2.8L V6 30V (Engine Code: Aha, Atq): Removal & Installation Audi A4 B5 facelift

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.

Remove

1. On A4 and A6, move lock carrier into service position for access to serpentine belt. See «LOCK CARRIER»(ref-147486-S40535456302002091600000).
2. Remove trim cover from top of engine. (Scheme 149) Remove engine noise insulation shield from under engine. (Scheme 136)
3. Using Spanner Wrench (3212), hold viscous fan pulley. (Scheme 154) 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 155)

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»(ref-147486-S30794586192002091600000) .
3. Install lock carrier to body. See «LOCK CARRIER»(ref-147486-S40535456302002091600000) .

Removal & Installation (A4)

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 136)- (Scheme 143).

1. Raise vehicle, remove front tires, remove lower front engine shield (noise insulator). (Scheme 136) With vehicle raised, loosen appropriate front bumper fasteners at this time. (Scheme 137)- (Scheme 143). 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 137)or (Scheme 140). Remove bumper cover carrier from impact absorbers.
4. To install, reverse removal procedure. Adjust front bumper height (A4; Up To VIN 8DXA20000) (Scheme 139) To move lock carrier into service position, see «LOCK CARRIER»(ref-147486-S40535456302002091600000).

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Removal (A6)

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 144)- (Scheme 148).

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 136) Loosen the front half of the wheel housing splash shield (liner). (Scheme 144) Unscrew flange nut (10) on both sides. (Scheme 146)
3. Unscrew with/washer assembly (6) from wheel housing liner (5). (Scheme 146) Remove socket-head bolts (7) and remove bumper cover together with impact absorbor towards front. (Scheme 146) To move lock carrier into service position. See «LOCK CARRIER»(ref-147486-S40535456302002091600000).

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Installation (A6)

1. Before installing the bumper, ensure the expanding clips are pressed into the fender. (Scheme 145) When installing the tabs, the bumper cover must latch into clip (4). (Scheme 146)
2. Latch bumper cover (1) into guide (2). (Scheme 146) 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 146)

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

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-147486-S17694092262002091600000). 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 149)
3. Remove lower engine shield. (Scheme 136) 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 150)- (Scheme 151).
4. Remove complete front bumper assembly. See «FRONT BUMPER»(ref-147486-S21797918242002091600000).
5. Disconnect power steering cooling coil, located at lower left of radiator. Let cooling coil hang free. (Scheme 152)
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 153) 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»(ref-147486-S40535456302002091600000).
8. Using Spanner Wrench (3212), hold viscous fan pulley. (Scheme 154) 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 155)
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 156)and (Scheme 157). 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 158) 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 159)and (Scheme 160). 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 161)
13. Disconnect exhaust manifold connections. Disconnect 4 oxygen sensor harness connectors. Remove ground wire at engine/cross member. (Scheme 162) 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 163) 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 164)
16. Detach A/C refrigerant line from oil pan at front of engine. (Scheme 165)
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 166) 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 167)
18. Mark positions of left and right engine mount locating sleeves from bottom. see scheme 40 Position Support Bridge (10-222A) on bolted flanges of fenders. Engage Support Adaptor (3147) in bolt hole in bellhousing on transmission. (Scheme 168)
19. Attach Engine Sling (2024A) to engine. Using hoist, lift engine from vehicle. (Scheme 168)and see scheme 42.

Scheme 165

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)»(ref-147486-S04109496632002091600000). 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. see scheme 43 See «TORQUE SPECIFICATIONS»(ref-147486-S18918128872002091600000).
4. Install engine mounts free of tension by aligning engine with shaking motions prior to tightening bolts. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).
5. Align exhaust so components are free of stress. Adjust accelerator pedal. See «ACCELERATOR PEDAL»(ref-147486-S13820663132002091600000) under ADJUSTMENTS. Verify engine fluids are filled to proper levels.
6. Install vacuum lines. (Scheme 169) Install serpentine drive belts. see scheme 46or see scheme 47.
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". see scheme 45 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 166)
9. Align engine to transmission bell-housing. Install proper length bolts and torque to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S18918128872002091600000). 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»(ref-147486-S30794586192002091600000).
11. Align exhaust so components are free of stress. Adjust accelerator pedal. See «ACCELERATOR PEDAL»(ref-147486-S13820663132002091600000) under ADJUSTMENTS. Verify engine fluids are filled to proper levels. Also check ATF fluid is filled to proper level.
12. Install vacuum lines. (Scheme 169)
13. Install serpentine drive belt. see scheme 46or see scheme 47.

Scheme 166

Scheme 167

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 .

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. see scheme 48 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»(ref-147486-S30794586192002091600000).
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»(ref-147486-S11057228442002091600000). Install viscous fan and serpentine belt. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(ref-147486-S28133037962002121900000).
10. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(ref-147486-S31613995762002091600000).

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. see scheme 49

Scheme 168

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). see scheme 52 Tighten crankshaft sprocket bolt to specification. See TORQUE SPECIFICATIONS. Reassemble in reverse order.

Scheme 169

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 174) 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 176) 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»(ref-147486-S30794586192002091600000).
4. Lightly bearing caps No. 1 and 7 mating surface with (AMV 174 004 01) sealant before installation. (Scheme 176) Install bearing caps No. 1, 3, 5 and 7. Evenly tighten bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).
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»(ref-147486-S11057228442002091600000).
7. To complete installation, reverse removal procedure.

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 177) Install camshaft drive sprocket. Reassemble in reverse order.

Scheme 170

Scheme 171

Scheme 172

1. Remove timing belt. See «TIMING BELT»(ref-147486-S11057228442002091600000).
2. Unbolt Camshaft Position (CMP) sensor housing. Remove CMP sensor shutter bolt and conical washer. see scheme 85 Noting installed position for reassembly, carefully pry off shutter.
3. Screw Oil Seal Extractor (2058/1 bolt) into camshaft. (Scheme 178) Unscrew inner part of (2058) 2 turns (about 3 mm) out of outer part and lock with knurled screw. see scheme 68
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 173

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. see scheme 69
2. Install CMP sensor and conical washer in original position. see scheme 85 Install and tighten bolt. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000). Reassemble in reverse order.

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. see scheme 50
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)»(ref-147486-S04109496632002091600000). 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)»(ref-147486-S27091027502002091600000).
3. Using an appropriate puller, remove pilot needle bearing. see scheme 73 To complete installation, reverse removal procedure. Use Bearing Driver (3264), or equivalent, to install pilot needle bearing.

Scheme 174

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)»(ref-147486-S20829430872002121900000) or «DUAL-MASS FLYWHEEL (M/T)»(ref-147486-S27091027502002091600000).
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»(ref-147486-S06159856372002091600000). Remove flange and oil seal together.
4. Install NEW flange and oil seal. Tighten crankshaft oil seal carrier bolts to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000). To complete installation, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-147486-S31613995762002091600000).
5. Using Seal Extractor (10-221), remove seal from carrier. see scheme 74 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. see scheme 75 To complete installation, reverse removal procedure.

Scheme 175

Scheme 176

1. Drain engine coolant. See «DRAINING COOLING SYSTEM»(ref-147486-S06159856372002091600000). Remove complete front bumper assembly. See «FRONT BUMPER»(ref-147486-S21797918242002091600000). Disconnect all necessary electrical connectors from front of vehicle.
2. Remove complete front bumper assembly. See «FRONT BUMPER»(ref-147486-S21797918242002091600000). Place lock carrier in service position. See «LOCK CARRIER»(ref-147486-S40535456302002091600000).
3. Remove serpentine belt and viscous fan. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(ref-147486-S28133037962002121900000).
4. Remove timing belt guard. Remove timing belt from camshaft sprockets. See «TIMING BELT»(ref-147486-S11057228442002091600000).
5. Remove bracket for viscous fan. Remove water pump bolts and remove pump. see scheme 76and see scheme 77.
6. To install, reverse removal procedure. Install new gasket with water pump. Tighten water pump fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000). Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-147486-S31613995762002091600000).

Removal (Lower Pan- A4 & A6)

1. Disconnect negative battery cable.
2. Remove engine noise insulator (undercover). (Scheme 136) Drain engine oil.
3. Unbolt left and right swaybar stabilizer bracket bolts (4) from mounting bracket. see scheme 79 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)»(ref-147486-S00881060942002122000000).

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. see scheme 80 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»(ref-147486-S30794586192002091600000).
4. To complete installation, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-147486-S31613995762002091600000).

Scheme 177

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 136) Drain engine oil.
3. Move lock carrier into service position. See «LOCK CARRIER»(ref-147486-S40535456302002091600000). 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 150)- (Scheme 151). 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. see scheme 78 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. see scheme 40 Mark positions threaded assembly and guide sleeves of left and right engine mount locating sleeves from bottom. see scheme 40 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). see scheme 79 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 178

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. see scheme 80 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.).

Valve Guide Removal

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

Removal & Installation (Cog Driven)

1. Oil pump drive components are located behind front engine cover. Drain engine coolant. See «DRAINING COOLING SYSTEM»(ref-147486-S06159856372002091600000).
2. Remove oil pan. See «OIL PAN»(ref-147486-S10326072892002091600000) under REMOVAL & INSTALLATION.
3. Remove timing belt. See «TIMING BELT»(ref-147486-S11057228442002091600000) under REMOVAL & INSTALLATION.
4. Remove idler pulley. Remove crankshaft gear. Remove oil spray jet valve from front cover. Remove timing belt tensioner. see scheme 88and see scheme 89.
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»(ref-147486-S17607505182002091600000) under REMOVAL & INSTALLATION.
6. Tighten components to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).
7. Refill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(ref-147486-S31613995762002091600000) 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 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

1. Drain engine coolant. See «DRAINING COOLING SYSTEM»(ref-147486-S06159856372002091600000).
2. Drain engine oil. Unbolt hardware from oil pan. Remove oil pan. See «OIL PAN»(ref-147486-S10326072892002091600000) under REMOVAL & INSTALLATION.
3. Once access is gained, check chain tensioner condition. See «CHAIN TENSIONER (OIL PUMP)»(ref-147486-S33928034582002091600000).
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»(ref-147486-S30794586192002091600000).
8. Refill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(ref-147486-S31613995762002091600000) under REMOVAL & INSTALLATION.

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 184

1. Gain access to oil check valves, remove intake manifold. See «INTAKE MANIFOLD»(ref-147486-S22112343502002091600000).
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»(ref-147486-S30794586192002091600000).