2.8l v6 30v (engine Code: Aha, Atq) Audi A4 B5 рестайлинг

ENGINE IDENTIFICATION

Note. For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION.

Engine can be identified by code and serial number stamped on right side of engine block, in front of right (passenger side) cylinder head. See ENGINE IDENTIFICATION CODES and (Scheme 135). Engine code is also identified on vehicle data label.

ENGINE IDENTIFICATION CODES

Scheme 135

ACCELERATOR PEDAL

1. Remove clip for accelerator pedal cable on throttle body. Depress and hold accelerator pedal to Wide Open Throttle (WOT) position.
2. On manual transmission vehicles, reinstall clip for accelerator pedal cable. On automatic transmission vehicles, disconnect kickdown switch 2-pin harness connector. Using DVOM, ensure continuity exists between kickdown switch terminals in WOT position. On all models, release accelerator pedal. Adjustment is complete. After adjusting accelerator pedal, check Closed Throttle Position (CTP) switch and WOT stops.

VALVE CLEARANCE ADJUSTMENT

Engine is equipped with non-adjustable, non-serviceable hydraulic valve lifters. Irregular valve adjuster noise during cranking is normal. If valve lifters are noisy under any other condition, see VALVE LIFTERS under REMOVAL & INSTALLATION.

TROUBLE SHOOTING

To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

Note. When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE

Note. For more information on relay identification, see appropriate COMPONENT LOCATIONS article in ELECTRICAL section.

Remove fuel pump fuse No. 28. from fuse/relay block, under left side of instrument panel. (Scheme 136) Start engine. Allow engine to run until it stops. Turn ignition off. Disconnect negative battery cable. Install fuel pump relay. Slight pressure may remain in system. Before disconnecting any fuel system line, cover connector with a clean shop towel.

Scheme 136

DRAINING COOLING SYSTEM

Remove lower engine shield (noise insulator). (Scheme 142) Open cap on engine coolant expansion tank. Drain coolant from radiator and at engine coolant drain screw on engine block using (3247) hex ball socket. (Scheme 156)and (Scheme 157).

COOLING SYSTEM BLEEDING

Scheme 137

1. Expose vent hole on heater pipe, at firewall connection, by pulling back heater hose. (Scheme 137) Fill cooling system through expansion tank until coolant comes out of vent hole. Tighten heater hose.
2. Fill expansion tank to proper level. Loosen bleeder screw on lower coolant hose, located under expansion tank. Unbolt expansion tank if necessary. Top off coolant until it flows from bleed screw. Close bleed screw.
3. Fill expansion tank to proper level. Loosen bleed screw on front coolant line between power steering pump and left of cylinder head. Top off coolant until it flows from bleed screw. Close bleed screw.
4. Fill expansion tank to proper level. Install expansion tank cap. Start engine and raise engine speed to 2000 RPM for about 5 minutes. Return engine to idle. Check coolant level in expansion tank. Fill as necessary.

A6

1. Inspect coolant lines for bleed screws. One is located at front of engine near the upper hose connection. Loosen bleed screws front and on rear coolant pipe.
2. Expose vent hole on heater pipe at firewall connection by pulling back heater hose. (Scheme 137) Fill cooling system through expansion tank until coolant comes out of vent hole and bleed screws. Tighten heater hose and bleed screws.
3. Fill expansion tank to proper level. Install expansion tank cap. Adjust heater controls to maximum heat position. Start engine and raise engine speed to 2000 RPM for about 3 minutes. Ensure cooling fan operates. Return engine to idle. Check coolant level in expansion tank. Fill as necessary. Repeat and recheck.

Remove

1. On A4 and A6, move lock carrier into service position for access to serpentine belt. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).
2. Remove trim cover from top of engine. (Scheme 155) Remove engine noise insulation shield from under engine. (Scheme 142)
3. Using Spanner Wrench (3212), hold viscous fan pulley. (Scheme 160) Using Open End Wrench (3312), or equivalent, rotate viscous fan clockwise to remove.
4. Using a wrench, rotate ribbed belt tensioner clockwise and install a drift to hold. Remove serpentine belt. (Scheme 161)

Installation

1. If reusing original serpentine belt, ensure belt is installed in original direction of rotation.
2. Install viscous fan and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications) .
3. Install lock carrier to body. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier) .

LOCK CARRIER

Note. Lock carrier is slid forward onto alignment tools. This will allow servicing of front engine components. Lock carrier can be removed at technicians discretion.

Placing In Service Position (A4 & A6)

Note. It is not necessary to completely removal noise insulation from beneath the engine. Only remove the quick release fasteners the attach to the front bumper assembly.

Scheme 138

Scheme 139

Scheme 140

1. Remove front bumper. See «FRONT BUMPER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
2. Unbolt air guide between lock carrier and air filter on lock carrier. Inspect headlight and turn signal electrical connectors and wiring harness (which may hang up when lock carrier is moved forward).
3. On right side, remove bolt (5) and install support tool (3369) in its place. (Scheme 138)and (Scheme 139).
4. On left side, install support tool (3369) in threaded hole in chassis. (Scheme 140)
5. Remove on both sides, all (No. 2) bolts. (Scheme 138)
6. Remove on both sides, all (No. 3 and 4) bolts. (Scheme 138) Slide lock carrier forward unit the rear bolt hole in lock carrier aligns with the forward threaded fender bolt hole.
7. Secure lock carrier in this position, by placing fender bolts in holes. (Scheme 141) To install, reverse placing in service position procedure.

Scheme 141

Removal & Installation (A4)

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 142)- (Scheme 149).

1. Raise vehicle, remove front tires, remove lower front engine shield (noise insulator). (Scheme 142) With vehicle raised, loosen appropriate front bumper fasteners at this time. (Scheme 143)- (Scheme 149). Lower vehicle.
2. Separate hood release lever from hood lock. Disconnect any wiring harness that attach to the front bumper.
3. Remove front bumper cover. (Scheme 143)or (Scheme 146). Remove bumper cover carrier from impact absorbers.
4. To install, reverse removal procedure. Adjust front bumper height (A4; Up To VIN 8DXA20000) (Scheme 145) To move lock carrier into service position, see «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Removal (A6)

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 150)- (Scheme 154).

1. Disconnect any wiring harness that attach to the front bumper.
2. Raise vehicle, remove front tires. Remove lower front engine shield (noise insulator). (Scheme 142) Loosen the front half of the wheel housing splash shield (liner). (Scheme 150) Unscrew flange nut (10) on both sides. (Scheme 152)
3. Unscrew with/washer assembly (6) from wheel housing liner (5). (Scheme 152) Remove socket-head bolts (7) and remove bumper cover together with impact absorbor towards front. (Scheme 152) To move lock carrier into service position. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Installation (A6)

1. Before installing the bumper, ensure the expanding clips are pressed into the fender. (Scheme 151) When installing the tabs, the bumper cover must latch into clip (4). (Scheme 152)
2. Latch bumper cover (1) into guide (2). (Scheme 152) Tighten flange nuts (10) to 53 INCH lbs. (6 N.m).
3. Screw in socket-head bolts (7) and tighten to 17 ft. lbs. (23 N.m). (Scheme 152)

Note. Obtain radio code before disconnecting battery. Remove engine, without transmission, through front of engine compartment.

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__fuel-pressure-release). Ensure ignition switch is in the OFF position. Disconnect battery cables. Remove clip for accelerator pedal cable on throttle body and remove cable from throttle body.
2. Turn ignition off. Disconnect negative battery cable. Remove engine cover. (Scheme 155)
3. Remove lower engine shield. (Scheme 142) Open cap on engine coolant expansion tank. Drain coolant from radiator and at engine coolant drain screw on engine block using Hex Ball Socket (3247). (Scheme 156)- (Scheme 157).
4. Remove complete front bumper assembly. See «FRONT BUMPER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
5. Disconnect power steering cooling coil, located at lower left of radiator. Let cooling coil hang free. (Scheme 158)
6. Remove left and right side air ducts (4). Remove condenser mounting bolts (1) and (2). Disconnect harness connector (3) for A/C pressure switch. (Scheme 159) Pull condenser up out of its bracket, rotate it to side and use wire to secure it on or near right front wheel.
7. Move lock carrier to service position. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).
8. Using Spanner Wrench (3212), hold viscous fan pulley. (Scheme 160) Using Open End Wrench (3312), or equivalent, rotate viscous fan clockwise to remove. Using a wrench, rotate ribbed belt tensioner clockwise and install a drift to hold. Remove serpentine belt. (Scheme 161)
9. Remove air intake hose between Mass Airflow (MAF) sensor and intake air elbow. Remove secondary air injection duct by turning it 1/4 turn to the right. (Scheme 162)and (Scheme 163). Remove upper part of air cleaner assembly. Disconnect cruise control vacuum unit. Disconnect accelerator pedal cable. DO NOT remove locking clip on accelerator pedal cable bracket.
10. Disconnect fuel supply and return lines. Disconnect coolant, electrical and vacuum connections at engine. (Scheme 164) Remove 3 bolts at rear part of intake manifold. Remove engine coolant expansion tank and position to side.
11. Disconnect 5 harness connectors below cover of ABS hydraulic control unit. Remove retainer form ground wire and remove ground electrical connector. (Scheme 165)and (Scheme 166). Remove vacuum connections at engine.
12. Remove wiper arms and water deflector. Remove cover from ECM (E-Box). Disconnect wiring harness connectors from ECM. (Scheme 167)
13. Disconnect exhaust manifold connections. Disconnect 4 oxygen sensor harness connectors. Remove ground wire at engine/cross member. (Scheme 168) Remove front exhaust pipes with converters. Disconnect starter and generator electrical connections. Unbolt starter and remove between subframe and drive axle.
14. Clamp off two hoses at hydraulic fluid supply line using Hose Clamps(3094). Disconnect supply line (see arrow) below left cylinder head. (Scheme 169) Place rag(s) under connection to catch escaping fluid.
15. Disconnect hydraulic pressure line at rear coolant line. Disconnect hydraulic pressure line at right side cylinder head. (Scheme 170)
16. Detach A/C refrigerant line from oil pan at front of engine. (Scheme 171)
17. Remove upper engine-to-transmission bolts. Remove lower left and right engine mount nuts. If equipped with automatic transmission, remove 3 torque converter bolts. (Scheme 172) Lift engine and transmission slightly usingHoist Crane (VAG 1202 A) to allow lower engine/transmission connecting bolts to be removed. Remove lower engine/transmission connecting bolts. (Scheme 173)
18. Mark positions of left and right engine mount locating sleeves from bottom. (Scheme 174) Position Support Bridge (10-222A) on bolted flanges of fenders. Engage Support Adaptor (3147) in bolt hole in bellhousing on transmission. (Scheme 175)
19. Attach Engine Sling (2024A) to engine. Using hoist, lift engine from vehicle. (Scheme 175)and (Scheme 176).

Scheme 171

1. To install, reverse removal procedure. Always replace self-locking nuts. Ensure engine and transmission locating dowel pins and centering sleeves are properly installed in cylinder block and bell housing. For manual transmission, go to next step. For automatic transmission, go to step 7.
2. For manual transmission, clean and lubricate transmission input shaft splines with lubricant (G 000100). Make sure clutch disc and pressure plate are properly installed. Make sure pilot needle bearing is installed. If pilot needle bearing is worn, see «PILOT NEEDLE BEARING (MANUAL TRANSMISSION)»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq). For more information on transmission servicing, see appropriate article in CLUTCHES.
3. Align engine to transmission bell-housing. Install proper length bolts and torque to specifications. (Scheme 177) See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
4. Install engine mounts free of tension by aligning engine with shaking motions prior to tightening bolts. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
5. Align exhaust so components are free of stress. Adjust accelerator pedal. See «ACCELERATOR PEDAL»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__accelerator-pedal) under ADJUSTMENTS. Verify engine fluids are filled to proper levels.
6. Install vacuum lines. (Scheme 178) Install serpentine drive belts. (Scheme 180)or (Scheme 181).
7. If the torque converter is installed correctly, the distance between contact surfaces at the mounting holes on the torque converter and contact surface of the bell housing flange will be about 7/8". (Scheme 179) If the torque converter was not completely installed, this distance will be about 7/16".
8. For automatic transmission, when mounting torque converter to drive plate, use only bolts specified for this use. Before installing engine, align torque converter and drive plate so that one hole in torque converter and one hole in drive plate are level with opening for starter. (Scheme 172)
9. Align engine to transmission bell-housing. Install proper length bolts and torque to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq). For more information, see appropriate REMOVAL & INSTALLATION article TRANSMISSION/TRANSAXLE.
10. Install engine mounts free of tension by aligning engine with shaking motions prior to tightening engine mounts. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
11. Align exhaust so components are free of stress. Adjust accelerator pedal. See «ACCELERATOR PEDAL»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__accelerator-pedal) under ADJUSTMENTS. Verify engine fluids are filled to proper levels. Also check ATF fluid is filled to proper level.
12. Install vacuum lines. (Scheme 178)
13. Install serpentine drive belt. (Scheme 180)or (Scheme 181).

Scheme 172

Scheme 173

INTAKE MANIFOLD

Note. Obtain radio code before disconnecting battery.

Note. Always replace seals, gaskets and O-rings.

Removal & Installation (Audi)

No removal or installation procedure provided by vehicle manufacturer.

Disconnect exhaust pipe flange connections. Remove upper and lower heat shields. Remove exhaust manifold bolts and remove manifolds. To install, reverse removal procedures. Ensure exhaust system is aligned so components are free of stress. Replace all self-locking nuts. Tighten exhaust manifold bolts to specification. See TORQUE SPECIFICATIONS .

CYLINDER HEAD

Note. Engine must be cool before proceeding with cylinder head removal. DO NOT position pistons at TDC during removal procedure.

Scheme 174

1. On A4 and A6 models, remove front bumper. See «FRONT BUMPER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq). Place lock carrier into service position. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).
2. On all models, remove trim cover from top of engine. Remove noise insulation panel from under engine. (Scheme 142)
3. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__fuel-pressure-release). Obtain radio anti-theft code (if equipped), and disconnect negative battery cable.
4. Drain coolant from radiator. Remove coolant drain plug from engine. See «DRAINING COOLING SYSTEM»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__draining-cooling-system). Remove air intake hose with MAF sensor and throttle valve control module. Disconnect accelerator pedal cable.
5. Noting installed position for reassembly reference, disconnect all necessary electrical and vacuum connections to facilitate cylinder head removal. Remove intake manifold securing plate at rear of manifold.
6. Remove serpentine drive belt. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
7. Remove timing belt from camshaft sprockets. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt). It is not necessary to completely remove timing belt from crankshaft sprocket.
8. Disconnect exhaust pipes from cylinder heads. Unbolt exhaust system from transmission bracket. Disconnect fuel supply and return lines.
9. Remove fuel injector harness connectors from fuel injectors. Unbolt fuel rail from intake manifold. Remove fuel rail and injectors as an assembly.
10. Unbolt bracket for ignition coils and set aside. Remove intake manifold. Remove secondary air system connection pipe below intake manifold. Unbolt coolant pipe at rear of cylinder head.
11. On driver side cylinder head, remove camshaft sprocket using sprocket puller. (Scheme 192) Remove rear (inboard) timing belt from drive side cylinder head.
12. Unbolt coolant pipe at front of cylinder head. Remove cylinder head covers. Remove cylinder head bolts in REVERSE order of installation tightening sequence. (Scheme 182)

Inspection

Measure cylinder head height and warpage. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. If machining causes cylinder head height to be less than specification, replace cylinder head.

1. Clean all oil and coolant from blind holes in cylinder block.
2. Carefully clean cylinder head and cylinder block sealing surfaces, ensuring nor scoring or scratches are formed.
3. Only remove new cylinder head gasket immediately before installation. Install cylinder head gasket with "oben" mark or part number facing up.
4. Before installing cylinder head, ensure camshafts are set to TDC of No. 3 cylinder. Place No. 3 piston at TDC, and turn crankshaft back slightly.
5. Install cylinder heads on cylinder block.
6. Install NEW cylinder head bolts. Hand tighten cylinder head bolts. Tighten cylinder head bolts in correct sequence. (Scheme 182) It is not necessary to retorque cylinder head bolts after completing repairs.
7. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
8. Before installing valve cover and new gasket, apply small amount of sealant at 4 corners of cylinder head mating surface.
9. Install timing belt. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt). Install viscous fan and serpentine belt. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
10. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__cooling-system-bleeding).

CORE PLUG (CYLINDER HEAD)

Removal

Removal procedure of core plug not provided by manufacturer.

Coat outside circumference of core plug (sealing cap) with sealant (AMV 188 001 02). Using needle Bearing Drift (VW295), drive in core plug until outside rim is flush with end of chamfer in cylinder head. (Scheme 183)

Scheme 175

CRANKSHAFT FRONT OIL SEAL

Note. During this procedure. No. 1. piston must be placed at Top Dead Center (TDC).

Scheme 176

Scheme 177

1. Remove sealing plug from hole in left side of cylinder block. Position crankshaft to Top Dead Center (TDC) for cylinder No. 1. Ensure TDC hole can be seen or felt through sealing plug hole. Install Crankshaft Holder (3242) into sealing plug hole to prevent crankshaft from rotating. (Scheme 184)
2. Remove timing belt. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt).
3. Using Seal Remover (3203), remove crankshaft seal. Unscrew inner part of Oil Seal Extractor (3202) 2 turns (about 3 mm) out of outer part and lock with knurled screw. (Scheme 185)
4. Lubricate thread head of oil seal extractor, place it in position while applying firm pressure screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against crankshaft until oil seal has been extracted. (Scheme 185)

PTFE Seal Installation Precautions

Some engines may be equipped with a PTFE (Teflon®) type oil seal. This seal can be identified by a wider sealing lip that is threaded. There is also no annual sealing ring on the seal. If the engine is equipped with a PTFE type seal, the replacement seal must be a PTFE seal.

Do NOT lubricate the sealing surface of the PTFE seal. It is installed dry. The seal MUST be installed with the direction arrow on the face of the seal facing the direction of rotation of the crankshaft.

Note. Manufacturer requires replacing crankshaft sprocket center bolt if loosened or removed.

Using Guide Sleeve (3202/1) and Installing Sleeve (3265), install dry (do not lube) crankshaft oil seal over guide sleeve. Press seal in flush with Installing Sleeve (3265). (Scheme 186) Tighten crankshaft sprocket bolt to specification. See TORQUE SPECIFICATIONS. Reassemble in reverse order.

Scheme 178

TIMING BELT

Note. Obtain radio code before disconnecting battery.

Note. For cylinder head removal. DO NOT position pistons at TDC during removal procedure.

Scheme 179

Scheme 180

1. For A4 and A6, move lock carrier into service position. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).
2. Remove serpentine belt and viscous fan. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
3. Remove noise insulation panel from under engine. (Scheme 142) Remove trim cover from top of engine. (Scheme 155)
4. Rotate crankshaft using center bolt so that timing marks are aligned. (Scheme 187) Remove upper timing belt guards.
5. Check position of camshafts. Larger holes of camshaft securing plates (located on front of camshaft sprockets) must be on inside and must align. (Scheme 188) If camshafts are in correct position, go to next step. If larger holes are positioned to the outside, rotate crankshaft one turn further. Go to next step.
6. Remove sealing plug from alignment access hole in left side of engine block. Ensure that hole in crankshaft is visible or be felt through alignment access hole. Install Crankshaft Holder (3242) into alignment access hole to prevent crankshaft from rotating. (Scheme 189)
7. Remove serpentine belt tensioner.
8. Remove center and right timing belt covers. If timing belt is to be reused, mark belt running direction with marker or crayon.
9. Using an 8-mm wrench, turn timing belt tensioning roller clockwise until tensioning lever compresses tensioner so that a pin (2 mm in diameter) can be inserted into plunger. (Scheme 190) Insert pin and release tension.
10. Remove vibration damper bolts around center bolt. (Scheme 191) Remove vibration damper. Remove serpentine belt idler pulley. Remove timing belt cover. Remove timing belt.

Scheme 181

Scheme 182

Scheme 183

1. Remove camshaft sprocket securing bolts and securing plates. Install a 10 mm bolt in center of camshaft. Install Sprocket Puller (3032) on camshaft sprocket. (Scheme 192) Remove camshaft sprockets.
2. Reinstall both camshaft sprockets, together with locking plate, and hand tighten bolts. Camshaft sprocket must be able to move on tapered camshaft. Repeat for each camshaft.
3. Install timing belt. (Scheme 193)
4. Install Camshaft Holding Bar (3391). (Scheme 194)
5. Use an 8-mm wrench to turn timing belt tensioning roller clockwise until tensioning lever compresses, and remove spring pin. (Scheme 190)
6. Using a torque wrench with an 8 mm hex bit, apply 11 ft. lbs. (15 N.m) to timing belt tensioner roller (pulley bearing). This ensures timing belt tensioner has expanded completely and properly tensioning belt.
7. Tighten camshaft sprockets to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications). To complete installation, reverse removal procedure.
8. Install serpentine belt and viscous fan. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq). On A4 and A6, secure lock carrier to body. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).

CAMSHAFTS

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 218)and (Scheme 219).

Scheme 184

Scheme 185

1. Remove timing belt. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt). Turn crankshaft back slightly (moves pistons off Top Dead Center TDC).
2. Remove camshaft drive sprocket bolt. Remove camshaft drive sprocket using puller. (Scheme 192)
3. Disconnect Camshaft Position (CMP) sensor housing and sensor rotor. Remove rear (inboard) timing belt guard. Remove valve cover.
4. Clean camshaft drive chain and chain sprockets. Moving only the camshafts, align the marks on the camshaft sprocket with arrows on the bearing caps. (Scheme 195) Using paint, mark chain and sprockets opposite arrows on bearing caps. Distance between both arrows (and between paint markings) is 16 rollers on the chain.
5. Carefully compress camshaft adjuster using Chain Tensioner (3366). Tighten to keep slight pressure on chain between camshafts. DO NOT overtighten camshaft adjuster. (Scheme 196)
6. Unbolt camshaft adjuster. Remove the following bearing caps. (Scheme 197) Evenly loosen bearing caps No. 1, 3, 5 and 7 alternately and diagonally. Identify each cap for installation in original position. No. 1 (Double Bearing Cap) No. 3 (Center Bearing Cap) No. 5 (Cap Located Behind Chain) No. 7 (Cap Next To Camshaft Adjuster)
7. Evenly loosen bearing caps No. 2 and No. 4 alternately and diagonally. Remove and place in correct order for reassembly in original position.
8. Remove camshafts together with camshaft adjuster. If reusing camshafts, inspect for wear. See «CAMSHAFT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq) table under ENGINE SPECIFICATIONS.
9. To check camshaft axial (end) play, see «CYLINDER HEAD»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq) under OVERHAUL.

Note. This is an interference engine. Pistons must not be positioned at TDC during assembly.

1. Apply clean engine oil to camshaft contact surfaces. Install chain onto both camshafts. Install camshaft adjuster between camshafts. Before installing camshafts, verify position of chain and chain sprockets (paint markings). (Scheme 195) Distance between both arrows (and between paint markings) is 16 rollers on the chain.
2. Install both camshafts in cylinder head together with camshaft adjuster.
3. Install camshaft bearing capsNo. 2 and No. 4. (Scheme 197) Casting of arrows on intake side point to chain. On exhaust side, arrows point to exhaust manifold. Evenly tighten bearing caps No. 2 and 4 for both camshafts, alternating in a diagonal sequence. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
4. Lightly bearing caps No. 1 and 7 mating surface with (AMV 174 004 01) sealant before installation. (Scheme 197) Install bearing caps No. 1, 3, 5 and 7. Evenly tighten bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
5. Remove Chain Tensioner (3366). Before installing valve cover and new gasket, apply small amount of sealant at 4 corners of cylinder head mating surface.
6. Install timing belt. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt).
7. To complete installation, reverse removal procedure.

VALVE LIFTERS

Note. Valve lifters are not repairable or adjustable. Replace faulty lifters. Irregular valve train noise is normal when starting engine.

Scheme 186

1. Start engine and run until cooling fan cycles at least once. Increase engine speed to 2500 RPM for 2 minutes or test drive vehicle and observe valve train noise. If valve train noise is still considered noisy, go to next step.
2. Turn engine off. Remove valve cover. Rotate crankshaft until camshaft lobes point upward on lifter being checked. Using a wooden or plastic wedge, push down on top of lifter. (Scheme 198)
3. Try inserting a.008" (.20 mm) feeler gauge between top of lifter and camshaft. If feeler gauge fits between top of lifter and camshaft, replace faulty lifter.
4. If irregular valve noise occurs repeatedly on short trips and disappears after extended driving, oil check valve must be replaced. See «OIL CHECK VALVE REPLACEMENT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__oil-check-valve-replacement).

CAMSHAFT OIL SEALS

Note. For help in identifying components and component locations (Scheme 218)and (Scheme 219).

Note. Various oil seal configurations may be used, ensure proper seal application is used.

Scheme 187

1. Remove timing belt. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt).
2. Remove camshaft drive sprocket bolt. Remove camshaft drive sprocket.
3. Unscrew inner part of Oil Seal Extractor (3240) oil seal extractor 2 turns (about 3 mm) out of outer part and lock with knurled screw. (Scheme 199)
4. Lubricate thread head of Oil Seal Extractor (3240), place it in position while applying firm pressure screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.

Installation (Left Side Camshaft)

DO NOT oil sealing lip or outer circumference of oil seal. Clean contact surface and sealing surface. Using Seal Installer (3241/2 guide sleeve and 3241/6 bolt), install new camshaft oil seal flush into cylinder head. (Scheme 200) Install camshaft drive sprocket. Reassemble in reverse order.

Scheme 188

Scheme 189

Scheme 190

1. Remove timing belt. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt).
2. Unbolt Camshaft Position (CMP) sensor housing. Remove CMP sensor shutter bolt and conical washer. (Scheme 219) Noting installed position for reassembly, carefully pry off shutter.
3. Screw Oil Seal Extractor (2058/1 bolt) into camshaft. (Scheme 201) Unscrew inner part of (2058) 2 turns (about 3 mm) out of outer part and lock with knurled screw. (Scheme 202)
4. Lubricate thread head of oil seal extractor, and place it in position. While applying firm pressure, screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.

Scheme 191

1. Clean contact surface and sealing surface (head and camshaft). DO NOT oil sealing lip or outer circumference of oil seal. Using seal installer with Press Sleeve (3241/1) and Bolt (3241/3), install new camshaft oil seal flush into cylinder head. (Scheme 203)
2. Install CMP sensor and conical washer in original position. (Scheme 219) Install and tighten bolt. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications). Reassemble in reverse order.

DRIVE PLATE (A/T)

Note. The following procedure is given assuming the transmission has been removed or the engine has been removed for servicing.

Scheme 192

1. Holding drive plate stationary, remove drive plate bolts. Manufacturer requires using NEW drive plate bolts on installation.
2. BEFORE removing shims and drive plate, note installed position for reassembly reference. (Scheme 204) Mark drive plate and shims for reference.
3. For vehicles equipped with an automatic transmission, inspect bushing at crankshaft flange. (Scheme 206) See «BEARING BUSHING FOR TORQUE CONVERTER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__bearing-bushing-for-torque-converter).

Scheme 193

Scheme 194

1. Install drive plate and shims in original locations. Install OLD bolts into flange. Check dimension "A" at 3 evenly space points. Find average of readings. Specification should be approximately 12.3 mm (0.484". (Scheme 205) If specification is not correct, different size shims are available from manufacturer to obtain correct clearance.
2. When correct shim size is installed, install NEW drive plate bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
3. If installing new crankshaft or engine block, ensure torque converter bearing bushing is installed correctly. (Scheme 206) See «BEARING BUSHING FOR TORQUE CONVERTER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__bearing-bushing-for-torque-converter).

Note. The following procedure is given assuming the transmission the engine has been removed for servicing.

1. Remove sealing plug from hole in left side of cylinder block. Position crankshaft to Top Dead Center (TDC) for cylinder No. 1. Ensure TDC hole can be seen or felt through sealing plug hole.
2. Install Crankshaft Holder (3242) into sealing plug hole to prevent crankshaft from rotating. (Scheme 184)
3. Mark the position of the dual-mass flywheel (M/T) with the block and the crank. Loosen the bolts in a cross pattern and remove drive plate.
4. Inspect pilot needle bearing. See «PILOT NEEDLE BEARING (MANUAL TRANSMISSION)»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq). If installing new drive plate, install pilot needle bearing.

Note. Manufacturer requires replacing flywheel bolts on installation.

Install flywheel in reverse order of removal. Tighten NEW bolts to specification. See TORQUE SPECIFICATIONS . If reusing original pressure plate and flywheel, check for White alignment marks. If present, align marks on reassembly.

1. Remove transmission. For M/T, see appropriate article in CLUTCHES.
2. Remove flywheel. See «DUAL-MASS FLYWHEEL (M/T)»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
3. Using an appropriate puller, remove pilot needle bearing. (Scheme 207) To complete installation, reverse removal procedure. Use Bearing Driver (3264), or equivalent, to install pilot needle bearing.

Scheme 195

BEARING BUSHING FOR TORQUE CONVERTER

Note. Ensure completed engine or crankshaft has bearing bushing installed. The bushings must be installed before installing the driveplate. (Scheme 206)

Removal and installation procedure not provided by manufacturer. To gain access to bearing bushing, see DRIVE PLATE (A/T) .

CRANKSHAFT REAR OIL SEAL

Note. If possible, replace oil seal together with flange.

1. Remove transmission. For M/T, see appropriate article in CLUTCHES. For A/T, see TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING.
2. Remove drive plate or flywheel. See «DRIVE PLATE (A/T)»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__drive-plate-at) or «DUAL-MASS FLYWHEEL (M/T)»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
3. If not replacing seal together with flange, go to step 5. If replacing seal together with flange, drain engine coolant before removing flange. See «DRAINING COOLING SYSTEM»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__draining-cooling-system). Remove flange and oil seal together.
4. Install NEW flange and oil seal. Tighten crankshaft oil seal carrier bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications). To complete installation, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__cooling-system-bleeding).
5. Using Seal Extractor (10-221), remove seal from carrier. (Scheme 208) Clean running and sealing surfaces. DO NOT lubricate sealing lip or outer edge of seal before installing. Using assembly aid (if provided with new seal ) press seal onto crankshaft. Using Seal Installer (2003/3), press new seal into carrier. (Scheme 209) To complete installation, reverse removal procedure.

Scheme 196

Scheme 197

THERMOSTAT

Note. Obtain radio code before disconnecting battery.

Scheme 198

Scheme 199

1. Drain engine coolant. See «DRAINING COOLING SYSTEM»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__draining-cooling-system).
2. Remove complete front bumper assembly. See «FRONT BUMPER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq). Place lock carrier in service position. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).
3. Remove serpentine belt. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
4. Remove timing belt guard. Remove timing belt from camshaft sprockets. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt).
5. Remove thermostat housing bolts. Housing is located near front of passenger side cylinder head. (Scheme 210)and (Scheme 211). Remove thermostat.
6. Lube new O-ring gasket with coolant. Install thermostat with bleeder valve at top (12 o'clock) position. Tighten thermostat housing bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications). To complete installation, reverse removal procedure.
7. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__cooling-system-bleeding).

WATER PUMP

Note. Obtain radio code before disconnecting battery.

Note. Water pump is driven by the timing belt. Timing belt removal is required.

1. Drain engine coolant. See «DRAINING COOLING SYSTEM»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__draining-cooling-system). Remove complete front bumper assembly. See «FRONT BUMPER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq). Disconnect all necessary electrical connectors from front of vehicle.
2. Remove complete front bumper assembly. See «FRONT BUMPER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq). Place lock carrier in service position. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier).
3. Remove serpentine belt and viscous fan. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
4. Remove timing belt guard. Remove timing belt from camshaft sprockets. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt).
5. Remove bracket for viscous fan. Remove water pump bolts and remove pump. (Scheme 210)and (Scheme 211).
6. To install, reverse removal procedure. Install new gasket with water pump. Tighten water pump fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications). Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__cooling-system-bleeding).

OIL PAN(A4 & A6)

Note. Obtain radio code before disconnecting battery. For help in identifying components and component locations, refer to illustrations (Scheme 222) - (Scheme 223).

Removal (Lower Pan- A4 & A6)

1. Disconnect negative battery cable.
2. Remove engine noise insulator (undercover). (Scheme 142) Drain engine oil.
3. Unbolt left and right swaybar stabilizer bracket bolts (4) from mounting bracket. (Scheme 213) Lower swaybar stabilizer not more than 10cm (3.94 INCHES) and secure with heavy wire.
4. If vehicle is equipped with automatic transmission, unbolt oil cooler pipe (line) bracket from right side oil pan.
5. Remove lower oil pan. To install oil pan (lower), see «INSTALLATION (LOWER OIL PAN- A4 & A6)»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__installation-lower-oil-pan-a4).

Installation (Lower Oil Pan- A4 & A6)

1. Ensure oil pan surfaces are clean and dry. Remove residual sealant from oil pan, if necessary, with hand drill and plastic brush instead of a flat scrapper. (Scheme 214) Install gasket.
2. Install 2 bolts diagonal to each other (to hold up pan). Install the rest of the bolts and hand tighten.
3. Starting at center and moving outward, tighten lower oil pan to upper oil pan bolts to 10 N.m (89 INCH lbs.). Tighten oil pan drain plug 30 N.m (22 ft. lbs.). Wait 30 minutes before filling with engine oil. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
4. To complete installation, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__cooling-system-bleeding).

Scheme 200

1. Disconnect negative battery cable. Remove oil dipstick. Unbolt oil dipstick tube at front of cylinder head. Remove oil dipstick tube.
2. Remove engine noise insulator (undercover). (Scheme 142) Drain engine oil.
3. Move lock carrier into service position. See «LOCK CARRIER»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__lock-carrier). This will allow servicing of front engine components and facilitate removal of oil pan.
4. Open coolant expansion tank cap, drain cooling system at radiator. Open the coolant pump bearing housing drain plug. Located at bottom of block near transmission bell housing, drivers side of vehicle. (Scheme 156)- (Scheme 157). If vehicle is equipped with automatic transmission, unbolt oil cooler pipe (line) bracket from right side oil pan.
5. Position Engine Support (10-222A) with (10-222A/3) engine support adapter, or equivalent, on bolted flanges of fenders. Connect support bracket to front and rear engine lifting eyes. Lift up engine as far as possible. DO NOT use excessive force to raise engine.
6. Cut tie wraps and open bracket supporting starter wiring. (Scheme 212) Disconnect electrical connection at starter.
7. Unbolt torque arm at front of engine.
8. Unbolt coolant pipe from oil pan at front of engine. Disconnect oil pressure switch at left side of oil pan. Disconnect 2 oil cooler lines at oil cooler below oil filter.
9. Remove lift and right nuts from lower engine mount. (Scheme 174) Mark positions threaded assembly and guide sleeves of left and right engine mount locating sleeves from bottom. (Scheme 174) Remove left and right engine mount nuts. Using hoist, lift engine up as far as possible.
10. First remove front bolts (2) and (3) from left and right-sides of subframe. Then remove bolts (1). (Scheme 213) Swing stabilizer down. Remove starter.
11. With bolts still installed, using a screw jack, lower front subframe, (DO NOT let weight of subframe rest solely on bolt heads). This should allow access to oil pan bolt.
12. Remove oil pan (lower part) and oil pan (upper parts). Remove both brackets for oil supply pipe. see scheme 109 Pull longer oil supply pipe out of oil pan upper part.
13. Remove oil pump mounting bolts (remove the bolts but DO NOT remove the oil pump). Remove shorter oil supply pipe. see scheme 111
14. Remove bolts from between oil pan (upper part) and transmission. Unbolt oil pan (upper part) from engine.
15. Remove appropriate lower and/or upper parts of oil pan from engine as needed for repair.

Installation (Upper Oil Pan- A4 & A6)

Note. Ensure excessive sealant is not used, too much sealant may find its way into the oil pan and may plug the oil pickup screen.

Scheme 201

1. Ensure oil pan surfaces are clean and dry. Remove residual sealant from oil pan, if necessary, with hand drill and plastic brush instead of a flat scrapper. (Scheme 214) Apply a bead of 0.04-0.12 in (2-3 mm) sealant (D 454 300 2) on the cylinder block. Ensure sealant is applied at overlap joints between sealing flanges and oil pan at front and rear.
2. Install all the bolts between the pan and the block, and between the pan and transmission. Tighten all bolts finger tight.
3. With all bolts in place, tighten upper oil pan to engine bolts to 5 N.m (44 in. lbs.). Tighten oil pan to transmission housing bolts to 45 N.m (33 ft. lbs.).In second step, tighten upper oil pan to engine block bolts again in a diagonal sequence to 15 N.m (11 ft. lbs.). Tighten M10 bolts between upper oil pan and engine block to 45 N.m (33 ft. lbs.).

OVERHAUL

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 210)and (Scheme 211). Also (Scheme 215)to (Scheme 224).

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

1. Measure cylinder head warpage, measure at several points along gasket surface using straight edge and feeler gauge. (Scheme 225)
2. If warpage exceeds specification, machine cylinder head. See «CYLINDER HEAD»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq) table under ENGINE SPECIFICATIONS. If machining causes cylinder head height to be less than specification, replace cylinder head. When checking dimensions for cylinder head height, measure at (A) through the holes for the head bolts. (Scheme 226)

Camshaft Axial Play

Measure camshaft axial play with lifter and camshaft chain removed, and camshaft bearing caps No. 2. and No. 4. installed. (Scheme 197) See CAMSHAFT table under ENGINE SPECIFICATIONS. (Scheme 227)

Scheme 214

Valves

Valves must not be refaced by grinding. Hand lap only. If lapping does not produce proper sealing, check valve seat. See VALVE SEAT .

Valve Guides Checking

Note. Intake valve stem diameter differs from exhaust valve stem diameter. Use intake valves in intake guides and exhaust valves in exhaust guides when measuring valve guide wear.

1. To measure valve guide wear, attach dial indicator to cylinder head. Insert valve into guide until valve stem tip is even with top end of guide.
2. Lightly push edge of valve head against dial indicator tip. Zero dial indicator. Push valve away from dial indicator, in direction opposite of camshaft axis.
3. Maximum allowable deflection is.032" (.8 mm) on intake or exhaust valve. (Scheme 228) If deflection does not exceed specification, guide is okay. If deflection exceeds specification, recheck using new valve. If deflection still exceeds specification, replace worn guides.

Scheme 215

Valve Guide Removal

Note. No procedure is given from manufacturer for Audi A4 or A6.

Valve Guide Installing

Note. When the shoulder on guide makes contact, the pressure must not exceed 10 kN (1.0 ton). Shoulder may break off if pressure is exceeded.

1. Coat new valves guides with clean oil. Using drift (3360) press into cold cylinder head from camshaft side. Stop when shoulder makes contact.
2. Ream guides out with hand reamer (3363), ensure plenty of cutting fluid is used.
3. Reface valve seats. See «VALVE SEAT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__valve-seat) .

Valve Seat

Note. When repairing engines with leaking valves, it is not sufficient to replace or renew valve seats and valves. It is also necessary to check the valve guides for wear. This is particularly important on high mileage engines. The valve seats should only be refaced just enough to produce a perfect seating pattern. The maximum permissible refacing dimension must be calculated before beginning refacing. If the refacing dimension is exceeded, the function of the hydraulic valve lifters can no longer be guaranteed and the cylinder head should be replaced. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

1. Insert valve into guide. Press valve tightly against valve seat. Lay a straightedge across top of cylinder head. Measure distance between valve stem tip and bottom of straightedge. This is valve installed height. If a new valve is going to be installed, use new valve to make this measurement.
2. If valve stem height is less than 1.339" (34.0 mm) on intake valve (outer), 1.327" (33.7 mm) intake valve (center), or 1.354" (34.4 mm) on exhaust valve, install a new valve and measure again. (Scheme 229)
3. If valve stem height measurement is still less than specification, replace cylinder head. If valve stem height exceeds specification, seat can be machined; however, DO NOT machine enough material away from seat to cause valve stem height to be less than minimum specification.

Scheme 216

Scheme 217

1. Remove camshafts. See «CAMSHAFTS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__camshafts) under REMOVAL & INSTALLATION.
2. Remove valve lifters and place them with contact surface downward. During removal make sure lifters are not interchanged.
3. Remove spark plugs with spark plug removal tool (3122B).
4. Set piston of relevant cylinder to Bottom Dead Center (BDC).
5. Screw VW pressure hose (653/3) into spark plug thread. (Scheme 230)
6. Secure (3362) valve spring compressor to cylinder head with tool securing bolt and position installing tool for compressing valve springs to following positions. Outer intake valves: lower position, Center intake valve: upper position and Exhaust valve: lower position. (Scheme 230)
7. Connect pressure hose to compressed air system supplying at least 6 bar (87 psi) and remove valve springs.
8. Remove valve stem seals with puller (3364) for valve shaft seal. (Scheme 231)

Valves Stem Seals Installing (Head Installed)

1. Slide plastic sleeve (A) supplied over relevant valve stem. This will prevent the new valve stem seal (B) from being damaged. (Scheme 232)
2. Place new valve stem seal into installation tool (3365).
3. Oil valve stem seal sealing lip and press carefully onto the valve guide. (Scheme 232) To assemble, reverse removal procedures. CAUTION: DO NOT start engine for about 30 minutes after installing camshafts. Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate crankshaft by hand 2 full revolutions before starting engine to ensure valves do not strike pistons.

Scheme 218

Valve lifter operation is checked with lifters installed in vehicle. See VALVE LIFTERS under REMOVAL & INSTALLATION.

CYLINDER BLOCK ASSEMBLY

Fitting Pistons

1. Measure cylinder bore diameter in 3 places: at center of bore and.39" (10 mm) from top and bottom of bore. If cylinder bore diameter is not within specification, hone cylinder bore until diameter meets first oversize specification. See «CYLINDER BLOCK»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq) table under ENGINE SPECIFICATIONS.
2. Measure piston diameter at 90-degree angle to piston pin, about.39" (10 mm) from bottom of piston skirt. see scheme 99 If piston diameter is not within specification, replace piston. See «PISTONS, PINS & RINGS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq) table under ENGINE SPECIFICATIONS. When measuring piston diameter, maximum allowable difference between actual measurement and standard specification is.0016" (.04 mm).

Scheme 219

Scheme 220

1. Install piston ring with TOP mark (if present) facing upward. Insert ring from bottom of cylinder block to a depth of about.591" (15 mm) to measure ring end gap. see scheme 100
2. Measure ring side clearance. see scheme 101 If ring end gap and side clearance are not within specification, replace ring and/or piston as necessary. See «PISTONS, PINS & RINGS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq) table under ENGINE SPECIFICATIONS. Space ring end gaps 120 degrees apart.

Scheme 221

Scheme 222

1. Mark connecting rod and piston assemblies to identify which cylinder they belong to.
2. If replacing rods, replace entire set.
3. Replace bearing cap bolts and nuts with NEW nuts and bolts after each use.
4. Ensure arrow on piston (top or bottom) faces front end of engine when piston is installed.
5. A serrated connecting rod was placed into production on some engines starting in 1998. To identify the connecting rod type see scheme 102
6. The different design connecting rods use different size bolts. The serrated connecting rod uses M8 and M8.5 bolts. ALWAYS measure the threads as different tightening torques are used. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
7. Make sure connecting rods are installed in original positions. see scheme 103
8. If piston pin is difficult to remove, heat piston to 140°F (60°C).

Connecting Rod Bearings

1. If using Plastigage to check rod bearing oil clearance, DO NOT fully tighten bearing cap bolts. Instead, tighten bolts to 15 ft. lbs. (20 N.m). (Scheme 220) Lubricate threads and contact surface.
2. If rod bearing oil clearance is not within specification, replace rod bearings. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq) table under ENGINE SPECIFICATIONS.
3. Replace rod bearing cap bolts after first use. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).

Scheme 223

1. Main bearing cap No. 1 is located at front (timing belt) end of engine. Main bearing cap No. 4 is located at rear of engine. see scheme 104
2. If main bearing oil clearance is not within specification, replace main bearings with oversize bearings. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq) table under ENGINE SPECIFICATIONS.
3. Do NOT reuse main bearing cap bolts. Install main bearing cap side bolts hand tight before fully tightening them. (Scheme 221) Replace main bearing cap bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).

Thrust Bearing

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 221)

Mount dial indicator on oil pump with plunger contacting crankshaft web. Push crankshaft toward dial indicator. Zero dial indicator. Push crankshaft away from dial indicator. If measured distance (end play) is not within specification, replace thrust bearing and/or crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

Measure cylinder bore diameter in 3 places: at center of bore and.39" (10 mm) from top and bottom of bore. see scheme 105 If cylinder bore diameter is not within specification, hone cylinder bore until diameter meets first oversize specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. When measuring cylinder bore, maximum allowable difference between actual measurement and standard specification is.0031" (.08 mm).

Scheme 224

Crankcase Capacity

See CRANKCASE CAPACITY SPECIFICATIONS table for oil capacity specifications.

CRANKCASE CAPACITY SPECIFICATIONS

Oil Pressure

With engine oil temperature at least 176°F (80°C), oil pressure should be 29 psi (2.0 bar) minimum at 2000 RPM.

Oil Viscosity & Type

Use a multi-grade oil with an API specification of at least SJ or SL. To select correct oil viscosity, see .

Scheme 225

OIL PUMP

Note. Two types of oil pumps where used on the 1997-98 AHA engine, the early flange type is driven off the snout of the crankshaft with cogs that engage the oil pump. The oil pump is part of front engine cover (flange). The second later chain driven type is used on both the AHA and ATQ engine and is driven by a chain, turned via a gear on the crankshaft. The oil pump is located in the oil pan.

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 222)and (Scheme 224).

Removal & Installation (Cog Driven)

1. Oil pump drive components are located behind front engine cover. Drain engine coolant. See «DRAINING COOLING SYSTEM»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__draining-cooling-system).
2. Remove oil pan. See «OIL PAN»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__oil-pana4-a6) under REMOVAL & INSTALLATION.
3. Remove timing belt. See «TIMING BELT»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__timing-belt) under REMOVAL & INSTALLATION.
4. Remove idler pulley. Remove crankshaft gear. Remove oil spray jet valve from front cover. Remove timing belt tensioner. (Scheme 222)and (Scheme 223).
5. Remove lever for timing belt tensioner. Remove oil pump. To install, reverse removal procedure. Ensure drive cog on oil pump engages crankshaft. Replace oil seal. See «CRANKSHAFT FRONT OIL SEAL»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__crankshaft-front-oil-seal) under REMOVAL & INSTALLATION.
6. Tighten components to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
7. Refill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__cooling-system-bleeding) under REMOVAL & INSTALLATION.

Removal & Installation (Chain Driven)

Note. Oil pump is not serviceable.

Note. For help in identifying chain driven oil pump components and component locations, refer to illustrations. see scheme 108

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

1. Drain engine coolant. See «DRAINING COOLING SYSTEM»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__draining-cooling-system).
2. Drain engine oil. Unbolt hardware from oil pan. Remove oil pan. See «OIL PAN»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__oil-pana4-a6) under REMOVAL & INSTALLATION.
3. Once access is gained, check chain tensioner condition. See «CHAIN TENSIONER (OIL PUMP)»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq).
4. Remove both brackets for oil supply pipe. see scheme 109
5. Pull longer oil supply pipe out of oil pan upper part. Unbolt chain sprocket from oil pump and pull down off oil pump drive shaft. see scheme 110 Remove oil pump mounting bolts together with shorter oil supply pipe. see scheme 111
6. To install, reverse removal procedure. Insert shorter supply pipe with NEW O-ring into oil pump, then install oil pump. Ensure chain sprocket is properly install on shaft.
7. Ensure gasket surfaces are clean of grease and oil. Use silicone gasket material on oil pan. Tighten components to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).
8. Refill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__cooling-system-bleeding) under REMOVAL & INSTALLATION.

Checking Procedure

1. Insert a screwdriver between chain and chain tensioner and pry carefully against tensioner in direction of arrow. see scheme 112
2. If there is no spring tension or drive chain is slack, chain tensioner is malfunctioning and must be replace. To replace tensioner, timing belt and front engine cover must be removed. See «OIL PUMP»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__oil-pump).

Scheme 231

OIL CHECK VALVE REPLACEMENT

Note. If irregular valve noise occurs repeatedly after short trips of driving and disappears after long periods of driving, the oil check valve must be replaced.

Scheme 232

1. Gain access to oil check valves, remove intake manifold. See «INTAKE MANIFOLD»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__intake-manifold).
2. Remove cover under intake manifold. Locate check valves and replace them. see scheme 113
3. To install, reverse removal procedure. Tighten cover bolts to 10 N.m (89 INCH lbs.). Install intake manifold. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1999-2001/remont/mechanical/#28l-v6-30v-engine-code-aha-atq__torque-specifications).

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK

ENGINE VALVES & VALVE GUIDES SPECIFICATIONS

VALVES & VALVE GUIDES

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

CAMSHAFT

See also:
• ENGINE IDENTIFICATION CODES
• VALVE LIFTERS
• LOCK CARRIER
• TORQUE SPECIFICATIONS
• FUEL PRESSURE RELEASE
• ACCELERATOR PEDAL
• DRAINING COOLING SYSTEM
• TIMING BELT
• COOLING SYSTEM BLEEDING
• OIL CHECK VALVE REPLACEMENT
• BEARING BUSHING FOR TORQUE CONVERTER
• DRIVE PLATE (A/T)
• INSTALLATION (LOWER OIL PAN- A4 & A6)
• VALVE SEAT
• CAMSHAFTS
• OIL PAN
• CRANKSHAFT FRONT OIL SEAL
• OIL PUMP
• INTAKE MANIFOLD