolt -1- for support mounting.
Caution
Danger of damage to the joints of the upper links.

♦ The weight of the wheel bearing housings must be sup‐
ported.
– Tie up wheel bearing housing on both sides using tensioning

strap - T10038- and hook - 10-222A/20- , as shown.

Audi Q5 2017 ➤
– To protect thread, unscrew nut -arrow- on joint pin of track rod

ball joint until nut is flush with thread of joint pin.
WARNING
Risk of injury if parts are allowed to drop out.

♦ The track rod ball joint will release suddenly from the
wheel bearing housing when pressed out. Use engine and
gearbox jack - VAS 6931- or similar to provide support.
Caution
Risk of damage to ball joint puller.

♦ Make sure the two lever arms of the puller are parallel
when maximum force is exerted.
– Press track rod ball joint off wheel bearing housing using ball
joint ejector - VAS 251 805- ; counterhold with a 6 mm hexagon
socket.
– To protect thread, unscrew nut -arrow- on joint pin of guide link

until nut is flush with thread of joint pin. Counterhold joint pin
if necessary.
WARNING
Risk of injury if parts are allowed to drop out.

♦ The swivel joint will release suddenly from the wheel bear‐
ing housing when pressed out. Use engine and gearbox
jack - VAS 6931- or similar to provide support.
– Press joint pin of guide link out of tapered seat using ball joint
puller -1- (tool in development), taking care not to damage
boot.
– Unscrew nut and move guide link clear at wheel bearing hous‐
ing; if necessary, counterhold at joint pin with a TX 40 socket
wrench.
– Clean steering rack and subframe in area of rubber boot.

– Release spring-type clip -3- using hose clip pliers - VAS 6362- .
– Detach hose clip -1- and pull boot -2- outwards off steering
rack.

Audi Q5 2017 ➤
– On appropriate versions: Remove nut -2- and move coupling

rod for vehicle level sender clear.
– Detach bolted connections -1, 3- for track control link.
– Swivel track control link towards front.
Note
To remove bolt -1-, turn steering to full left/right lock.
– Repeat procedure on opposite side of vehicle.
– On both sides, unscrew nut -3- and pull out bolt -1- for coupling
rod -2-.
– Unbolt drive shaft (left and right) from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Remove bolt -arrow- for subframe shield on both sides.

– Detach intermediate steering shaft from steering rack and
move clear by telescoping together ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and instal‐
ling intermediate steering shaft .
– Remove poly V-belt from air conditioner compressor pulley ⇒
Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ;
Cylinder block (pulley end); Removing and installing poly V-
belt .
– Remove air conditioner compressor from bracket ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor; De‐
taching and attaching air conditioner compressor at bracket .
Caution
Risk of irreparable damage to gearbox control unit (mecha‐

tronic unit) because of electrostatic discharge.
♦ Before unplugging or plugging in electrical connector, me‐
chanic must discharge static electricity. To do so, touch
vehicle earth, heater radiator, or lifting platform, with your
hand.
♦ Do NOT touch connector contacts in gearbox connector
with your hands.
– Turn retainer catch anti-clockwise -arrow- and unplug electri‐

cal connector -1- at gearbox.
– Remove underbody trim (front left and centre left) ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underbody trim; Removing
and installing underbody trim .

Audi Q5 2017 ➤
– Unplug electrical connectors -1, 4- and move them clear.

– Remove nuts -2, 3-.
– Detach control unit for NOx sender 2 - J881- and particulate
sensor - G784- from bracket, move them clear and tie up to
front exhaust pipe.
– Unplug electrical connector -1- for exhaust flap control unit -

J883- .

– Release pressure in SCR system ⇒ Servicing 4-cylinder TDI
engine, common rail; Rep. gr. 26 ; SCR (selective catalytic
reduction) system; Releasing pressure in SCR system .
– Press release tabs on both sides and disconnect SCR supply
line -2-.
– Disconnect supply line with release catches ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 26 ; SCR (selective
catalytic reduction) system; Exploded view - reducing agent
supply line .
– Remove bolts -arrows- and move manual release cable -1- for
parking lock clear.
Note
If separating the engine from the gearbox for subsequent work,

unscrew the bolted connection securing the drive plate to the fly‐
wheel/torque converter ⇒ page 20 .

Audi Q5 2017 ➤
Set up the scissor-type assembly platform as follows:

– Set up scissor-type assembly platform - VAS 6131 B- with
support set for Audi - VAS 6131/10- , adapter -VAS 6131/11-1-
and adapters -VAS 6131/13-2- as follows:
Platform Parts from -VAS 6131/10- , adapter -VAS
coordinates 6131/11-1- and adapter -VAS 6131/13-2-
C4 /10-1 /10-4 /10-5 /10-11
E4 /10-1 /10-4 /10-5 /10-11
E10 /10-1 /10-2 /10-5 /13-2
B15 /10-1 /10-2 /10-5 /11-1
F15 /10-1 /10-2 /10-5 /11-1
F17 /10-1 /10-2 /10-5 /13-2
– Initially hand-tighten the support elements on the scissor-type
assembly platform.
– Position scissor-type assembly platform - VAS 6131 B- hori‐
zontally.
• Take note of spirit level (bubble gauge).
– Position scissor-type assembly platform - VAS 6131 B- below
engine/gearbox assembly.
– Position support elements from -VAS 6131/10- at both sides

of engine, as shown.
– Make sure that threaded spindles are screwed in completely.
– Support subframe as shown using support elements from -

VAS 6131/10- and adapter -VAS 6131/13-2- .
Note
The support elements only support the subframe; the base plate
is not secured to the scissor-type assembly platform.

Audi Q5 2017 ➤
– Position support elements from -VAS 6131/10- and adapters

-VAS 6131/11-1- at tunnel cross member, as shown.
– Position support elements from -VAS 6131/10- and adapter -

VAS 6131/13-2- under front exhaust pipe, as shown.
– Turn remaining spindles for support elements upwards until all
locating lugs make contact with mounting points.
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform - VAS 6131 B- .
– Fix position of subframe ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Fixing position of subframe .
– Remove bolts -arrows- on tunnel cross member.
Caution
Danger of damage to hoses, pipes and wiring connections and

to engine compartment.
♦ Check that all hoses and wiring connections between en‐
gine, gearbox, subframe and body have been detached.
♦ Carefully guide out engine/gearbox assembly with sub‐
frame from engine compartment when lowering.
♦ Guide drive shafts carefully past gearbox.
– Lower scissor-type assembly platform - VAS 6131 B- with en‐

gine/gearbox assembly and pull out from underneath vehicle.
– Tie up drive shafts.
1.2 Separating engine and gearbox


Audi Q5 2017 ➤
♦ Lambda probe open ring spanner set - 3337-
♦ Support set for Audi - VAS 6131/10-

Procedure
• Engine/gearbox assembly removed and secured to scissor-
type assembly platform - VAS 6131 B-

Audi Q5 2017 ➤
– Remove bolt -arrow- and move bracket -1- clear with electrical
wiring harness.
– Move SCR supply line -1- clear at subframe.
WARNING
Risk of accident caused by weight of subframe.

♦ A second mechanic is required for removal of the sub‐
frame.
– On both sides, remove bolt -2- and detach subframe to one

side (remove support elements).
Note
The illustration shows the installation position with the engine in‐
stalled.
– Remove bolts -arrows- and push ATF cooler slightly to one

side with hoses -1, 2, 4- attached.
– Detach bottom cover -1- from gearbox -arrow-.

Audi Q5 2017 ➤
Caution
Irreparable damage can be caused if the camshaft timing chain

slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– To slacken bolts for flywheel, counterhold crankshaft at vibra‐

tion damper using wrench, 21 mm - T40263- and adapter -
T40314- .
– Remove 6 bolts -arrow- for flywheel from drive plate -1-. Turn
crankshaft 60° in direction of engine rotation each time.
– Unscrew bolt -2- and loosen retaining clip.

– Detach injector for reducing agent - N474- -item 1- and press
to one side.
– Unplug electrical connectors -1, 2, 3- and move electrical wir‐

ing clear.

Audi Q5 2017 ➤
– Remove exhaust gas temperature sender 4 - G648- -item 1-.
– Remove bolt -arrow-.

– Move bracket -2- clear with pressure differential sender -
G505- .
– Remove nuts -1- at bracket for front exhaust pipe.
– Remove bolt -3- on retainer.
WARNING
Please note the following warnings when working on all parts

of the exhaust system:
♦ Wear gloves (e.g. rubber, not textile) and safety goggles
to avoid contact with eyes and skin - risk of injury.
– Open screw-type clip -1- and place it on intake funnel of emis‐

sion control module -2-.
– Detach emission control module with front exhaust pipe.

Audi Q5 2017 ➤

– Release hose clip -arrow- and detach coolant hose.
– Remove bolts -arrows-.

– Release screw-type clip -1- and detach exhaust gas recircu‐
lation pipe -2-.

– Remove bolt -2- and move pressure differential sender 2 -
G524- clear.
– Unplug electrical connectors and move electrical wiring clear:

1- Continued coolant circulation pump - V51-
2- Exhaust gas recirculation control motor 2 - V339-

Audi Q5 2017 ➤
– Remove bolts -arrows- and move coolant pipes (rear) to one

side.
– Remove bolts -arrows- and move coolant pipe (right-side) to

one side.
– Set up scissor-type assembly platform - VAS 6131 B- with

support set for Audi - VAS 6131/10- , adapter -VAS 6131/11-2-
and adapter -VAS 6131/12-2- as follows:
Note
The other support elements remain unchanged.
Platform Parts of support set for Audi - VAS 6131/10- ,

coordinates adapter -VAS 6131/11-2- and adapter -
VAS 6131/12-2-
C7 /10-1 /12-2 /10-5 /10-12
E7 /10-1 /10-4 /10-5 /10-12
C10 /10-1 /10-4 /10-5 /10-12
F10 /10-1 /10-4 /10-5 /11-1

Audi Q5 2017 ➤

VAS 6131/12-2- at both sides of engine, as shown.
– Position support elements from -VAS 6131/10- at left of gear‐

box.

VAS 6131/11-1- at right of gearbox.
– Turn spindles (left and right) upwards until all locating lugs
make contact with mounting points.
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform - VAS 6131 B- .

Audi Q5 2017 ➤
– Remove bolts -2 ... 11- securing gearbox to engine.

– Loosen bolt -1- for starter.
– Loosen clamping bolts on sides of scissor-type assembly plat‐

form - VAS 6131 B- , pull rear section of platform (together with
gearbox) slightly towards rear -arrow-, and at the same time
remove bolt for starter completely.
– Pull gearbox towards rear as far as it will go; lower it slightly
with front spindles if necessary.
1.3 Securing engine to engine and gearbox

support
♦ Lifting tackle - 3033-
♦ Engine and gearbox support - VAS 6095A-

Audi Q5 2017 ➤
♦ Universal mounting - VAS 6095/1- and bracket for V6 TDI en‐

gine - VAS 6095/1-14-
♦ Workshop hoist - VAS 6100-
♦ Lift arm extension/workshop hoist - VAS 6101-
Procedure
• Engine/gearbox assembly removed and secured to scissor-
type assembly platform - VAS 6131 B- (with engine detached
from gearbox)
– Attach lift arm extension - VAS 6101- to workshop hoist -
VAS 6100- .
– Attach lifting tackle - 3033- to engine lifting eyes and workshop
hoist as shown in illustration.
– Take up weight of engine with workshop hoist, but do not lift.

Audi Q5 2017 ➤
– Remove bolts -arrows- and detach engine support (left-side)

-1-.

– Detach coolant pipe (left-side) -1- and move clear to side.
– Remove bolt -2- for earth wire.

– Remove bolts -arrows- and detach engine support -1-.
– Tie up starter on engine.
– Using universal mounting - VAS 6095/1- and bracket for V6

TDI engine - VAS 6095/1-14- , secure engine to engine and
gearbox support - VAS 6095A- (40 Nm), as shown.

Audi Q5 2017 ➤
1.4 Installing engine

♦ Ring spanner insert AF 16 - V.A.G 1332/14-
♦ Assembly aid - T40169-
♦ Transportation lock - T40170-
♦ All special tools listed under "Removing engine"

♦ Cleaning solution - D 009 401 04-

Audi Q5 2017 ➤
Procedure
Note
♦ After removing, renew bolts tightened with specified tightening

angle.
♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings after removal.
♦ Do not remove plugs or protective caps until you are ready to
fit the relevant line.
♦ Hose connections and air pipes/hoses must be free of oil and
grease prior to fitting.
♦ Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
♦ Re-install all cable ties in the same locations when installing.
♦ Bonded rubber bushes can only be turned to a limited extent.
Therefore, only tighten the bolted connections for the suspen‐
sion once the vehicle is in the unladen position or the reference
position.
– Install coolant pipe (left-side) ⇒ page 84 .

– Install engine supports and engine mountings ⇒ page 36 .
• Engine with subframe positioned on scissor-type assembly
platform - VAS 6131 B-
– Before installing gearbox, remove residue from threaded holes
for engine/gearbox bolts in cylinder block using a thread tap.
– The following preparations are required before joining engine
and gearbox:
– Clean contact surface -1- on timing chain cover (bottom) and
on sealing element -2- with cleaning fluid - D 009 401 04- .
– Bond sealing element to timing chain cover (bottom).

Audi Q5 2017 ➤
– Insert transportation lock - T40170- into gearbox housing from

below and clamp onto flange shaft -1-.
– Check whether dowel sleeves -A- for centring engine and

gearbox are fitted in cylinder block.
– Check whether aluminium bolts securing engine to gearbox
can be reused; if so, apply marking ⇒ 8-speed automatic
gearbox; Rep. gr. 37 ; Removing and installing gearbox;
Tightening torques for gearbox .
• When joining the engine and the gearbox, make sure that the
end seal is seated correctly.
– Bring gearbox into position on engine and at the same time
screw in bolt -1- for starter.
– Screw in bolts -2 … 11- by hand until they make contact.
– Tighten bolts -1 ... 11- ⇒ 8-speed automatic gearbox; Rep. gr.
37 ; Removing and installing gearbox; Tightening torques for
gearbox .
– Remove transport lock - T40170- .
• The following step is necessary to ensure that the torque con‐

verter is straight and that it makes even contact with the drive
plate.
– Use assembly lever -1- to press torque converter -2- slightly
against drive plate -3- -arrow-.

Audi Q5 2017 ➤
– Bolt torque converter onto drive plate as follows:

– Turn torque converter until hole is visible next to notch
-arrow- in recess in bottom of gearbox housing.
Note
There is only one notch on the circumference; turn the torque

converter accordingly.
– Tighten bolt -arrow- for torque converter -1- accessible in this

position ⇒ 8-speed automatic gearbox; Rep. gr. 32 ; Torque
converter; Exploded view - torque converter .
Note
Use ring spanner insert AF 16 - V.A.G 1332/14- to tighten bolts.

Audi Q5 2017 ➤
Caution
Irreparable damage can be caused if the camshaft timing chain

slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– Then tighten remaining 5 bolts to specified torque (turn crank‐

shaft by 60° each time -arrow-) ⇒ 8-speed automatic gearbox;
Rep. gr. 32 ; Torque converter; Exploded view - torque con‐
verter .
– Install coolant pipes (rear) and coolant pipe (right-side)
⇒ page 84 .
– Install emission control module ⇒ page 159 .
– Install front exhaust pipe ⇒ page 153 .
– Install pressure differential sender - G505- ⇒ page 144 .
– Install pressure differential sender 2 - G524- and exhaust gas
recirculation pipe ⇒ page 184 .
– Install exhaust gas temperature sender 4 - G648- ⇒ Servicing
6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
temperature control; Exploded view - exhaust gas temperature
control .
– Connect SCR supply line ⇒ Servicing 6-cylinder TDI engine,
common rail; Rep. gr. 26 ; SCR (selective catalytic reduction)
system; Exploded view - reducing agent supply line .
– Install ATF cooler ⇒ 8-speed automatic gearbox; Rep. gr. 37 ;
ATF circuit; Removing and installing ATF cooler .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Remove locating pins ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Fixing position of subframe .
– Install tunnel cross member ⇒ 8-speed automatic gearbox;
Rep. gr. 37 ; Assembly mountings; Exploded view - assembly
mountings .
– Install manual release cable for parking lock ⇒ 8-speed au‐
tomatic gearbox; Rep. gr. 37 ; Selector mechanism .
– Install bracket for NOx sender 2 - G687- / particulate sensor -
G784- ⇒ page 144 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Exploded view - air
conditioner compressor drive unit .
– Install poly V-belt ⇒ Servicing 6-cylinder TDI engine, common
rail; Rep. gr. 13 ; Cylinder block (pulley end); Removing and
installing poly V-belt .
– Install intermediate steering shaft ⇒ Running gear, axles,
– Install subframe shield ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Exploded view - subframe .
– Secure drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Exploded view - drive shaft .

Audi Q5 2017 ➤
– Install coupling rod ⇒ Running gear, axles, steering; Rep. gr.

40 ; Subframe; Exploded view - subframe .
– Install lower suspension links ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Lower suspension links, swivel joint; Exploded
view - lower suspension links, swivel joint .
– Install track rod ball joint ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Steering rack; Exploded view - steering rack .
– Install boot for steering rack ⇒ Running gear, axles, steering;
Rep. gr. 48 ; Steering rack; Removing and installing boot .
– Install engine control unit - J623- ⇒ page 150 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Connect fuel hoses ⇒ Fuel supply system, diesel engines;
Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-in con‐
nectors .
– Observe steps required after re-connecting battery ⇒ Electri‐
cal system; Rep. gr. 27 ; Battery; Disconnecting and connect‐
ing battery .
Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– Install air cleaner housing ⇒ page 126 .

– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
830 .
– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
– Install wheel spoiler and wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
– Install lock carrier cover ⇒ General body repairs, exterior;
– If engine was renewed, perform adaptions listed in Guided
Function “0001 - Adapt learnt values - after component re‐
placement” ⇒ Vehicle diagnostic tester.
Caution
Risk of damage to components.

♦ Only perform additional adaptions for those components
which were renewed after removal.
– Bleed fuel system ⇒ Servicing 6-cylinder TDI engine, common

rail; Rep. gr. 23 ; Injection system; Filling and bleeding fuel
system .
– Install engine cover panel ⇒ Servicing 6-cylinder TDI engine,
common rail; Rep. gr. 10 ; Engine cover panel; Removing and
installing engine cover panel .

Audi Q5 2017 ➤
– Connect coolant hoses with plug-in connector ⇒ page 99 .
Note
Do not reuse coolant.
– Fill up with coolant ⇒ page 71 .

– Check ATF level ⇒ 8-speed automatic gearbox; Rep. gr. 37 ;
ATF; Checking ATF level .
– Install underbody trim ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody trim; Exploded view - underbody trim .
– Install noise insulation panels ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques: ± 15 %.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ ⇒ “2.1 Exploded view - assembly mountings”, page 36
♦ Engine to gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Tightening torques for gearbox

Audi Q5 2017 ➤
2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 36
⇒ “2.2 Supporting engine in installation position”, page 38
⇒ “2.3 Removing and installing engine mountings”, page 39
⇒ “2.4 Removing and installing gearbox mounting”, page 42
2.1 Exploded view - assembly mountings

Engine mounting
1 - Subframe
2 - Bolt
❑ 20 Nm
3 - Bolt
❑ 10 Nm
4 - Support mounting
❑ Removing and installing
⇒ page 41
❑ Installation position
⇒ page 37
5 - Bolt
❑ 55 Nm
6 - Engine support
⇒ page 49
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
10 - Engine mounting
❑ with
♦ Left electrohydraulic en‐
gine mounting solenoid
valve - N144-
♦ Right electrohydraulic en‐
gine mounting solenoid
valve - N145-
⇒ page 39
11 - Bolt
❑ Renew after removing
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm

Audi Q5 2017 ➤
Installation position of support mounting

♦ Projection -2- on engine support must engage in recess -1- on
support mounting.
Gearbox mounting
1 - Bolt
❑ Tightening torques ⇒ 8-
speed automatic gear‐
box; Rep. gr. 37 ; As‐
sembly mountings; Ex‐
ploded view - assembly
mountings
2 - Tunnel cross member
⇒ 8-speed automatic
gearbox; Rep. gr. 37 ;
Assembly mountings;
Exploded view - assem‐
bly mountings
3 - Nut
❑ Only remove if detach‐
ing gearbox mounting
from gearbox support
mountings
4 - Gearbox support
⇒ page 42
5 - Bolt
mountings
6 - Gearbox mounting
❑ Removing and installing ⇒ page 42
7 - Stop plate
❑ For gearbox mounting
8 - Bolt
❑ Only remove if detaching gearbox mounting from gearbox support
❑ Tightening torques ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view -
assembly mountings
2. Assembly mountings 37
Audi Q5 2017 ➤
9 - Nut
❑ Only remove if detaching gearbox mounting from gearbox support
❑ Tightening torques ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view -
assembly mountings
2.2 Supporting engine in installation posi‐

tion
♦ Support bracket - 10-222A-
Procedure
WARNING
Risk of accident when weight of engine is shifted.

♦ In order to support the engine as described below, the
gearbox and tunnel cross members must be installed.
– Remove engine cover panel ⇒ Servicing 6-cylinder TDI en‐

gine, common rail; Rep. gr. 10 ; Engine cover panel; Remov‐
ing and installing engine cover panel .

Audi Q5 2017 ➤
– Set up support bracket - 10-222A- on longitudinal members

(left and right), as shown.
– Engage spindles -10-222A/11- at engine lifting eyes (left and
right).
– Tighten spindles slightly to take up weight of engine, but do
not lift.
Attaching
Assembly is performed in reverse sequence; note the following:
Note
Secure all hose connections with correct type of hose clips (as

Tightening torques
♦ ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ;
Turbocharger; Exploded view - turbocharger
Charge air system; Exploded view - hose connections for
charge air system
♦ ⇒ Fig. ““Bracket with pressure differential sender -G505- -
tightening torque”“ , page 144
2.3 Removing and installing engine mount‐

ings
⇒ “2.3.1 Removing and installing engine mounting (left-side)”,
page 39
⇒ “2.3.2 Removing and installing engine mounting (right-side)”,
page 41
⇒ “2.3.3 Removing and installing engine mounting - support
mounting (left-side)”, page 41
⇒ “2.3.4 Removing and installing engine mounting - support
mounting (right-side)”, page 42
2.3.1 Removing and installing engine mount‐

ing (left-side)
Removing
– Support engine in installation position ⇒ page 38 and take up
weight with spindle - 10-222A/11- until load on engine mount‐
ing is relieved.
Caution
Risk of damage to drive shafts.

♦ When lifting the engine, the drive shafts must not make
contact with the suspension struts.
– Remove support mounting (left-side) ⇒ page 41 .
Audi Q5 2017 ➤
– Remove front longitudinal member (bottom left) ⇒ General

body repairs, exterior; Rep. gr. 50 ; Lock carrier; Removing
and installing longitudinal member (bottom) .
belt .
– Remove air conditioner compressor from bracket and tie up to
left side ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor; Detaching and attaching air conditioner
compressor at bracket .
– Unplug electrical connector -arrow- for left electrohydraulic
engine mounting solenoid valve - N144- .

– Raise engine slightly with spindle - 10-222A/11- and move en‐
gine mounting -1- to one side.

Audi Q5 2017 ➤
– Unscrew bolts -arrows- and remove engine support.

– Detach engine mounting.
Installing
Installation is carried out in reverse order; note the following:
Note
After removing, renew bolts tightened with specified tightening

angle.

Tightening torques
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Exploded view - air conditioner compressor drive unit
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier;
Exploded view - lock carrier

ing (right-side)
Removing
– Lower subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Lowering subframe .
– Remove bolts -arrows- and detach engine mounting (right-
side) -1-.
Installing
Note

angle.
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.

40 ; Subframe; Lowering subframe .
Tightening torques

ing - support mounting (left-side)
Removing
– Remove noise insulation panels ⇒ General body repairs, ex‐
noise insulation .
Audi Q5 2017 ➤
– Remove bolts -arrows- and detach support mounting (left-

side) -2-.
Installing
Note

angle.
• Installation position ⇒ page 37 .

Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation

ing - support mounting (right-side)
Removing
– Remove support mounting (left-side) ⇒ page 41 .
– Unscrew bolts -arrows- for support mounting (right-side) -1-
and detach support mounting towards left side.
Installing
• Installation position ⇒ page 37 .
Tightening torques
2.4 Removing and installing gearbox

mounting
Removing gearbox support with gearbox mounting
– Remove tunnel cross member ⇒ 8-speed automatic gearbox;
Rep. gr. 37 ; Assembly mountings; Exploded view - assembly
mountings .
– Remove bolts -arrows- and detach gearbox support and gear‐
box mounting from gearbox.

Audi Q5 2017 ➤
Removing and installing gearbox mounting

– Unscrew bolts -1- and detach stop -2- for gearbox mounting.
– Remove nut -5- and detach gearbox mounting -3- from gear‐
box support -4-.
Installing
– Tighten nut -5- hand-tight initially.
– Tighten bolts -1- and then nut -5-.
Tightening torques
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mount‐
ings; Exploded view - assembly mountings
Audi Q5 2017 ➤
3 Engine cover panel

All procedures are described in ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 10 ; Engine cover panel; Removing
and installing engine cover panel .

Audi Q5 2017 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 45
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 45
⇒ “1.3 Removing and installing poly V-belt”, page 45
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 45
⇒ “1.5 Removing and installing vibration damper”, page 46
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 49
⇒ “1.7 Removing and installing engine support”, page 49
⇒ “1.8 Renewing crankshaft oil seal (pulley end)”, page 49
⇒ “1.9 Removing and installing sealing flange (pulley end)”, page
50
1.1 Exploded view - cylinder block (pulley

end)
All components are described in ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Exploded view - cylinder block (pulley end) .
1.2 Exploded view - sealing flange (pulley

end)
Exploded view - sealing flange (pulley end) .
1.3 Removing and installing poly V-belt

Removing
– Remove noise insulation (front) ⇒ General body repairs, ex‐
noise insulation .
– Remove bolt -1- on both sides and press coolant pipe towards
rear at lock carrier.
All other procedures are described in ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing poly V-belt .
Tightening torques
♦ ⇒ Fig. ““Coolant pipe at lock carrier - tightening torques”“ ,
page 85
1.4 Removing and installing tensioner for

poly V-belt
Removing and installing tensioner for poly V-belt .
1. Cylinder block (pulley end) 45

Audi Q5 2017 ➤
1.5 Removing and installing vibration damp‐

er
Removing
– Remove lock carrier cover, air intake grille (left and right) and
closure plate at bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63 ; Bumper (front) .
noise insulation .
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Release hose clip -arrow- and detach air hose from air pipe.
– Unfasten hose clip -1- and detach air pipe (left-side) from
charge air cooler.
46 Rep. gr.13 - Crankshaft group

Audi Q5 2017 ➤

– Lift retaining clip -2-, disconnect coolant hose (bottom right)
from radiator and drain off coolant.
– Lift retaining clip -arrow-, disconnect coolant hose (bottom left)

– Release fasteners -arrows- on both sides and pull retaining

pins -1- for radiator out upwards.

Audi Q5 2017 ➤
– Use side-cutting pliers to cut open air duct -1- in area of open‐
ing for refrigerant lines -arrows-.
– Release catches -arrow- and detach air ducts -1, 3-.

– Secure radiator (top) again with retaining pins.
– Release fasteners -arrows- and detach air duct -1-.
– Remove bolt -2- on both sides and press radiator bracket -1-
with radiator towards front -arrow-.
Removing and installing vibration damper .
Installing
Additional work:
– Install lock carrier cover, air intake grille (left and right) and
Tightening torques
♦ ⇒ “4.1 Exploded view - radiator/radiator fans”, page 98
♦ ⇒ “3.1 Exploded view - coolant pipes”, page 84

Audi Q5 2017 ➤
1.6 Removing and installing bracket for an‐

cillaries
Removing bracket for air conditioner compressor
Removing and installing bracket for ancillaries .
Tightening torques
1.7 Removing and installing engine support

Removing
– Remove engine mounting ⇒ page 39 .
Engine support (right-side):
– Remove drive shaft cover (right-side) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Remove bolts -arrows- and press coolant pipe (right-side)
slightly to one side.
– Remove bolt -2- for earth wire.

– Remove bolts -arrows- and detach engine support -1-.
Installing
– Install engine mountings ⇒ page 39 .
Tightening torques
Coolant pipes; Exploded view - coolant pipes
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
1.8 Renewing crankshaft oil seal (pulley

end)
Renewing crankshaft oil seal (pulley end) .

Audi Q5 2017 ➤
1.9 Removing and installing sealing flange

(pulley end)
Removing
– Remove intake manifold flap motor - V157- ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 23 ; Intake mani‐
fold; Removing and installing intake manifold flap motor -
V157- .
– Remove tensioner for poly V-belt ⇒ Servicing 6-cylinder TDI
– Remove vibration damper ⇒ page 46 .
– Remove coolant pipe (front) ⇒ page 87 .
Removing and installing sealing flange (pulley end) .
Installing
– Install coolant pipe (front) ⇒ page 87 .
– Install vibration damper ⇒ Servicing 6-cylinder TDI engine,
common rail; Rep. gr. 13 ; Cylinder block (pulley end); Re‐
moving and installing vibration damper .
– Install tensioner for poly V-belt ⇒ Servicing 6-cylinder TDI en‐
– Install intake manifold flap motor - V157- ⇒ Servicing 6-cylin‐
der TDI engine, common rail; Rep. gr. 23 ; Intake manifold;
Removing and installing intake manifold flap motor - V157- .

Audi Q5 2017 ➤
2 Cylinder block (gearbox end)

All procedures and components are described in ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block
(gearbox end) .
2. Cylinder block (gearbox end) 51

Audi Q5 2017 ➤
3 Crankshaft
cylinder TDI engine, common rail; Rep. gr. 13 ; Crankshaft .

Audi Q5 2017 ➤
4 Balance shaft
cylinder TDI engine, common rail; Rep. gr. 13 ; Balance shaft .
4. Balance shaft 53
Audi Q5 2017 ➤
5 Pistons and conrods

cylinder TDI engine, common rail; Rep. gr. 13 ; Pistons and
conrods .

Audi Q5 2017 ➤
15 – Cylinder head, valve gear

1 Timing chain cover
⇒ “1.1 Exploded view - timing chain cover”, page 55
⇒ “1.2 Removing and installing timing chain cover”, page 55
1.1 Exploded view - timing chain cover

gine, common rail; Rep. gr. 15 ; Timing chain cover; Exploded
view - timing chain cover .
1.2 Removing and installing timing chain

cover
⇒ “1.2.1 Removing and installing timing chain cover (top left)”,
page 55
⇒ “1.2.2 Removing and installing timing chain cover (top right)”,
page 55
⇒ “1.2.3 Removing and installing timing chain cover (bottom)”,
page 55
1.2.1 Removing and installing timing chain

cover (top left)
gine, common rail; Rep. gr. 15 ; Timing chain cover; Removing
and installing timing chain cover .

cover (top right)
Removing
– Remove coolant pipe (bottom front) for turbocharger ⇒ 6-cyl‐
inder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 19 ;
Coolant pipes; Removing and installing coolant pipes .

cover (bottom)
1. Timing chain cover 55

Audi Q5 2017 ➤
2 Chain drive
cylinder TDI engine, common rail; Rep. gr. 15 ; Chain drive .
56 Rep. gr.15 - Cylinder head, valve gear

Audi Q5 2017 ➤
3 Cylinder head
⇒ “3.1 Exploded view - cylinder head”, page 57
⇒ “3.2 Exploded view - cylinder head cover”, page 57
⇒ “3.3 Removing and installing cylinder head”, page 57
⇒ “3.4 Removing and installing cylinder head cover”, page 57
⇒ “3.5 Removing and installing seals for injectors”, page 58
⇒ “3.6 Checking compression”, page 58
3.1 Exploded view - cylinder head

gine, common rail; Rep. gr. 15 ; Cylinder head; Exploded view -
cylinder head .
3.2 Exploded view - cylinder head cover

gine, common rail; Rep. gr. 15 ; Cylinder head; Exploded view -
cylinder head cover .
3.3 Removing and installing cylinder head

gine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
installing cylinder head .
3.4 Removing and installing cylinder head

cover
⇒ “3.4.1 Removing and installing cylinder head cover - bank 1
(right-side)”, page 57
⇒ “3.4.2 Removing and installing cylinder head cover - bank 2
(left-side)”, page 58
3.4.1 Removing and installing cylinder head

cover - bank 1 (right-side)
Removing
– Remove air cleaner housing ⇒ page 126 .
G505- .
All further procedures are described in ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
Installing
Additional work:
Tightening torques
3. Cylinder head 57
Audi Q5 2017 ➤
3.4.2 Removing and installing cylinder head

cover - bank 2 (left-side)
Removing
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
engine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
Installing
Additional work:
ing battery .
3.5 Removing and installing seals for injec‐

tors
gine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
installing seals for injectors .
3.6 Checking compression

gine, common rail; Rep. gr. 15 ; Cylinder head; Checking com‐
pression .

Audi Q5 2017 ➤
4 Valve gear
⇒ “4.1 Exploded view - valve gear”, page 59
⇒ “4.2 Removing and installing cam actuators”, page 59
⇒ “4.3 Measuring axial clearance of camshaft”, page 59
⇒ “4.4 Measuring radial clearance of camshaft”, page 59
⇒ “4.5 Removing and installing camshaft”, page 59
⇒ “4.6 Removing and installing valve stem oil seals”, page 59
4.1 Exploded view - valve gear

gine, common rail; Rep. gr. 15 ; Valve gear; Exploded view - valve
gear .
4.2 Removing and installing cam actuators

Removing
– Cylinder bank 1 (right-side): Remove air cleaner housing
⇒ page 126 .
– Cylinder bank 2 (left-side): Detach engine control unit - J623-
from bracket and move it to one side ⇒ page 150 .
engine, common rail; Rep. gr. 15 ; Valve gear; Removing and
installing cam actuators .
Installing
Additional work:
Tightening torques
♦ ⇒ “9.1 Exploded view - engine control unit”, page 149
4.3 Measuring axial clearance of camshaft

gine, common rail; Rep. gr. 15 ; Valve gear; Measuring axial
clearance of camshaft .
4.4 Measuring radial clearance of camshaft

gine, common rail; Rep. gr. 15 ; Valve gear; Measuring radial
clearance of camshaft .
4.5 Removing and installing camshaft

gine, common rail; Rep. gr. 15 ; Valve gear; Removing and
installing camshaft .
4.6 Removing and installing valve stem oil

seals
gine, common rail; Rep. gr. 15 ; Valve gear; Removing and
installing valve stem oil seals .
4. Valve gear 59
Audi Q5 2017 ➤
5 Inlet and exhaust valves

gine, common rail; Rep. gr. 15 ; Inlet and exhaust valves .

Audi Q5 2017 ➤
17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 61
⇒ “1.2 Engine oil”, page 61
⇒ “1.3 Removing and installing sump (bottom section)”,
page 61
⇒ “1.4 Removing and installing sump (top section)”, page 61
⇒ “1.5 Removing and installing oil pump”, page 62
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 62
1.1 Exploded view - sump/oil pump

gine, common rail; Rep. gr. 17 ; Sump/oil pump; Exploded view
- sump/oil pump .
1.2 Engine oil

♦ Refer to ⇒ Maintenance ; Booklet 830 for instructions on
draining and filling up engine oil, checking oil level, removing
and installing oil filter element.
1.3 Removing and installing sump (bottom

section)
gine, common rail; Rep. gr. 17 ; Sump/oil pump; Removing and
installing sump (bottom section) .
1.4 Removing and installing sump (top sec‐

tion)
Removing
– Remove bolt -2- and disconnect vacuum hose -1-.
1. Sump/oil pump 61
Audi Q5 2017 ➤
– Remove bolts -1, 3- and pull out guide tube -2- for oil dipstick.
engine, common rail; Rep. gr. 17 ; Sump/oil pump; Removing and
installing sump (top section) .
Tightening torques
Cylinder block (pulley end); Exploded view - cylinder block
(pulley end)
1.5 Removing and installing oil pump

installing oil pump .
1.6 Removing and installing oil level and oil

temperature sender - G266-
installing oil level and oil temperature sender - G266- .
62 Rep. gr.17 - Lubrication

Audi Q5 2017 ➤
2 Engine oil cooler

cylinder TDI engine, common rail; Rep. gr. 17 ; Engine oil cooler .
2. Engine oil cooler 63

Audi Q5 2017 ➤
3 Crankcase breather
cylinder TDI engine, common rail (EA 897 Gen II); Rep. gr. 17 ;
Crankcase breather .

Audi Q5 2017 ➤
4 Oil filter/oil pressure switches

⇒ “4.1 Exploded view - oil filter”, page 65
⇒ “4.2 Exploded view - oil pressure switches/oil pressure control”,
page 65
⇒ “4.3 Removing and installing oil filter housing”, page 65
⇒ “4.4 Removing and installing oil pressure switch F22 ”,
page 66
⇒ “4.5 Removing and installing oil temperature sender G8 ”, page
66
⇒ “4.6 Removing and installing oil pressure sender G10 ”,
page 66
⇒ “4.7 Checking oil pressure”, page 66
⇒ “4.8 Removing and installing valve for oil pressure control N428
”, page 66
⇒ “4.9 Removing and installing oil temperature sender 2 G664 ”,
page 67
4.1 Exploded view - oil filter

gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches;
Exploded view - oil filter .
4.2 Exploded view - oil pressure switches/oil

pressure control
Exploded view - oil pressure switches/oil pressure control .
4.3 Removing and installing oil filter housing

Removing
– Remove oil filter element ⇒ page 61 .
– Remove poly V-belt ⇒ page 45 .
– Drain coolant ⇒ 6-cylinder TDI engine, 3.0 ltr. 4-valve common
rail; Rep. gr. 19 ; Cooling system/coolant; Draining and filling
cooling system .
– Unbolt coolant pipe (front) and disconnect from thermostat ⇒
6-cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr.
19 ; Coolant pipes; Removing and installing coolant pipes .
4. Oil filter/oil pressure switches 65

Audi Q5 2017 ➤
– Unplug electrical connector -2- for oil pressure sender - G10- .

– Release hose clip -1- and disconnect coolant hose.
engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch;
Removing and installing oil filter housing .
Installing
Additional work:
– Install poly V-belt ⇒ page 45 .
4.4 Removing and installing oil pressure

switch - F22-
gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch;
Removing and installing oil pressure switch - F22- .
4.5 Removing and installing oil temperature

sender - G8-
gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches ;
Removing and installing oil temperature sender - G8- .
4.6 Removing and installing oil pressure

sender - G10-
Removing
engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches ;
Removing and installing oil pressure sender - G10- .
Installing
Additional work:
Tightening torques
♦ ⇒ “3.1 Exploded view - air cleaner housing”, page 125
4.7 Checking oil pressure

Checking oil pressure .
4.8 Removing and installing valve for oil

pressure control - N428-
Removing
noise insulation .

Audi Q5 2017 ➤

engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches;
Removing and installing valve for oil pressure control - N428- .
Tightening torques
4.9 Removing and installing oil temperature

sender 2 - G664-
Procedure
noise insulation .
Caution
Oil will escape through mounting hole for oil temperature send‐
er.
♦ Lay a cloth under the mounting hole to catch escaping
engine oil or close the mounting hole using a clean plug
from the engine bung set - VAS 6122- .
– Unscrew bolt -1- and remove oil temperature sender 2 -

G664- .
Note
Renew O-ring after removal.
Tightening torques
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 45
4. Oil filter/oil pressure switches 67

Audi Q5 2017 ➤
19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 68
⇒ “1.2 Checking cooling system for leaks”, page 71
⇒ “1.3 Draining and filling cooling system”, page 71
1.1 Connection diagram - coolant hoses

⇒ “1.1.1 Connection diagram - coolant hoses, equipment version
without auxiliary heater”, page 68
⇒ “1.1.2 Connection diagram - coolant hoses, equipment version
with auxiliary heater”, page 70
1.1.1 Connection diagram - coolant hoses, equipment version without auxiliary

heater
Note
♦ Blue = Large coolant circuit

♦ Red = Small coolant circuit
♦ Orange = Coolant circuit for cylinder block.
♦ Brown = Heating circuit
♦ Green = Coolant circuit for gearbox
♦ Arrows show direction of coolant flow.
68 Rep. gr.19 - Cooling

Audi Q5 2017 ➤
1 - Auxiliary radiator (right-

side)
2 - Radiator
3 - Restrictor
4 - Thermostat
5 - Non-return valve
6 - Cylinder block
❑ Cylinder bank 1 (right-
side)
7 - Coolant temperature send‐
er - G62-
8 - Cylinder head
side)
9 - Turbocharger
10 - Exhaust gas recirculation
cooler
11 - Heat exchanger for heater
12 - Coolant circulation pump -
V50-
cooler
❑ Low pressure
14 - Thermostat
❑ For coolant circuit for
gearbox
15 - Injector for reducing agent
- N474-
16 - ATF cooler
17 - Engine oil cooler
18 - Coolant shut-off valve
19 - Restrictor
20 - Cylinder head
❑ Cylinder bank 2 (left-side)
21 - Cylinder block
23 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Cooling
system/coolant; Checking cooling system for leaks
24 - Coolant expansion tank
25 - Restrictor
26 - Temperature sender for engine temperature regulation - G694-
28 - Coolant pump
29 - Auxiliary radiator (left-side)
❑ Depending on vehicle equipment
1. Cooling system/coolant 69
Audi Q5 2017 ➤
1.1.2 Connection diagram - coolant hoses, equipment version with auxiliary heat‐
er
Note
♦ Blue = Large coolant circuit

♦ Red = Small coolant circuit
♦ Orange = Coolant circuit for cylinder block.
♦ Brown = Heating circuit
♦ Green = Coolant circuit for gearbox
♦ Arrows show direction of coolant flow.
1 - Auxiliary radiator (right-

side)
2 - Radiator
3 - Restrictor
4 - Thermostat
7 - Heater coolant shut-off
valve - N279-
8 - Auxiliary heater
❑ With circulation pump -
V55-
9 - Cylinder block
side)
10 - Coolant temperature
sender - G62-
11 - Cylinder head
side)
12 - Turbocharger
cooler
V50-
cooler
❑ Low pressure
16 - Heat exchanger for heater
17 - Thermostat
❑ For coolant circuit for gearbox

Audi Q5 2017 ➤
18 - Injector for reducing agent - N474-

19 - ATF cooler
20 - Engine oil cooler
21 - Coolant shut-off valve
22 - Restrictor
23 - Cylinder head
24 - Cylinder block
26 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Cooling
system/coolant; Checking cooling system for leaks
27 - Coolant expansion tank
28 - Restrictor
29 - Temperature sender for engine temperature regulation - G694-
31 - Coolant pump
32 - Auxiliary radiator (left-side)
❑ Depending on vehicle equipment
1.2 Checking cooling system for leaks

gine, common rail; Rep. gr. 19 ; Cooling system/coolant; Check‐
ing cooling system for leaks .
1.3 Draining and filling cooling system

♦ Adapter for cooling system tester - V.A.G 1274/8-
Audi Q5 2017 ➤
♦ Pipe for cooling system tester - V.A.G 1274/10-
♦ Cooling system charge unit - VAS 6096-


Audi Q5 2017 ➤
♦ Refractometer - T10007A-
♦ Safety goggles
♦ Protective gloves
Draining coolant
WARNING
Risk of injury as the radiator fans may start up automatically.

♦ Even when the ignition is switched off, the radiator fans
can start up without warning due to accumulated heat in
the engine compartment, etc.
WARNING

– Release fastener -arrow- and open filler cap -1- on coolant

expansion tank.
noise insulation .
Audi Q5 2017 ➤

WARNING

– Release hose clip -2-.

– Disconnect coolant hose from coolant pipe at lock carrier and
drain off coolant.
– Release hose clip -arrow-.

– Disconnect coolant hose from ATF cooler, hold end of hose
downwards and drain off coolant.
– Release hose clip -arrow-.

– Disconnect coolant hose from exhaust gas recirculation cool‐
er, hold end of hose downwards and drain off coolant.
– Re-connect coolant hoses.
Coolant specifications
common rail; Rep. gr. 19 ; Cooling system/coolant; Draining and
filling cooling system .
Recommended mixture ratio for coolant
• Coolant (40 %) and distilled water (60 %) for frost protection
to -25 °C
• Coolant (50 %) and distilled water (50 %) for frost protection
to -36 °C
• Coolant ⇒ Electronic parts catalogue

Audi Q5 2017 ➤
Filling cooling system

• Ignition switched off.
– Fill reservoir of -VAS 6096- with 10 litres of premixed coolant
(according to recommended ratio; for recommended ratio see
⇒ page 74 ).
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-.
Note:
The vented air draws along a small amount of coolant, which
should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air supply.
• Pressure: 7 ... 10 bar.
– Open valve -B- by setting lever in direction of flow.

• The suction jet pump generates a partial vacuum in the cooling
system; the needle on the gauge should move into the green
zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on reservoir of -VAS 6096- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump continues to generate a partial vacuum
in the cooling system; the needle on the gauge should remain
in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
• If the needle does not reach the green zone, repeat the proc‐
ess.
• Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.
– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
– Detach cooling system charge unit - VAS 6096- from adapter
-V.A.G 1274/8- on coolant expansion tank.
Audi Q5 2017 ➤
– Attach pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .

– Fill up with coolant until pipe for cooling system tester is filled.
If required, add further coolant when performing bleeding pro‐
cedure.
Bleeding cooling system
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Release hose clip on coolant hose going to heat exchanger

for heater and pull back hose until bleeder hole -arrow- is no
longer blocked by connection.
– Fill up with coolant until it flows out at bleeder hole in coolant
hose.
– Push coolant hose back onto connection and secure with hose
clip.

Audi Q5 2017 ➤
– Close filler cap -1- on coolant expansion tank (make sure it

engages).
– On vehicles with auxiliary/supplementary heater, switch heat‐
er on for about 30 seconds.
– Start engine.
Time period Engine speed Air conditioner/heater setting
2 minutes 2500 rpm • Air conditioning system
“OFF”, LED in AC button not
lit
• Heating at “HI”, select low‐
est possible blower speed
(= 0)
3 minutes Idling speed • Air conditioning system

2 minutes 2500 rpm “OFF”
3 minutes Idling speed • Heating at “HI”
2 minutes 2500 rpm
3 minutes Idling speed
1 minute Switch off en‐
gine
2 minutes 2500 rpm
Until both Idling
large coolant
hoses at ra‐
diator be‐
come warm
1 minute 2500 rpm
– Switch off engine.
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
Checking coolant level
WARNING

Audi Q5 2017 ➤
• The coolant level must be at the “MAX” marking when the en‐
gine is cold.
• The coolant level can be above the “MAX” marking when the
engine is warm.
– Top up with coolant again if necessary.
Tightening torques

Audi Q5 2017 ➤
2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump”, page 79
⇒ “2.2 Exploded view - electric coolant pump”, page 79
⇒ “2.3 Exploded view - thermostat”, page 80
⇒ “2.4 Exploded view - coolant temperature senders”,
page 80
⇒ “2.5 Removing and installing electric coolant pump”,
page 80
⇒ “2.6 Removing and installing coolant pump”, page 82
⇒ “2.7 Removing and installing thermostat”, page 82
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 83
⇒ “2.9 Removing and installing temperature sender for engine
temperature regulation G694 ”, page 83
⇒ “2.10 Removing and installing coolant valves”, page 83
2.1 Exploded view - coolant pump

gine, common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Exploded view - coolant pump .
2.2 Exploded view - electric coolant pump

Coolant circulation pump - V50-
2. Coolant pump/thermostat assembly 79

Audi Q5 2017 ➤
1 - Coolant pipes (rear)

⇒ page 95
V50-
⇒ page 80
3 - Coolant hoses
4 - Bolt
❑ 1.5 Nm
2.3 Exploded view - thermostat

sembly; Exploded view - thermostat .
2.4 Exploded view - coolant temperature

senders
sembly; Exploded view - coolant temperature senders .
2.5 Removing and installing electric coolant

pump

Audi Q5 2017 ➤

Removing
– Remove subframe shield (left-side) ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing
subframe shield .

Audi Q5 2017 ➤

– Remove bolt -1- and push coolant hose to one side.
– Remove bolts -2-.
– Release hose clips -arrows-, detach coolant circulation pump
- V50- and remove coolant hoses.
Installing
Note
♦ Do not reuse coolant.

Tightening torques
♦ ⇒ “2.2 Exploded view - electric coolant pump”, page 79
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe
2.6 Removing and installing coolant pump

Removing
noise insulation .
engine, common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Removing and installing coolant pump .
Tightening torques
2.7 Removing and installing thermostat

sembly; Removing and installing thermostat .

Audi Q5 2017 ➤
2.8 Removing and installing coolant temper‐

ature sender - G62-
sembly; Removing and installing coolant temperature sender -
G62- .
2.9 Removing and installing temperature

sender for engine temperature regula‐
tion - G694-
Removing
– Detach changeover valve -3- from bracket and move clear to
side.
engine, common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Removing and installing temperature sender for engine
temperature regulation - G694- .
Installing
Additional work:
2.10 Removing and installing coolant valves

sembly; Removing and installing coolant valves .

Audi Q5 2017 ➤
3 Coolant pipes
⇒ “3.1 Exploded view - coolant pipes”, page 84
⇒ “3.2 Removing and installing coolant pipes”, page 87
3.1 Exploded view - coolant pipes
Note
The arrow markings on coolant pipes and on ends of hoses must

align.
Part I
Part II ⇒ page 85
1 - O-ring
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
5 - Coolant pipe (front)
⇒ page 87
6 - O-ring
7 - Seal
8 - O-ring
9 - Coolant pipe (top right)
⇒ page 93
10 - Bolts
❑ 9 Nm
11 - O-ring
12 - Coolant pipe (top)
⇒ page 87
13 - Bolt
❑ 9 Nm
14 - Bolt
❑ 9 Nm
15 - Coolant pipe
❑ For cylinder head

Audi Q5 2017 ➤
16 - O-ring
17 - O-ring
18 - Sealing plug
❑ For cylinder block
19 - Bolt
❑ 9 Nm
20 - Gasket
21 - Bolt
❑ 9 Nm
22 - Housing cover
❑ For cylinder block
23 - Coolant pipe (left-side)
24 - Bolt
❑ 20 Nm
25 - Bolt
❑ 9 Nm
26 - O-ring
27 - Bolt
❑ 9 Nm
28 - Connection
❑ For coolant hose
29 - O-ring
30 - Bracket
❑ For air conditioner compressor
❑ Removing and installing ⇒ 6-cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder
block (pulley end); Removing and installing bracket for ancillaries
Coolant pipe at lock carrier - tightening torques

– Tighten bolt -1- to 4.5 Nm on both sides.
Part II
Part I ⇒ page 84
3. Coolant pipes 85
Audi Q5 2017 ➤
1 - Coolant pipes (rear)

⇒ page 95
2 - Bolt
❑ 9 Nm
3 - Coolant pipe (rear) for tur‐
bocharger
⇒ page 92
4 - O-ring
5 - Bolt
❑ 9 Nm
6 - O-ring
7 - Bolt
❑ 9 Nm
8 - Coolant pipe (top front) for
turbocharger
⇒ page 94
9 - Bolt
❑ 9 Nm
10 - O-ring
11 - Bolts
❑ 9 Nm
12 - Coolant pipe (bottom front)
for turbocharger
13 - Bolt
❑ 9 Nm
14 - Coolant pipe (right-side)
15 - Bolt
❑ 9 Nm
16 - Bolt
❑ 9 Nm
17 - Bolt
❑ 20 Nm
18 - Bolt
❑ 20 Nm

Audi Q5 2017 ➤
3.2 Removing and installing coolant pipes

⇒ “3.2.1 Removing and installing coolant pipe (top)”, page 87
⇒ “3.2.2 Removing and installing coolant pipe (front)”,
page 87
⇒ “3.2.3 Removing and installing coolant pipe (left-side)”,
page 90
⇒ “3.2.4 Removing and installing coolant pipe (rear) for turbo‐
charger”, page 92
⇒ “3.2.5 Removing and installing coolant pipe (top right)”,
page 93
⇒ “3.2.6 Removing and installing coolant pipe (right-side)”,
page 93
⇒ “3.2.7 Removing and installing coolant pipes (front) for turbo‐
charger”, page 94
⇒ “3.2.8 Removing and installing coolant pipes (rear)”,
page 95
3.2.1 Removing and installing coolant pipe

(top)
Removing
– Remove exhaust gas recirculation cooler ⇒ page 186 .
– Unscrew bolts -arrows- and remove coolant pipe (top) -1-.
Installing
Note
Renew seal and O-ring after removing.
– Clean and smoothen sealing surface for O-ring.

– Lubricate O-ring with coolant and slide onto coolant pipe.
– Install exhaust gas recirculation cooler ⇒ page 186 .
Tightening torques

(front)
3. Coolant pipes 87
Audi Q5 2017 ➤

Removing
WARNING


Audi Q5 2017 ➤
– To relieve residual pressure in cooling system, release fas‐

tener -arrow- and briefly open filler cap -1- on coolant expan‐
sion tank.
noise insulation .

– Release hose clip -2-, disconnect coolant hose and drain off
coolant.
3. Coolant pipes 89
Audi Q5 2017 ➤
– Release hose clips -1, 2- and disconnect coolant hoses.

– Remove bolts -arrows- and detach front coolant pipe -3- from
thermostat housing.
Installing
Note
♦ Renew O-ring after removal.

– Clean and smoothen sealing surface for O-ring.

– Lubricate O-ring with coolant and slide onto coolant pipe.
Note

Tightening torques

(left-side)
Removing
– Drain coolant ⇒ page 71 .

Audi Q5 2017 ➤
– Remove noise insulation (front and centre) ⇒ General body

repairs, exterior; Rep. gr. 66 ; Noise insulation; Removing and
installing noise insulation .
belt .
– Remove drive shaft cover (left-side) ⇒ General body repairs,
– Release hose clip -2- and detach coolant hose from coolant
pipe.
– Detach coolant pipe (left-side) -1-.
Note
For illustration purposes, the installation position is shown with

the engine support removed.
Installing
Note

Tightening torques
3. Coolant pipes 91
Audi Q5 2017 ➤

(rear) for turbocharger
Removing
Note
Reinstall heat insulation sleeves in the same locations when in‐

stalling.

– Remove emission control module ⇒ page 159 .
– Fold heat insulation sleeve back slightly.
– Unscrew bolt -arrow- and detach coolant pipe -1- from turbo‐
charger.
– Loosen hose clip -2- and detach coolant pipe.
Installing
Note

Note

Tightening torques

Audi Q5 2017 ➤

(top right)
Removing
– Remove exhaust gas recirculation cooler ⇒ Servicing 6-cyl‐
inder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
recirculation; Removing and installing exhaust gas recircula‐
tion cooler .
– Detach coolant pipe (top right).
Installing
Installation is carried out in reverse sequence.

(right-side)
♦ Socket Torx T30 - T10405-
Removing
– Disconnect earth wire from battery terminal ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
– Remove noise insulation (front and centre) ⇒ General body
– Remove drive shaft cover (right-side) and wheel spoiler (front
right) ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
housing liners; Exploded view - wheel housing liner (front) .
3. Coolant pipes 93
Audi Q5 2017 ➤
– Remove bolt -arrow- and move bracket -1- clear with electrical
wiring harness.

– Release hose clips -1, 2- and disconnect coolant hoses.
– Unscrew bolts -arrows- using socket Torx T30 - T10405- and
detach coolant pipe (right-side).
Installing
Note

ing battery .
Tightening torques
3.2.7 Removing and installing coolant pipes

(front) for turbocharger

Audi Q5 2017 ➤
Removing coolant pipe (top front) for turbocharger

– Remove exhaust gas temperature sender 2 - G448- -item 2-
⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ;
Exhaust gas temperature control; Removing and installing ex‐
haust gas temperature sender 2 - G448- .
– Remove bolts -1, 3-.
– Release hose clips -arrows-, detach coolant pipe (top front)
from turbocharger and remove.
Removing coolant pipe (bottom front) for turbocharger

• Coolant pipe (top front) for turbocharger removed
– Detach coolant pipe (bottom front) -1- from cylinder block and
remove.
Installing
Note

– Install exhaust gas temperature sender 2 - G448- ⇒ Servicing

temperature control; Removing and installing exhaust gas
temperature sender 2 - G448- .
Note

Tightening torques
3.2.8 Removing and installing coolant pipes

(rear)
3. Coolant pipes 95
Audi Q5 2017 ➤
♦ Bit XZN 10 - T10501-
Removing

Audi Q5 2017 ➤

G524- clear.
– Unplug electrical connector -2- for coolant circulation pump -

V50- .
– Release hose clip -1- and disconnect coolant hose.

– Unscrew bolts -arrows- and detach coolant pipes -1-.
Installing
Note


– Install pressure differential sender 2 - G524- ⇒ page 184 .
– Connect coolant hose with plug-in connector ⇒ page 99 .
Note

Tightening torques
3. Coolant pipes 97
Audi Q5 2017 ➤
4 Radiator/radiator fans
⇒ “4.1 Exploded view - radiator/radiator fans”, page 98
⇒ “4.2 Exploded view - auxiliary radiator”, page 101
⇒ “4.3 Removing and installing radiator”, page 101
⇒ “4.4 Removing and installing radiator cowl”, page 105
⇒ “4.5 Removing and installing radiator fan V7 ”, page 107
4.1 Exploded view - radiator/radiator fans

Radiator
1 - Coolant hose
❑ Lift retaining clip to de‐
tach
❑ Connecting
⇒ page 99
2 - Radiator
⇒ page 101
❑ If there are slight im‐
pressions on the fins, re‐
fer to ⇒ Servicing 6-
cylinder TDI engine,
common rail; Rep. gr.
00 ; Repair instructions;
Installing radiators and
condensers
3 - O-ring
4 - Coolant hose
tach
❑ Connecting
⇒ page 99
5 - O-ring
6 - Coolant hose
tach
❑ Connecting
⇒ page 99
7 - Coolant pipe
❑ To coolant expansion
tank
❑ Lift retaining clip to detach
❑ Connecting ⇒ page 99
8 - O-ring
9 - Rubber bush
❑ For radiator

Audi Q5 2017 ➤
10 - Sleeve
11 - Retaining pin
❑ Use screwdriver to release and pull off
12 - Air duct
13 - Rubber bush
❑ For radiator
14 - Radiator bracket
15 - Bolt
❑ 5 Nm
16 - Washer
17 - Bolt
❑ 4.5 Nm
18 - O-ring
19 - Drain plug
❑ 1.5 … 3 Nm
20 - O-ring
Connecting coolant hose with plug-in connector
Note
If damaged, renew retaining clip -4-.
– Remove old O-ring -2- from coolant hose -3-.

– Lightly lubricate new O-ring with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto connection -1- until it engages audi‐
bly.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
Radiator cowl and radiator fans
4. Radiator/radiator fans 99
Audi Q5 2017 ➤
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
⇒ page 105
3 - Bolt
❑ 5 Nm
4 - Radiator fan - V7-
❑ With radiator fan control
unit - J293-
⇒ page 107
5 - Radiator fan 2 - V177-
❑ With radiator fan control
unit 2 - J671-
⇒ page 107

Audi Q5 2017 ➤
4.2 Exploded view - auxiliary radiator
1 - Air duct
2 - Auxiliary radiator
3 - Bolt
❑ 9 Nm
4 - Bracket
❑ For auxiliary radiator
5 - Nut
❑ 9 Nm
6 - Clip
7 - Rubber bush
8 - Coolant hoses
9 - Clip
10 - Rubber bush
❑ For auxiliary radiator
11 - Washer
12 - Bolt
❑ 4.5 Nm
4.3 Removing and installing radiator
Note
The radiator must be removed and installed together with the ra‐
diator cowl.

Audi Q5 2017 ➤

♦ Assembly tool - T10118-
Removing
WARNING


noise insulation .
– Remove impact bar ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing impact bar .

Audi Q5 2017 ➤

– Unplug electrical connectors -1, 2- for radiator fan.
– Release fasteners -arrow- using assembly tool - T10118- and

detach air duct -1- (but leave air duct -2- in installation posi‐
tion).
– Remove charge air cooler ⇒ page 112 .

Audi Q5 2017 ➤
– Unplug electrical connector -2- for high-pressure sender -

G65- .
Caution
Risk of irreparable damage to radiator.

♦ The radiator must be renewed if the fasteners are dam‐
aged.
Risk of damage to refrigerant lines and hoses
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Release fasteners -arrows- on both sides, disengage con‐

denser -1- from radiator and tie up to one side.
– Release fasteners -arrows- and detach air ducts -1, 2-.
– Lift retaining clips -1, 2-, detach coolant connection from radi‐
ator and move connection clear.
– Remove bolts -2- on both sides and press radiator bracket

-1- with radiator towards front -arrow-.

Audi Q5 2017 ➤

– Detach radiator.
– Press locking tabs on left and right sides of radiator cowl to‐
gether -arrow- and lift radiator cowl off radiator.
Installing
Note
If there are slight impressions on the fins, refer to ⇒ Servicing 6-

cylinder TDI engine, common rail; Rep. gr. 00 ; Repair instruc‐
tions; Installing radiators and condensers .
– Install charge air cooler ⇒ page 112 .

– Connect coolant hose with plug-in connector ⇒ page 99 .
Note

Tightening torques
charge air system
4.4 Removing and installing radiator cowl


Audi Q5 2017 ➤

Removing
WARNING

♦ Unplug electrical connectors before working in vicinity of
radiator cowl.

noise insulation .
– Remove charge air cooler ⇒ page 112 .


Audi Q5 2017 ➤
– Unplug electrical connectors -1, 2- for radiator fan.
– Remove bolts -2- on both sides and press radiator bracket

-1- with radiator towards front -arrow-.
– Press locking tabs on left and right sides of radiator cowl si‐
multaneously -arrow-, lift radiator cowl off radiator and remove
from below.
Installing
Note
– Install charge air cooler ⇒ page 112 .

– Attach connection with plug-in connector ⇒ page 99 .
Tightening torques
charge air system
4.5 Removing and installing radiator fan -

V7-
Description applies to radiator fan - V7- and radiator fan 2 - V177- .

Audi Q5 2017 ➤
Removing
• Use correct type of fasteners for electrical wiring (as original
equipment) ⇒ Electronic parts catalogue .
– Remove radiator cowl ⇒ page 105 .
– Move electrical wiring harness clear.
– Unscrew bolts -1- or -2- and remove the corresponding radi‐
ator fan.
Caution
Risk of noise due to imbalance in fan wheel.

♦ Do not remove balancing clamps from fan wheel.
Installing
– Install radiator cowl ⇒ page 105 .
Tightening torques

Audi Q5 2017 ➤
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 109
⇒ “1.2 Removing and installing turbocharger”, page 109
1.1 Exploded view - turbocharger

gine, common rail; Rep. gr. 21 ; Turbocharger; Exploded view -
turbocharger .
1.2 Removing and installing turbocharger

Removing

– Release hose clip -1- and detach exhaust gas recirculation
pipe -2-.
1. Turbocharger 109
Audi Q5 2017 ➤
– Remove bolts -1- and pull air pipe -2- off turbocharger (leave
in installation position).
engine, common rail; Rep. gr. 21 ; Turbocharger; Removing and
installing turbocharger .
Installing
Additional work:
Note

Tightening torques
charge air system
♦ ⇒ “5.1.2 Exploded view - exhaust gas recirculation system,
low-pressure side (rear)”, page 184
110 Rep. gr.21 - Turbocharging/supercharging

Audi Q5 2017 ➤
2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 111
⇒ “2.2 Exploded view - hose connections for charge air system”,
page 112
⇒ “2.3 Removing and installing charge air cooler”, page 112
⇒ “2.4 Removing and installing charge pressure sender G31 ”,
page 114
⇒ “2.5 Removing and installing charge air temperature sender af‐
ter charge air cooler G811 ”, page 115
⇒ “2.6 Checking charge air system for leaks”, page 115
2.1 Exploded view - charge air system
1 - Not fitted
2 - Charge air cooler
⇒ page 112
3 - Hose clip
❑ Tightening torque ⇒
Servicing 6-cylinder TDI
engine, common rail;
Rep. gr. 21 ; Charge air
system; Exploded view -
hose connections for
charge air system
4 - Air hose
❑ To charge air cooler
❑ Must be free of oil and
grease when installing
5 - Hose clip
❑ Tightening torque ⇒
Rep. gr. 21 ; Charge air
system; Exploded view -
hose connections for
charge air system
6 - Bolt
❑ 9 Nm
7 - Spacer sleeve
8 - Grommet
9 - Air pipe (right-side)
10 - Bolt
❑ 9 Nm
11 - O-ring
12 - Hose clip
❑ Tightening torque ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Charge air system;
Exploded view - hose connections for charge air system
2. Charge air system 111

Audi Q5 2017 ➤
13 - Air hose
❑ To turbocharger
❑ Must be free of oil and grease when installing
14 - Hose clip
15 - Grommet
16 - Spacer sleeve
17 - Bolt
❑ 9 Nm
18 - O-ring
19 - Bolt
❑ 5 Nm
20 - Charge air temperature sender after charge air cooler - G811-
21 - Hose clip
22 - Air hose
❑ To intake manifold
❑ Must be free of oil and grease when installing
23 - Hose clip
24 - Not fitted
2.2 Exploded view - hose connections for

charge air system
gine, common rail; Rep. gr. 21 ; Charge air system; Exploded
view - hose connections for charge air system .
2.3 Removing and installing charge air cool‐

er
Removing
Note
Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI engine,

common rail; Rep. gr. 00 ; Repair instructions; Rules for cleanli‐
ness .
– Remove lock carrier cover, air intake grille (left and right) and

Audi Q5 2017 ➤

– Use side-cutting pliers to cut open air duct -1- in area of open‐
ing for refrigerant lines -arrow-.
– Release catches -arrow- and detach air ducts -1, 3-.

Audi Q5 2017 ➤
– Release hose clip -1- on both sides and detach air pipe from
charge air cooler.
Caution
Risk of irreparable damage to charge air cooler.

♦ The charge air cooler must be renewed if the fasteners are
damaged.
– Release fasteners -arrows- on both sides and disengage

charge air cooler from radiator.
– Take out charge air cooler from underneath.
Installing
Note
♦ If there are slight impressions on the fins, refer to ⇒ Servicing

6-cylinder TDI engine, common rail; Rep. gr. 00 ; Repair in‐
structions; Installing radiators and condensers .
– Install lock carrier cover, air intake grille (left and right) and
Tightening torques
charge air system
2.4 Removing and installing charge pres‐

sure sender - G31-
gine, common rail; Rep. gr. 21 ; Charge air system; Removing
and installing charge pressure sender - G31- .

Audi Q5 2017 ➤
2.5 Removing and installing charge air tem‐

perature sender after charge air cooler -
G811-
Removing
– Remove bolt -1- and detach charge air temperature sender
after charge air cooler - G811- .
Installing
Note
Renew O-ring after removal.
Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 111
2.6 Checking charge air system for leaks

gine, common rail; Rep. gr. 21 ; Charge air system; Checking
charge air system for leaks .

Audi Q5 2017 ➤
23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview - fuel system”, page 116
⇒ “1.2 Overview of fitting locations - injection system”,
page 117
⇒ “1.3 Filling and bleeding fuel system”, page 123
⇒ “1.4 Checking fuel system for leaks”, page 123
1.1 Overview - fuel system
Note
♦ Red = fuel supply

♦ Blue = fuel return
♦ Arrows = direction of fuel flow
1 - Injector
2 - High-pressure reservoir
(rail)
❑ For cylinder bank 1
(right-side)
3 - Fuel temperature sender -
G81-
4 - Fuel filter
5 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
6 - Fuel metering valve - N290-
7 - High-pressure pump
8 - Fuel pressure sender -
G247-
9 - High-pressure reservoir
(rail)
❑ For cylinder bank 2 (left-
side)
10 - Injector
11 - Restrictor
❑ Maintains a residual
pressure in fuel return
hoses
12 - Fuel pressure regulating
valve - N276-
116 Rep. gr.23 - Mixture preparation - injection

Audi Q5 2017 ➤
1.2 Overview of fitting locations - injection system

Engine compartment
1 - Air mass meter - G70-

❑ Exploded view
⇒ page 125
2 - Pressure differential sender
- G505-
❑ Exploded view
⇒ page 143
3 - Exhaust flap control unit -
J883-
❑ Fitting location
⇒ page 119
4 - Accelerator pedal module -
GX2-
❑ With:
♦ Accelerator position sender
- G79-
♦ Accelerator position sender
2 - G185-
⇒ page 118
valve 2 - GX6-
❑ With:
♦ Exhaust gas recirculation
potentiometer 2 - G466-
♦ Exhaust gas recirculation
control motor 2 - V339-
⇒ page 119
V50-
⇒ page 118
7 - Brake light switch - F-
❑ Fitting location ⇒ page 118
8 - Pressure differential sender 2 - G524-
9 - Engine control unit - J623-
❑ Exploded view ⇒ page 149
10 - Charge air temperature sender after charge air cooler - G811-
11 - Left electrohydraulic engine mounting solenoid valve - N144-
12 - Right electrohydraulic engine mounting solenoid valve - N145-
1. Injection system 117

Audi Q5 2017 ➤
Fitting location of accelerator position sender - G79- / accelerator

position sender 2 - G185-
♦ Integrated in accelerator pedal module -3-. Accelerator posi‐
tion senders cannot be renewed separately if defective.
Exploded view ⇒ Fuel supply system; Rep. gr. 20 ; Accelerator
mechanism; Exploded view - accelerator pedal module
Fitting location of brake light switch - F-

♦ In plenum chamber on brake master cylinder
1- Electrical connector for brake light switch - F-
Exploded view ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake
master cylinder; Exploded view - brake servo/brake master cyl‐
inder
Fitting location of electrohydraulic engine mounting solenoid

valves -N144- / -N145-
♦ Integrated in engine mounting. It cannot be renewed sepa‐
rately if defective.
Pfeil - Electrical connector for left electrohydraulic engine mount‐
ing solenoid valve - N144-
Removing and installing
⇒ “2.3 Removing and installing engine mountings”, page 39
Fitting location of coolant circulation pump - V50-

♦ At coolant pipes (rear)
3 - Coolant circulation pump - V50-
Exploded view ⇒ page 79 .

Audi Q5 2017 ➤
Fitting location of exhaust gas recirculation control motor 2 -

V339-
♦ On left of gearbox
2 - Exhaust gas recirculation control motor 2 - V339-
Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail;
Rep. gr. 26 ; Exhaust gas recirculation; Exploded view - exhaust
gas recirculation
Fitting location of exhaust flap control unit - J883-

♦ At trap catalytic converter
2 - Exhaust flap control unit - J883-
Exploded view ⇒ page 159 .
Engine (top view)

Audi Q5 2017 ➤
1 - Fuel pressure regulating

valve - N276-
⇒ page 139
❑ Checking ⇒ page 137
2 - Glow plug 1 - Q10-
❑ Exploded view ⇒ Serv‐
icing 6-cylinder TDI en‐
gine, common rail; Rep.
gr. 28 ; Glow plug sys‐
tem; Exploded view -
glow plug system
glow plug system
glow plug system
5 - Control unit for turbocharg‐
er 1 - J724-
❑ On turbocharger
❑ Exploded view
⇒ page 109
6 - Fuel metering valve - N290-
❑ At high-pressure pump
valve 1 - GX5-
❑ With:
♦ Exhaust gas recirculation potentiometer - G212-
♦ Exhaust gas recirculation control motor - V338-
8 - Fuel pressure sender - G247-
❑ Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug system; Exploded
view - glow plug system
10 - Glow plug 5 - Q14-
11 - Glow plug 4 - Q13-
12 - Exhaust gas recirculation temperature sensor - G98-

Audi Q5 2017 ➤
13 - Coolant temperature sender - G62-

14 - Fuel temperature sender - G81-
Engine (front view)
1 - Oil temperature sender 2 -

G664-
❑ Exploded view
⇒ page 45
2 - Oil pressure sender - G10-
cooler change-over valve -
N345-
4 - Intake manifold flap motor -
V157-
❑ Exploded view
⇒ page 128
5 - Coolant valve for cylinder
head - N489-
6 - Charge pressure sender -
G31-
❑ Exploded view
⇒ page 128
7 - Throttle valve module -
GX3-
❑ With:
♦ Throttle valve potentiome‐
ter - G69-
♦ Throttle valve module -
J338-
♦ Exploded view
⇒ page 128
8 - Temperature sender for en‐
gine temperature regulation -
G694-
9 - Valve for oil pressure con‐
trol - N428-
Engine (side view, left-side)

Audi Q5 2017 ➤
1 - Injector, cylinder 4 - N33-

gr. 23 ; Injectors/high-
pressure reservoir (rail);
Exploded view - injec‐
tors
tors
tors
Engine (side view, right-side)

Audi Q5 2017 ➤
1 - Engine speed sender -

G28-
glow plug system
tors
3 - Fuel pressure sender for
low pressure - G410-
tors
tors
6 - Hall sender - G40-
icing 6-cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug system; Exploded view - glow plug
system
7 - Starter-alternator coolant pump - V621-
❑ Not installed in all vehicle versions
8 - Oil level and oil temperature sender - G266-
❑ Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail (EA 897 Gen II); Rep. gr. 17 ; Sump/oil
pump; Exploded view - sump/oil pump
1.3 Filling and bleeding fuel system

gine, common rail; Rep. gr. 23 ; Injection system; Filling and
bleeding fuel system .
1.4 Checking fuel system for leaks

gine, common rail; Rep. gr. 23 ; Injection system; Checking fuel
system for leaks .

Audi Q5 2017 ➤
2 Vacuum system
All procedures and components are described in ⇒ 6-cylinder TDI
engine, 3.0 ltr. 4-valve common rail; Rep. gr. 23 ; Vacuum sys‐
tem .

Audi Q5 2017 ➤
3 Air cleaner
⇒ “3.1 Exploded view - air cleaner housing”, page 125
⇒ “3.2 Removing and installing air cleaner housing”, page 126
3.1 Exploded view - air cleaner housing
1 - Snow screen
❑ Equipment version
2 - Water drain
❑ Clean
3 - Mounting bracket
❑ For air cleaner housing
4 - Air cleaner (bottom section)
❑ Remove any salt depos‐
its or dirt
⇒ “3.2 Removing and in‐
stalling air cleaner hous‐
ing”, page 126
5 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by
hand so that it is
screwed into old thread.
Then tighten bolt to tor‐
que
❑ 3.5 Nm
6 - Air cleaner (top section)
❑ Remove any salt depos‐
its or dirt
⇒ Maintenance ; Book‐
let 830
7 - Air mass meter - G70-
⇒ page 135
8 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by hand so that it is screwed into old thread. Then tighten bolt to torque
❑ 3.5 Nm
9 - Air pipe
❑ Observe installation markings
10 - Air filter element
❑ Use genuine air filter element ⇒ Electronic parts catalogue
❑ Change intervals ⇒ Maintenance tables
❑ Removing and installing ⇒ Maintenance ; Booklet 830
11 - Sealing element
12 - Heat shield
13 - Bolt
❑ Thread-forming
3. Air cleaner 125

Audi Q5 2017 ➤
❑ Fit and screw in bolt by hand so that it is screwed into old thread. Then tighten bolt to torque
❑ 1.5 Nm
14 - Air duct
❑ On lock carrier
❑ Remove any salt deposits or dirt
15 - Bolt
❑ 3.5 Nm
3.2 Removing and installing air cleaner

housing
Removing

Audi Q5 2017 ➤
– Unplug electrical connector -2- for air mass meter - G70- .

– Move fuel hoses -3- clear and press to one side.
– Lift off air cleaner housing -1- and detach.
Installing
Note
♦ The air cleaner housing must always be clean.

♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Use silicone-free lubricant when fitting air hoses.
– Check for salt residue and dirt in air pipe (engine intake side).
– Check air duct leading from lock carrier to air cleaner housing
for dirt and leaves.
Tightening torques
charge air system
3. Air cleaner 127

Audi Q5 2017 ➤
4 Intake manifold
⇒ “4.1 Exploded view - intake manifold”, page 128
⇒ “4.2 Removing and installing intake manifold (top section)”,
page 128
⇒ “4.3 Removing and installing intake manifold (bottom section)”,
page 129
⇒ “4.4 Removing and installing intake manifold flap motor V157
”, page 129
⇒ “4.5 Removing and installing throttle valve module J338 ”, page
129
4.1 Exploded view - intake manifold

gine, common rail; Rep. gr. 23 ; Intake manifold; Exploded view
- intake manifold .
4.2 Removing and installing intake manifold

(top section)
Removing
Caution
Risk of malfunctions caused by dirt.

♦ Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 00 ; Repair instructions;
Rules for cleanliness .

engine, common rail; Rep. gr. 23 ; Intake manifold; Removing
and installing intake manifold (top section) .
Installing
Additional work:
Note

Tightening torques
charge air system

Audi Q5 2017 ➤

(bottom section)
gine, common rail; Rep. gr. 23 ; Intake manifold; Removing and
installing intake manifold (bottom section) .

flap motor - V157-
gine, common rail; Rep. gr. 23 ; Intake manifold; Removing and
installing intake manifold flap motor - V157- .
4.5 Removing and installing throttle valve

module - J338-
Removing
– Release hose clip -arrow-, detach air hose and tie up to left
side.
engine, common rail; Rep. gr. 23 ; Intake manifold; Removing
and installing throttle valve module - J338- .
Installing
Additional work:
Note

Tightening torques
charge air system
4. Intake manifold 129

Audi Q5 2017 ➤
5 Injectors/high-pressure reservoir
(rail)
⇒ “5.1 Exploded view - injectors”, page 130
⇒ “5.2 Checking injectors”, page 130
⇒ “5.3 Performing adaption of correction values for injectors”,
page 130
⇒ “5.4 Checking for injectors sticking open”, page 130
⇒ “5.5 Checking return flow rate of injectors with engine running”,
page 130
⇒ “5.6 Checking return flow rate of injectors at starter cranking
speed”, page 130
⇒ “5.7 Checking restrictor in fuel return line”, page 131
⇒ “5.8 Removing and installing injectors”, page 131
⇒ “5.9 Removing and installing high-pressure pipes”, page 133
⇒ “5.10 Removing and installing high-pressure reservoir (rail)”,
page 133
5.1 Exploded view - injectors

gine, common rail; Rep. gr. 23 ; Injectors/high-pressure reservoir
(rail); Exploded view - injectors .
5.2 Checking injectors

(rail); Checking injectors .
5.3 Performing adaption of correction val‐

ues for injectors
(rail); Performing adaption of correction values for injectors .
5.4 Checking for injectors sticking open

(rail); Checking for injectors sticking open .
5.5 Checking return flow rate of injectors

with engine running
(rail); Checking return flow rate of injectors with engine running .
5.6 Checking return flow rate of injectors at

starter cranking speed
(rail); Checking return flow rate of injectors at starter cranking
speed .

Audi Q5 2017 ➤
5.7 Checking restrictor in fuel return line

(rail); Checking restrictor in fuel return line .
5.8 Removing and installing injectors

♦ Removal lever - 80-200-
Removing
Note
All cable ties which are released or cut open when removing must
be refitted in the same position when installing.

Cylinder bank 1 (right-side):
Cylinder bank 1 (right-side), injector for cylinders 1 and 2:
5. Injectors/high-pressure reservoir (rail) 131

Audi Q5 2017 ➤
Cylinder bank 2 (left-side), injector for cylinder 4:

– Lift retaining clip -1- and disconnect coolant line.
– Remove bolt -3-.
– Release fastener -arrow- and tie up coolant expansion tank to
left side.
Cylinder bank 2 (left-side), injector for cylinders 5 and 6:

– Detach engine control unit - J623- from bracket and move
aside ⇒ page 150 .
– Unscrew bolts -arrows- and detach bracket -1-.

Audi Q5 2017 ➤
– Move electrical connector -1- for injector for reducing agent -

N474- clear at bracket -2-.
– Unscrew bolts -arrows- and detach bracket.
engine, common rail; Rep. gr. 23 ; Injectors/high-pressure res‐
ervoir (rail); Removing and installing injectors .
Installing
Additional work:
Note
– Connect fuel hoses ⇒ Fuel supply system; Rep. gr. 20 ; Plug-

in connectors; Disconnecting plug-in connectors .
– Install engine control unit - J623- ⇒ page 150 .
Tightening torques
Cylinder head; Exploded view - cylinder head cover
♦ ⇒ Rep. gr. 21 ; Charge air system; Exploded view - hose
connections for charge air system
5.9 Removing and installing high-pressure

pipes
(rail); Removing and installing high-pressure pipes .
5.10 Removing and installing high-pressure

reservoir (rail)
Removing
5. Injectors/high-pressure reservoir (rail) 133

Audi Q5 2017 ➤
Cylinder bank 1 (right-side):


engine, common rail; Rep. gr. 23 ; Injectors/high-pressure res‐
ervoir (rail); Removing and installing high-pressure reservoir
(rail) .
Installing
Additional work:
Note
– Connect fuel hoses ⇒ Fuel supply system, diesel engines;

Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-in con‐
nectors .
Tightening torques
charge air system

Audi Q5 2017 ➤
6 Senders and sensors

⇒ “6.1 Removing and installing air mass meter G70 ”, page 135
⇒ “6.2 Removing and installing fuel temperature sender G81 ”,
page 136
⇒ “6.3 Removing and installing fuel pressure sender G247 ”, page
136
⇒ “6.4 Removing and installing fuel pressure sender for low pres‐
sure G410 ”, page 136
⇒ “6.5 Checking fuel pressure regulating valve N276 ”,
page 137
⇒ “6.6 Removing and installing fuel pressure regulating valve
N276 ”, page 139
⇒ “6.7 Removing and installing pressure differential sender G505
”, page 139
6.1 Removing and installing air mass meter

- G70-
Removing
6. Senders and sensors 135

Audi Q5 2017 ➤

– Unscrew bolts -arrows- and detach air mass meter - G70- .
Installing
To ensure that the air mass meter -G70- functions correctly, it is
important to observe the following notes and procedures.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter and falsify the detected air mass
values. This will cause a loss of power as the calculated in‐
jection quantities will be too low.
♦ Check air filter element and inside of air cleaner housing for
dirt and clean if necessary ⇒ Maintenance ; Booklet 830 .
♦ Hose connections and air pipes/hoses must be free of oil and
grease prior to fitting.
Tightening torques
charge air system
6.2 Removing and installing fuel tempera‐

ture sender - G81-
gine, common rail; Rep. gr. 23 ; Senders and sensors; Removing
and installing fuel temperature sender - G81- .
6.3 Removing and installing fuel pressure

sender - G247-
and installing fuel pressure sender - G247- .

sender for low pressure - G410-
Removing

Audi Q5 2017 ➤

engine, common rail; Rep. gr. 23 ; Senders and sensors; Re‐
moving and installing fuel pressure sender for low pressure -
G410- .
Installing
Additional work:
Tightening torques
charge air system
6.5 Checking fuel pressure regulating valve

- N276-
♦ Hose clamps, up to 25 mm - 3094-
♦ Test lead - VAS 6551/3- from pressure tester (diesel) - VAS

6551-
♦ Fuel-resistant measuring container

♦ Test hose for return line connection
Procedure
• Fuel temperature above 15 °C.

Audi Q5 2017 ➤
Caution
Risk of malfunctions caused by dirt.

♦ Observe rules for cleanliness when working on the fuel
supply system ⇒ Servicing 6-cylinder TDI engine, com‐
mon rail; Rep. gr. 00 ; Repair notes; Rules for cleanliness .
Procedure
– Seal fuel return hose -arrow- with hose clamp up to 25 mm
-3094- and disconnect hose ⇒ Fuel supply system; Rep. gr.
20 ; Plug-in connectors; Disconnecting plug-in connectors .
– Move fuel return hose clear and place it on one side.

Audi Q5 2017 ➤
– Connect test lead - VAS 6551/3- to return hose -arrow- and

hold into measuring container, as shown in illustration.
– Start engine and run at idling speed for one minute.
• Return flow rate (engine start): 0 ml
– Leave engine running at idling speed.
– While engine is running, empty measuring container, or ex‐
change it for an empty container and begin measurement.
– Leave engine running at idling speed for two minutes and
measure return flow rate.
• Return flow rate after 2 minutes: 0 ... 60 ml
Note
If specified values are obtained, fuel pressure regulating valve -

N276- is OK.
If values do not match specifications:
Note
♦ The fuel pressure regulating valve - N276- and injectors were

checked during the preceding measuring process.
♦ To determine which component is defective, you must check
the return flow rate of the injectors.
– Measure return flow rate of injectors with engine running

⇒ page 130 .
– If return flow rate of injectors is OK, renew fuel pressure reg‐
ulating valve - N276- .
– If return flow rate of injectors is not OK, renew defective injec‐
tor.
Attaching
– Connect fuel hose ⇒ Fuel supply system, diesel engines; Rep.

regulating valve - N276-
and installing fuel pressure regulating valve - N276- .
6.7 Removing and installing pressure differ‐

ential sender - G505-
Description for removal applies to pressure differential sender -
G505- and pressure differential sender 2 - G524- .
♦ Vehicle diagnostic tester

Audi Q5 2017 ➤
Removing

Pressure differential sender - G505- :

G505- .
– Press release tabs on both sides and disconnect crankcase

breather hose -2-.
– Unscrew bolts -arrows- and detach intake connecting pipe
-1-.

Audi Q5 2017 ➤
Pressure differential sender 2 - G524- :

– Remove body brace (left-side) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Suspension strut, upper links; Removing and
installing body brace .
G524- clear.
Continued for both pressure differential senders:

– Detach retaining clip -3-.
– Release catches -arrows- and detach bracket for pressure dif‐
ferential sender -2-.
– Release hose clips -1-.
– Spray hoses on pressure differential sender with silicone-free
lubricant.
– To prevent hose connections from breaking off, carefully dis‐
connect hoses and keep them straight when pulling them off.
Installing
Note
♦ Blow through hose (towards emission control module) with

compressed air to remove dirt or ice (frozen condensation).
♦ Make sure that hoses are securely fitted and seal properly.
♦ If pressure pipes have been detached from emission control
module, tighten them to specified torque.

– If pressure differential sender was renewed, perform adap‐
tions listed in Guided Function “0001 - Adapt learnt values -
after component replacement” ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ Rep. gr. 21 ; Charge air system; Exploded view - hose
connections for charge air system
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Suspension
strut, upper links; Exploded view - suspension strut, upper
links

Audi Q5 2017 ➤
7 High-pressure pump
cylinder TDI engine, common rail; Rep. gr. 23 ; High-pressure
pump .

Audi Q5 2017 ➤
8 Lambda probe
⇒ “8.1 Exploded view - Lambda probe”, page 143
⇒ “8.2 Removing and installing Lambda probe”, page 144
⇒ “8.3 Removing and installing NOx senders”, page 144
⇒ “8.4 Removing and installing particulate sensor G784 ”,
page 147
8.1 Exploded view - Lambda probe
1 - NOx sender 2 - G687- with

control unit for NOx sender 2 -
J881-
⇒ page 146
❑ Tightening torques ⇒
Rep. gr. 23 ; Lambda
probe; Exploded view -
Lambda probe
2 - Particulate sensor - G784-
⇒ page 147
Rep. gr. 23 ; Lambda
probe; Exploded view -
Lambda probe
❑ Tightening torques for
control units
⇒ page 144 and
⇒ page 144
- G505-
⇒ page 139
❑ Tightening torques and
installation instructions
⇒ Servicing 6-cylinder
TDI engine, common
rail; Rep. gr. 23 ; Lamb‐
da probe; Exploded
view - Lambda probe
4 - Exhaust gas temperature
sender 3 - G495-
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
temperature control; Removing and installing exhaust gas temperature sender 3 - G495-
5 - NOx sender - G295- with control unit for NOx sender - J583-
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe; Ex‐
ploded view - Lambda probe
6 - Exhaust gas temperature sender 2 - G448-
8. Lambda probe 143

Audi Q5 2017 ➤
7 - Lambda probe - G39- with Lambda probe heater - Z19-

❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe;
Removing and installing Lambda probe
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe; Ex‐
ploded view - Lambda probe
Bracket with pressure differential sender - G505- - tightening tor‐

que
– Tighten bolt -arrow- to 4.5 Nm.
Bracket with NOx sender 2 - G687- / particulate sensor - G784- -

tightening torque
– Tighten nuts -2 and 3- to 9 Nm.
8.2 Removing and installing Lambda probe

gine, common rail; Rep. gr. 23 ; Lambda probe; Removing and
installing Lambda probe .
8.3 Removing and installing NOx senders

⇒ “8.3.1 Removing and installing NOx sender G295 ”,
page 144
⇒ “8.3.2 Removing and installing NOx sender 2 G687 ”,
page 146
8.3.1 Removing and installing NOx sender -

G295-

Audi Q5 2017 ➤
♦ High-temperature paste ⇒ Electronic parts catalogue

Removing
WARNING
When working on all parts of the exhaust system:

♦ Observe safety precautions when working on the exhaust
system ⇒ Servicing 6-cylinder TDI engine, common rail;
Rep. gr. 00 ; Safety precautions; Safety precautions when
working on the exhaust system .
Note
Re-install all cable ties in the same locations when installing.

– Unscrew nuts -arrows-, detach control unit for NOx sender -
J583- -item 1- and move it clear.
8. Lambda probe 145

Audi Q5 2017 ➤
– Unscrew NOx sender - G295- -arrow- using a tool from Lamb‐

da probe open ring spanner set - 3337- .
Installing
Note
Coat thread with high-temperature paste ⇒ Electronic parts cata‐

logue .
– Move control unit for NOx sender - J583- into installation po‐
sition and secure.
Tightening torques
Lambda probe; Exploded view - Lambda probe
8.3.2 Removing and installing NOx sender 2 -

G687-
♦ High-temperature paste ⇒ Electronic parts catalogue

Removing
WARNING

Note

Audi Q5 2017 ➤
– Unfasten underbody trim (left-side) and lower it slightly ⇒

General body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Removing and installing underbody trim .
– Unscrew nut -3- and move control unit for NOx sender 2 -
J881- clear.
– Unscrew NOx sender 2 - G687- -item 2- using a tool from

Lambda probe open ring spanner set - 3337- .
Installing
Note
Coat thread with high-temperature paste ⇒ Electronic parts cata‐

logue .

Tightening torques
♦ ⇒ Fig. ““Bracket with NOx sender 2 -G687- / particulate sensor
-G784- - tightening torque”“ , page 144
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody trim
8.4 Removing and installing particulate sen‐

sor - G784-
Removing
WARNING

Note
8. Lambda probe 147

Audi Q5 2017 ➤

– Remove nut -2- and move particulate sensor - G784- clear.
– Unscrew particulate sensor - G784- -item 1-.

Installing
Tightening torques
♦ ⇒ Fig. ““Bracket with NOx sender 2 -G687- / particulate sensor
-G784- - tightening torque”“ , page 144

Audi Q5 2017 ➤
9 Engine control unit

⇒ “9.1 Exploded view - engine control unit”, page 149
⇒ “9.2 Removing and installing engine/motor control unit J623 ”,
page 150
9.1 Exploded view - engine control unit
1 - Suspension turret
2 - Mounting
❑ For engine control unit -
J623-
3 - Engine control unit - J623-
❑ After renewing, perform
adaptions listed in Gui‐
ded Function “0001 -
Adapt learnt values -
after component re‐
placement” ⇒ Vehicle
diagnostic tester
⇒ page 150
4 - Bolt
❑ 4.5 Nm
5 - Bolts
❑ 9 Nm
9. Engine control unit 149

Audi Q5 2017 ➤
9.2 Removing and installing engine/motor

control unit - J623-
Removing
Note
♦ If renewing the engine control unit, perform the adaptions lis‐

ted in the Guided Function “0001 - Adapt learnt values - after
component replacement” ⇒ Vehicle diagnostic tester.
♦ If the adaption values of the injectors cannot be read out of the
old (defective) engine control unit, they must be entered into
the new engine control unit manually and the adaption proce‐
dure must be performed accordingly.
– Remove bolts -arrows- and take out engine control unit - J623-
-item 1-.
– Unplug electrical connectors -arrows- and remove engine con‐

trol unit - J623- .
Installing
– If engine control unit - J623- has been renewed, perform adap‐
Tightening torques

Audi Q5 2017 ➤
26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 151
⇒ “1.2 Removing and installing front exhaust pipe”, page 153
⇒ “1.3 Separating exhaust pipes/silencers”, page 155
⇒ “1.4 Removing and installing silencers”, page 156
⇒ “1.5 Stress-free alignment of exhaust system”, page 157
⇒ “1.6 Checking exhaust system for leaks”, page 158
1.1 Exploded view - silencers
WARNING

1. Exhaust pipes/silencers 151

Audi Q5 2017 ➤
1 - Clamp (rear)
❑ For separate replace‐
ment of centre and rear
silencers
❑ Before tightening, align
exhaust system so it is
free of stress
⇒ page 157
❑ Installation position
⇒ page 153
❑ Tighten screw connec‐
tions evenly to 23 Nm
2 - Rear silencer
⇒ page 156
❑ Combined as one unit
with centre silencer as
original equipment
❑ Centre silencer and rear
silencer can be renewed
separately
❑ Cutting point
⇒ page 155
❑ Align exhaust system so
it is free of stress
⇒ page 157
3 - Bolt
❑ 20 Nm
4 - Mounting
❑ Renew if damaged
❑ Align exhaust system so
it is free of stress
⇒ page 157
5 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 157
❑ Installation position ⇒ page 153
❑ Tighten screw connections evenly to 23 Nm
6 - Bolt
❑ Tightening torque ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view -
assembly mountings
7 - Rubber mounting
❑ Align exhaust system so it is free of stress ⇒ page 157
8 - Bracket
❑ For rubber mounting
9 - Centre silencer
❑ Supplied as one unit with silencer as original equipment
❑ Centre silencer and rear silencer can be renewed separately
❑ Cutting point ⇒ page 155
10 - Rubber mounting
152 Rep. gr.26 - Exhaust system

Audi Q5 2017 ➤

11 - Mounting
12 - Bolt
❑ 20 Nm
Clamps - installation position

– Fit clamp in position shown.
• Angle -α- = approx. 20°
• Bolt connections face outwards.
1.2 Removing and installing front exhaust

pipe
Note
The SCR catalytic converter is integrated in the front exhaust

pipe.
Removing
WARNING

– Remove noise insulation (centre and rear) ⇒ General body


Audi Q5 2017 ➤

– Unbolt subframe shield (right-side) and move it to one side ⇒
Running gear, axles, steering; Rep. gr. 40 ; Subframe; Re‐
moving and installing subframe shield .
– Unplug electrical connectors -1, 4- and move them clear.
– Remove nuts -2, 3-.
– Detach control unit for NOx sender 2 - J881- and particulate
sensor - G784- from bracket, move them clear and tie up to
front exhaust pipe.
– Remove nuts -arrows-.

Audi Q5 2017 ➤
Caution
Risk of damage to flexible joint in front exhaust pipe.

♦ Do NOT bend flexible joint in front exhaust pipe more than
10°.
– Remove bolt -2- and nuts -1-.

– Detach front exhaust pipe.
Installing
Note
Renew gaskets and self-locking nuts after removal.
– Align the exhaust system so it is free of stress ⇒ page 157 .

Tightening torques
♦ ⇒ “2.1 Exploded view - emission control system”, page 159
1.3 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at the cutting point in
order to renew the centre or rear silencer separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.
♦ Chain pipe cutter - VAS 6254-

Audi Q5 2017 ➤
Procedure
WARNING

– Cut through exhaust pipe at right angle at centre notch

-arrow- using chain pipe cutter - VAS 6254- .
– Position centre of clamp over cutting point ⇒ page 153 and

tighten nuts -arrows-.
Tightening torques
♦ ⇒ “1.1 Exploded view - silencers”, page 151
1.4 Removing and installing silencers

Removing
WARNING


Audi Q5 2017 ➤
– Loosen clamp -arrows- and push towards rear.

– Lower front exhaust pipe slightly and detach clamp.
– Tie up front exhaust pipe.
WARNING
Risk of accident caused by weight of silencers.

♦ A second mechanic is required for removal of the rear si‐
lencer.
– Disengage rubber mountings -3, 4-.

– Unscrew bolts -1, 2- and detach silencer.
Installing
Tightening torques
1.5 Stress-free alignment of exhaust system

Procedure
WARNING

• The exhaust system must be aligned when it is cool.

Audi Q5 2017 ➤
– Loosen clamp -arrows- and push towards rear.
– Push exhaust system towards front of vehicle -arrow- so that

mounting for exhaust pipe is preloaded by -a- = 10 ± 2 mm.
– Position clamp at front ⇒ page 153 and tighten bolted con‐
nections evenly.
Tightening torques
1.6 Checking exhaust system for leaks

gine, common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Check‐
ing exhaust system for leaks .

Audi Q5 2017 ➤
2 Emission control system

⇒ “2.1 Exploded view - emission control system”, page 159
⇒ “2.2 Removing and installing emission control module”,
page 159
⇒ “2.3 Removing and installing trap catalytic converter”,
page 162
⇒ “2.4 Removing and installing exhaust flap control unit J883 ”,
page 162
2.1 Exploded view - emission control sys‐

tem
gine, common rail; Rep. gr. 26 ; Emission control system; Explo‐
ded view - emission control system .
2.2 Removing and installing emission con‐

trol module
Removing
WARNING

– Remove noise insulation (centre) ⇒ General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Removing and instal‐
ling noise insulation .
– Unbolt subframe shield (right-side) and move it to one side ⇒
Running gear, axles, steering; Rep. gr. 40 ; Subframe; Re‐
moving and installing subframe shield .
– Remove nuts -1-.
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and instal‐
ling plenum chamber partition panel .
2. Emission control system 159

Audi Q5 2017 ➤

G505- .
– Remove exhaust gas temperature sender 4 - G648- -item 1-.
– Detach electrical connectors -1, 2, 3- from bracket, unplug

connectors and move electrical wiring clear.

Audi Q5 2017 ➤
– Unscrew bolt -2- and loosen retaining clip.

– Detach injector for reducing agent - N474- -item 1- and place
to one side.
– Unscrew NOx sender - G295- -arrow- using a tool from Lamb‐

da probe open ring spanner set - 3337- .
2. Emission control system 161

Audi Q5 2017 ➤
– Remove bolt -3- on retainer.

– Open screw-type clip -1- and place it on intake funnel of emis‐
sion control module.
– Remove emission control module -2- (pay attention to brake
servo pressure sensor - G294- ).
Installing
Note
Renew gaskets and self-locking nuts after removal.

– Install injector for reducing agent - N474- ⇒ page 171 .
– If emission control module has been renewed, perform adap‐
Tightening torques
♦ ⇒ “2.1 Exploded view - emission control system”, page 159
Exhaust gas temperature control; Exploded view - exhaust
gas temperature control
charge air system
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead;
Exploded view - plenum chamber partition panel
2.3 Removing and installing trap catalytic

converter
gine, common rail (EA 897 Gen. II) ; Rep. gr. 26 ; Emission control
system; Exploded view - emission control system .
2.4 Removing and installing exhaust flap

control unit - J883-
gine, common rail (EA 897 Gen. II) ; Rep. gr. 26 ; Emission control
system; Exploded view - emission control system .

Audi Q5 2017 ➤
3 SCR (selective catalytic reduction)

system
⇒ “3.1 Exploded view - reducing agent tank”, page 163
⇒ “3.2 Exploded view - control unit for SCR system”, page 165
⇒ “3.3 Exploded view - delivery unit”, page 166
⇒ “3.4 Exploded view - reducing agent supply line”, page 166
⇒ “3.5 Releasing pressure in SCR system”, page 167
⇒ “3.6 Draining reducing agent tank”, page 167
⇒ “3.7 Removing and installing reducing agent tank”, page 168
⇒ “3.8 Removing and installing injector for reducing agent N474
”, page 171
⇒ “3.9 Removing and installing control unit for reducing agent
metering system J880 ”, page 171
⇒ “3.10 Removing and installing pump for reducing agent V437 ”,
page 171
⇒ “3.11 Removing and installing pressure sender for reducing
agent metering system G686 ”, page 174
⇒ “3.12 Removing and installing connection for SCR supply line”,
page 177
3.1 Exploded view - reducing agent tank
3. SCR (selective catalytic reduction) system 163

Audi Q5 2017 ➤
1 - SCR supply line

❑ With heater
❑ May comprise several
segments
2 - Bolt
❑ 23 Nm
3 - Spacer sleeve
4 - Grommet
5 - Filler neck
❑ For reducing agent tank
6 - Filler neck
❑ For fuel tank
7 - Filler cap
❑ For filler neck for reduc‐
ing agent tank
8 - Bolt
❑ 8 Nm
9 - Reducing agent tank
❑ With delivery unit for re‐
ducing agent metering
system - GX19-
❑ The following compo‐
nents are integrated in
the delivery unit for re‐
ducing agent metering
system - GX19- :
♦ Filter
♦ Tank sender for reducing
agent - G684-
♦ Temperature sender for re‐
ducing agent - G685-
♦ Pressure sender for reducing agent metering system - G686-
♦ Pump for reducing agent - V437-
♦ Heater for reducing agent tank - Z102-
♦ Heater 2 for reducing agent tank (heater circuit 3) - Z167-
❑ Fitting location: on rear right under underbody
❑ Draining ⇒ page 167
10 - Heat shield
11 - Bolt
❑ 2 Nm
12 - Drain plug

Audi Q5 2017 ➤
3.2 Exploded view - control unit for SCR system
1 - Electrical connector
2 - Control unit for reducing
agent metering system - J880-
❑ Checking ⇒ Vehicle di‐
agnostic tester
⇒ page 171
❑ After renewing ⇒ Serv‐
gr. 00 ; Repair notes;
Adapting learnt values
for SCR system
3 - Nut
❑ 5 Nm

Audi Q5 2017 ➤
3.3 Exploded view - delivery unit
1 - Bolts
❑ 2 Nm
2 - Sealing cap
3 - Bolts
❑ 2 Nm
4 - Pump for reducing agent -
V437-
⇒ “3.10 Removing and
installing pump for re‐
ducing agent V437 ”,
page 171
5 - O-rings
❑ When installing, lightly
lubricate O-rings using a
cotton bud soaked in re‐
ducing agent
6 - Delivery unit
7 - O-ring
❑ When installing, lightly
lubricate O-ring using a
cotton bud soaked in re‐
ducing agent
8 - SCR supply line
9 - Connection
⇒ “3.12 Removing and
installing connection for
SCR supply line”,
page 177
10 - Bolts
❑ 2 Nm
11 - O-ring
❑ When installing, lightly lubricate O-ring using a cotton bud soaked in reducing agent
12 - Pressure sender for reducing agent metering system - G686-
⇒ “3.11 Removing and installing pressure sender for reducing agent metering system G686 ”,
page 174
13 - Bolts
❑ 2 Nm
3.4 Exploded view - reducing agent supply

line
gine, common rail; Rep. gr. 26 ; SCR (selective catalytic reduc‐
tion) system; Exploded view - reducing agent supply line .

Audi Q5 2017 ➤
3.5 Releasing pressure in SCR system

tion) system; Releasing pressure in SCR system .
3.6 Draining reducing agent tank

♦ Safety goggles
Procedure
• Re-install all cable ties in the same locations when installing.
– Switch off ignition.
WARNING
Safety risk due to escaping reducing agent.

♦ To prevent large amounts of reducing agent from escap‐
ing when the metering line is opened, wait until the reduc‐
ing agent has been drawn back automatically.
Note:
It can take up to 10 minutes after the ignition has been switched
off for the reducing agent to be drawn back completely.
– Open tank flap.
– Unscrew filler cap -arrow- from filler neck for reducing agent.
– Remove underbody trim (rear right) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim .
WARNING
Risk of injury caused by escaping reducing agent

Reducing agent can cause eye and skin irritation, damage to
the respiratory tract and poisoning.
• Wear protective clothing.
• Ensure that there is sufficient fresh air. In enclosed
spaces, switch on the exhaust extraction system.
– Release pressure in SCR system ⇒ Servicing 4-cylinder TDI

engine, common rail; Rep. gr. 26 ; SCR (selective catalytic
reduction) system; Releasing pressure in SCR system .

Audi Q5 2017 ➤
– Place drip tray underneath.

– Press release tab and remove sealing plug -arrow-.
– Allow reducing agent to drain off into drip tray.
Attaching
– Seal off drain pipe with sealing plug.
– After filling with reducing agent or renewing components ⇒
Repair notes; Adapting learnt values for SCR system .
Tightening torques
trim
3.7 Removing and installing reducing agent

tank
♦ Engine bung set - VAS 6122-

Audi Q5 2017 ➤
Removing
– Drain reducing agent tank ⇒ page 167 .
– Remove rear wheel housing liner (right-side) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (rear) .
Remove underbody trim (rear right); to do so, unscrew nut -1- and
bolts -arrows- and detach underbody trim -2-.
– Wrap a cloth around SCR supply line -4- and disconnect SCR
supply line from connection -3-.
Note
To disconnect SCR supply line, press release catches in direction

of -arrows-.

Audi Q5 2017 ➤
– Unplug electrical connectors -arrows- and move electrical wir‐

ing harness clear.
– Release hose clips -arrows- and disconnect hoses.

Caution

♦ Reducing agent tank must be empty when it is removed.
– Remove bolts -arrows- and detach reducing agent tank -1-.

Installing
– Connect SCR supply line ⇒ Servicing 4-cylinder TDI engine,
common rail; Rep. gr. 26 ; SCR (selective catalytic reduction)
system; Exploded view - reducing agent supply line .
– Check that lines are clipped onto reducing agent tank.
– Install rear wheel housing liner (right-side) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (rear) .
Install underbody trim (rear right).
– After filling with reducing agent or renewing components ⇒
Repair notes; Adapting learnt values for SCR system .
Tightening torques
♦ ⇒ “3.1 Exploded view - reducing agent tank”, page 163
liners; Exploded view - wheel housing liner (rear)

Audi Q5 2017 ➤
3.8 Removing and installing injector for re‐

ducing agent - N474-
tion) system; Removing and installing injector for reducing agent
- N474- .
3.9 Removing and installing control unit for

reducing agent metering system - J880-
♦ Vehicle diagnostic tester
Removing
– Remove service cover from luggage compartment side trim
(right-side) ⇒ General body repairs, interior; Rep. gr. 70 ;
Luggage compartment trim panels; Removing and installing
luggage compartment side trim .
– Remove nuts -arrows- and detach control unit for reducing
agent metering system - J880- -item 2-.
Installing
– If control unit for reducing agent metering system - J880- is
renewed ⇒ Servicing 4-cylinder TDI engine, common rail;
Rep. gr. 00 ; Repair notes; Adapting learnt values for SCR
system .
Tightening torques
♦ ⇒ “3.2 Exploded view - control unit for SCR system”,
page 165
3.10 Removing and installing pump for re‐

ducing agent - V437-
♦ Safety goggles
Procedure
WARNING


Audi Q5 2017 ➤
WARNING

/8
Note

of -arrows-.
– Unscrew bolts -1 to 6- and detach sealing cap.

Audi Q5 2017 ➤
– Unscrew bolts -1, 2, 3- for pump for reducing agent - V437- .

– Pull out pump for reducing agent (hold it only at the two points
indicated -arrows-).
– Use a cloth to catch any drops of reducing agent.
– To avoid damage, use a plastic tool to remove any O-rings that
remain lodged in housing.
Installing
– Remove cap from pump and rotate pump rotor -3- twice by
hand in direction of -arrow-.
– Fit O-rings -1 and 2- onto connections of pump for reducing
agent - V437- .
– Lightly lubricate O-rings using a cotton bud soaked in reducing
agent.
– Carefully fit pump for reducing agent - V437- (hold it only at

the two points indicated -arrows-).
– Press in pump for reducing agent as far as stop by pressing
point -A-.
– Screw in bolts by hand until they make contact, then unscrew
by one turn and finally tighten to specified torque.
Tightening torques
♦ ⇒ “3.3 Exploded view - delivery unit”, page 166
Note
Renew sealing cap and bolts.

Audi Q5 2017 ➤
– Clean sealing surface -arrow- on delivery unit.
Caution
Risk of leaks
♦ The seal must not be pinched or damaged when fitting the
sealing cap.
– Fit sealing cap, screw in bolts -1 to 6- by hand until they make

contact and then tighten.
– Install underbody trim (rear right) -2-.

– If pump for reducing agent - V437- was renewed, “Reset learnt
values”.
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and then Start diagnosis .
– Choose Select own test tab and select following options
one after the other:
♦ Drive train
♦ Select engine code and engine
♦ 01 - Self-diagnosis compatible systems
♦ 01 - Engine electronics
♦ 01 - Engine electronics, functions
♦ 01 - Reset reduction agent system learned values
3.11 Removing and installing pressure send‐

er for reducing agent metering system -
G686-
♦ Safety goggles
Procedure

Audi Q5 2017 ➤
WARNING

WARNING

Note

of -arrows-.

Audi Q5 2017 ➤
– Unscrew bolts -1 to 6- and detach sealing cap.
– Unscrew bolts -1 and 2- for pressure sender for reducing agent

metering system - G686- .
– Pull out pressure sender for reducing agent metering system
(hold it only at the two points indicated -arrows-).
– To avoid damage, use a plastic tool to remove O-ring if it re‐
mains lodged in housing.
Installing
– Remove cap from pressure sender for reducing agent meter‐
ing system - G686- .
– Lightly lubricate O-ring using a cotton bud soaked in reducing
agent.
– Fit pressure sender for reducing agent metering system -

G686- (hold it only at the two points indicated -arrows-).
– Press in pressure sender for reducing agent metering system
- G686- as far as stop; press only on point -A-.
Tightening torques
Note
Renew sealing cap and bolts.

Audi Q5 2017 ➤
– Clean sealing surface on delivery unit.
Caution
Risk of leaks
♦ The seal must not be pinched or damaged when fitting the
sealing cap.
– Fit sealing cap, screw in bolts -1 to 6- by hand until they make

contact and then tighten.

– If pressure sender for reducing agent metering system - G686-
was renewed, “Reset learnt values”.
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and then Start diagnosis .
– Choose Select own test tab and select following options
one after the other:
♦ Drive train
♦ Select engine code and engine
♦ 01 - Self-diagnosis compatible systems
♦ 01 - Engine electronics
♦ 01 - Engine electronics, functions
♦ 01 - Reset reduction agent system learned values
3.12 Removing and installing connection for

SCR supply line
♦ Safety goggles
Procedure

Audi Q5 2017 ➤
WARNING

WARNING

Note

of -arrows-.

Audi Q5 2017 ➤
– Unscrew bolts -1 and 2- for connection.
Note
♦ The tool for bolts -1 and 2- is supplied together with the new
connection.
♦ Do not reuse the tool.
– Pull out connection (hold it only at the two points indicated

-arrows-).
Installing
– Lightly lubricate O-ring using a cotton bud soaked in reducing
agent.
– Take hold of connection at the two points -arrows- and fit it.
– Press in connection -3- as far as stop; press only on point
-A-.
– Detach cap from connection and connect SCR supply line.
• Plug-in connector must engage audibly when connecting.
• Pull to check that plug-in connectors are correctly engaged.

Tightening torques

Audi Q5 2017 ➤
4 Exhaust gas temperature control

⇒ “4.1 Exploded view - exhaust gas temperature control”,
page 180
⇒ “4.2 Removing and installing exhaust gas temperature sender 1
G235 ”, page 182
G448 ”, page 182
G495 ”, page 182
G648 ”, page 182
4.1 Exploded view - exhaust gas tempera‐

ture control
WARNING


Audi Q5 2017 ➤
1 - NOx sender 2 - G687- with

control unit for NOx sender 2 -
J881-
⇒ page 144
2 - Particulate sensor - G784-
⇒ page 147
- G505-
⇒ page 139
4 - Exhaust gas temperature
sender 3 - G495-
TDI engine, common
rail; Rep. gr. 26 ; Ex‐
haust gas temperature
control; Removing and
installing exhaust gas
temperature sender 3 -
G495-
Rep. gr. 26 ; Exhaust
gas temperature con‐
trol; Exploded view - ex‐
haust gas temperature
control
5 - NOx sender - G295- with
control unit for NOx sender -
J583-
⇒ page 144
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas temper‐
ature control; Exploded view - exhaust gas temperature control
7 - Lambda probe - G39- with Lambda probe heater - Z19-
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe;
Removing and installing Lambda probe
4. Exhaust gas temperature control 181

Audi Q5 2017 ➤
4.2 Removing and installing exhaust gas

temperature sender 1 - G235-
gine, common rail; Rep. gr. 26 ; Exhaust gas temperature control;
Removing and installing exhaust gas temperature sender 1 -
G235- .

G448- .

G495- .

Removing
WARNING

Note


Audi Q5 2017 ➤

G505- .

breather hose -2-.
– Remove bolts -arrows- and detach resonator -1-.
engine, common rail; Rep. gr. 26 ; Exhaust gas temperature con‐
trol; Removing and installing exhaust gas temperature sender 4
- G648- .
Installing
Additional work:
Note

Tightening torques
charge air system
4. Exhaust gas temperature control 183

Audi Q5 2017 ➤
5 Exhaust gas recirculation

⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 184
⇒ “5.2 Removing and installing exhaust gas recirculation cooler”,
page 186
⇒ “5.3 Removing and installing exhaust gas recirculation control
motor 2 V339 ”, page 188
⇒ “5.4 Removing and installing exhaust gas recirculation temper‐
ature sensor G98 ”, page 189
5.1 Exploded view - exhaust gas recircula‐

tion system
⇒ “5.1.1 Exploded view - exhaust gas recirculation system, engine
side (front)”, page 184
⇒ “5.1.2 Exploded view - exhaust gas recirculation system, low-
pressure side (rear)”, page 184
5.1.1 Exploded view - exhaust gas recircula‐

tion system, engine side (front)
gine, common rail; Rep. gr. 26 ; Exhaust gas recirculation system;
Exploded view - exhaust gas recirculation system .
5.1.2 Exploded view - exhaust gas recirculation system, low-pressure side (rear)

Audi Q5 2017 ➤
1 - Hoses
❑ To pressure differential
sender 2 - G524-
2 - G524-
⇒ page 139
3 - Bracket
❑ For pressure differential
sender 2 - G524-
4 - Bolt
❑ 9 Nm
5 - Nut
❑ 9 Nm
6 - Connection
7 - Hose
❑ For exhaust gas recircu‐
lation
8 - Bolt
❑ 9 Nm
9 - Seal
control motor 2 - V339-
⇒ page 188
11 - Gasket
❑ On some vehicle ver‐
sions, gasket and dirt
screen -12- are a single component
12 - Dirt screen
❑ On some vehicle versions, gasket -11- and dirt screen are a single component
❑ Dirt screen must be renewed if emission control module was renewed
13 - Bolt
❑ 20 Nm
14 - Bolt
❑ Tightening torque ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger
15 - Resonator
16 - Seal
17 - Exhaust gas recirculation pipe
18 - Exhaust gas recirculation cooler (rear)
19 - Bolt
❑ 9 Nm
5. Exhaust gas recirculation 185

Audi Q5 2017 ➤
20 - Gasket
21 - Screw-type clip
❑ 15 Nm
22 - Mounting
23 - Bolt
❑ 23 Nm
24 - Exhaust gas recirculation pipe
❑ With flexible joint
25 - Clamp
❑ Tighten screw connections evenly to 30 Nm
5.2 Removing and installing exhaust gas re‐

circulation cooler
⇒ “5.2.1 Removing and installing exhaust gas recirculation cooler
(front)”, page 186
⇒ “5.2.2 Removing and installing exhaust gas recirculation cooler
(rear)”, page 186
5.2.1 Removing and installing exhaust gas re‐

circulation cooler (front)
gine, common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation cooler .
5.2.2 Removing and installing exhaust gas re‐

circulation cooler (rear)

Audi Q5 2017 ➤
♦ Socket Torx T30 - T10405-
Removing
G524- clear.
– Remove subframe shield (left-side) ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing
subframe shield .
– Release clamp -arrow- on exhaust gas recirculation pipe.
– Loosen screw-type clip -2-.

– Remove bolts -arrows- and detach exhaust pipe -1-.
– Remove tunnel cross member and lower gearbox ⇒ 8-speed
automatic gearbox; Rep. gr. 37 ; Assembly mountings; Ex‐
ploded view - assembly mountings .

Audi Q5 2017 ➤
– Release hose clip -3- at hose for exhaust gas recirculation.

– Remove bolt -1- from retaining clip.
– Release hose clip -2- and detach coolant hose from coolant
circulation pump - V50- .
– Unplug electrical connector -4- and move electrical wire clear.
– Remove bolts -arrows- and detach exhaust gas recirculation
cooler (rear) -5-.
Installing
Note
♦ Renew seals and O-rings after removal.

Note

Tightening torques
♦ ⇒ “1.1 Exploded view - turbocharger”, page 109
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mount‐
ings; Exploded view - assembly mountings

circulation control motor 2 - V339-
Removing
– Remove exhaust gas recirculation cooler (rear) ⇒ Servicing
tion cooler .

Audi Q5 2017 ➤
– Unscrew bolt -2- and nuts -arrows- and detach exhaust gas
recirculation control motor 2 - V339- -item 1-.
Installing
Note
Renew seals and O-rings after removal.
– Clean and insert strainer ⇒ Item 12 (page 185) .

– Install exhaust gas recirculation cooler (rear) ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
tion cooler .
Tightening torques

circulation temperature sensor - G98-
gine, common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation temperature
sensor - G98- .

Audi Q5 2017 ➤
6 Exhaust manifolds
⇒ “6.1 Exploded view - exhaust manifold”, page 190
⇒ “6.2 Removing and installing exhaust manifolds”, page 191
6.1 Exploded view - exhaust manifold
WARNING

1 - Nut
❑ Tightening torques and
installation instructions
TDI engine, common
haust manifolds; Explo‐
ded view - exhaust
manifold
2 - Exhaust manifold
❑ Shown for cylinder bank
2 (left-side)
⇒ page 191
3 - Gasket
❑ Installation instructions
TDI engine, common
ded view - exhaust
manifold
4 - Gasket
❑ Installation instructions
TDI engine, common
ded view - exhaust
manifold
5 - Clamp
Rep. gr. 21 ; Turbo‐
charger; Exploded view
- turbocharger

Audi Q5 2017 ➤
6.2 Removing and installing exhaust mani‐

folds
⇒ “6.2.1 Removing and installing exhaust manifold (left-side)”,
page 191
⇒ “6.2.2 Removing and installing exhaust manifold (right-side)”,
page 192
6.2.1 Removing and installing exhaust mani‐

fold (left-side)
Removing
WARNING

– Remove front wheel (left-side) ⇒ Running gear, axles, steer‐

ing; Rep. gr. 44 ; Wheels, tyres .
– Detach poly V-belt from air conditioner compressor pulley
⇒ page 45 .
– Remove drive shaft cover (left-side) ⇒ General body repairs,
– Release clip -1- and slide it onto intake funnel of turbocharger.
6. Exhaust manifolds 191

Audi Q5 2017 ➤
– Remove nuts -arrows- and detach exhaust manifold towards

rear.
Installing
Note
Renew gaskets, seals, self-locking nuts and screw-type clip after

removal.

– Install poly V-belt ⇒ page 45 .
Tightening torques
Exhaust manifolds; Exploded view - exhaust manifold
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
6.2.2 Removing and installing exhaust mani‐

fold (right-side)
Removing
WARNING


– Remove coolant pipes (rear) ⇒ page 95 .
– Unbolt coolant pipe (front) and detach from thermostat
⇒ page 87 .
– Release screw-type clip -1- and detach exhaust gas recircu‐
lation pipe -2-.

Audi Q5 2017 ➤

breather hose -2-.
– Remove bolts -arrows- and detach resonator -1-.
– Remove bolts -1, 3- and press air pipe -2- to one side.
– Release clip -2- and slide it onto intake funnel of turbocharger.

– Remove engine support (right-side) ⇒ page 49 .
6. Exhaust manifolds 193

Audi Q5 2017 ➤
– Remove nuts -arrows- and detach exhaust manifold towards

rear.
Installing
Note
Renew O-ring, bolts and screw-type clips after removal.
– Install engine support ⇒ page 49 .

– Install rear coolant pipes ⇒ page 95 .
– Install coolant pipe (front) ⇒ page 87 .
Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 111
Exhaust manifolds; Exploded view - exhaust manifold

Audi Q5 2017 ➤
28 – Glow plug system

1 Glow plug system
cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug
system .
1. Glow plug system 195

07-6-Cyl. TDI Engine, 3.0 Ltr. 4-Valve Common Rail (EA 897 - Gen. II)

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Service Department. Technical Information

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Copyright © 2018 Audi AG, Ingolstadt D4B806BCE78

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

♦ Removal lever - 80-200-

♦ Engine bung set - VAS 6122-

4 Rep. gr.10 - Removing and installing engine

♦ Scissor-type assembly platform - VAS 6131 B-

♦ Support set for Audi - VAS 6131/10-

♦ Adapter -VAS 6131/11-1- from support set, Audi A8 >2002 -

♦ Coolant collecting system - VAS 5014- or drip tray for work‐

1. Removing and installing engine 5

♦ Hose clip pliers - VAS 6362-

♦ Hose clip pliers - VAS 6340-

♦ Ball joint ejector - VAS 251 805-

6 Rep. gr.10 - Removing and installing engine

♦ Ball joint puller (tool currently being developed)

♦ The engine is removed from underneath together with the

– Before starting work, determine unladen position ⇒ Running

The electromechanical parking brake must be released before

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

1. Removing and installing engine 7

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

– Release fastener -arrow- and open filler cap -1- on coolant

– Place collector tank from coolant collecting system -VAS

8 Rep. gr.10 - Removing and installing engine

– Remove bolts -arrows- and detach air duct -1-.

– Release hose clips -arrows- and detach air pipe -1-.

– Unplug electrical connector -2- for air mass meter - G70- .

1. Removing and installing engine 9

– Disconnect fuel hoses -1, 2, 3- ⇒ Fuel supply system; Rep.

– Move electrical connector -arrow- clear and unplug.

– Release fastener -arrow B- and open terminal 30 wiring junc‐

– Release hose clip -arrow- and disconnect coolant hose from

10 Rep. gr.10 - Removing and installing engine

– Unplug electrical connector -2-.

– Release fastener -arrow- and disconnect vacuum hose -1-,

1. Removing and installing engine 11

– Detach electrical connectors -2- from bracket, unplug and

– Unplug electrical connector “K” -arrow-.

– Detach electrical connector -3- from bracket, unplug and move

– Remove nut -arrow- and move earth wires clear.

12 Rep. gr.10 - Removing and installing engine

– Unplug electrical connector -2- for electrohydraulic engine

Danger of damage to the joints of the upper links.

– Tie up wheel bearing housing on both sides using tensioning

1. Removing and installing engine 13

– To protect thread, unscrew nut -arrow- on joint pin of track rod