2.0l 4-cyl 4v Turbo Engine Mechanical, Engine Code(s): Bpg, Bwt Audi A4 B7

Engine number

The engine number ("engine code" and "serial number") are located at front of engine/transmission joint.

In addition, a sticker with "engine code" and "serial number" is affixed to timing belt cover.

The engine code is also included on vehicle data plates.

Engine data

Safety precautions

Note the following when working on the fuel system

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following

1. The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
2. It is possible that the engine control module will recognize a malfunction and store a DTC during some tests. Therefore, when all tests and repairs are completed, the DTC memory must be checked and, if necessary, erased. After DTC memory is erased, a readiness code must be generated for the engine control module using operating mode "Guided Functions".
3. Clean engine only with the ignition switched off.

Note the following when working on the cooling system

If special testing equipment is required during road test, note the following

Rules for cleanliness

Fuel injection system/fuel system

Even minor contaminations can lead to malfunctions in the fuel injection system. When working on fuel supply/fuel injection system, observe the following rules of cleanliness

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Plug open lines and connections immediately with appropriate protective caps.
3. Place parts that have been removed on a clean surface and cover them. Do not use fluffy cloths!
4. Only install clean parts: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpackaged (e.g. in tool boxes etc.).

1. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
2. Separated electrical connections: Protect from dirt and moisture. Connect only when dry.

Turbocharger

When working on turbocharger, carefully observe the following "5 rules" of cleanliness

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover them. Do not use fluffy cloths!
3. Carefully cover over opened components or seal, if repairs are not performed immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (e.g. in tool boxes etc.).

1. When the system is open: Avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary.

Engine, removing

Note. The engine is removed toward the front with lock carrier removed. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Drained coolant must be stored in a clean container for disposal or reuse.

Work procedure

1. On a vehicle with automatic transmission, shift selector lever to position "N".

Scheme 385

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

1. Open cap of coolant expansion tank.
2. Remove both front wheels.

Scheme 386

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Scheme 387

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.

Scheme 388

1. Remove bracket for noise insulation - arrows -.

Scheme 389

1. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Remove air guides from in front of charge air coolers at left and right - arrows -.

Scheme 390

1. Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
2. Open drain plug - arrow - from lower left coolant hose and drain coolant.

Scheme 391

1. Disconnect lower coolant hose from radiator - arrow -.

Scheme 392

1. Remove air duct hose - 1 - to bottom of left charge air cooler.

1. Unhook refrigerant line from bracket - 2 -.

Scheme 393

1. Remove air duct hose - 1 - to turbocharger at bottom right.
2. Remove air duct hose - 2 - to charge air cooler at lock carrier.

Scheme 394

1. Clamp off hydraulic hoses to power steering system cooling coil using Hose Clamps Up to 25 mm dia. 3094.
2. Place old oil collecting and extracting device V.A.G 1782 underneath.
3. Disconnect hydraulic hoses - arrows -.

Scheme 395

Vehicles with automatic transmission

Note. Observe the rules of cleanliness for working on automatic transmissions --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .

1. Place old oil collecting and extracting device V.A.G 1782 underneath.
2. Disconnect ATF lines - 2 and 3 - at separating point.
3. Remove ATF line bracket - 1 - on engine.

All

Scheme 396

1. Remove engine cover - arrows -.

Scheme 397

1. Remove bolts - arrows -.
2. Remove air duct - 1 - and - 2 -.

Scheme 398

1. Disconnect coolant hose - 1 - at top of radiator.
2. Disconnect electrical harness connector - 2 - for left and right airbag sensors on lock carrier.

Scheme 399

1. Disconnect electrical harness connector - arrow - for headlights at both sides of vehicle.

Scheme 400

1. Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
2. Free up electrical wiring.

Scheme 401

1. Separate left and right electrical connectors - 3 - of horns - 2 -.

Note. Ignore - 1 -.

Scheme 402

1. Remove bumper - arrows -.

Scheme 403

1. Remove left and right air guides at radiator - arrows -.

Scheme 404

1. Unclip Outside Air Temperature Sensor G17 - 2 - from bracket.
2. Remove bolts - 3 - and - 4 - and remove power steering system cooling coil.
3. Disconnect electrical harness connector - 1 - at High Pressure Sensor G65.

1. Remove bolts - arrows - for condenser.

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that lines and hoses are not stretched, kinked or bent.

1. Pivot condenser downward with lines connected.

Scheme 405

1. Remove bolts - arrows - at left and right side of bumper.
2. Unhook cable for hood release at lock.
3. Pull off hood seal from lock carrier and fender edges.

Scheme 406

1. Remove bolts - arrows - at left and right impact absorbers.

Note. A second technician is required to remove lock carrier.

1. Remove lock carrier and set aside so it cannot topple.

Note. Before removing ribbed belt, mark turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

Scheme 407

1. Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
2. Secure tensioning element using Locking Tool T40098.
3. Remove ribbed belt.

Scheme 408

1. Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor G266.

Scheme 409

1. Remove bracket for refrigerant line on oil pan - arrow -.

Scheme 410

1. Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.

1. Remove air conditioning compressor from bracket - arrows -.

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Hang up air conditioning compressor and condenser with attached lines on right side of vehicle.

Scheme 411

1. Unfasten Ground (GND) cable - 1 -.
2. Disconnect vacuum line to brake booster at bulkhead - 2 -.
3. Disconnect EVAP hose - 3 -.

Scheme 412

1. Remove coolant hoses - 1 and 2 - and unfasten coolant expansion tank - arrow -.
2. Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.

Scheme 413

1. Separate electrical connector from Charge Air Pressure Sensor G31 - 1 -.
2. Remove left charge air hose - 2 -.

Scheme 414

1. Remove right charge air hose - 1 -.

Scheme 415

1. Pull electrical connector - 1 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 (brown connector) out from retainer
2. Pull electrical connector - 2 - for Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 (black connector) out from retainer

Scheme 416

1. Disconnect fuel line - arrow - (catch escaping fuel and plug open lines immediately).
2. Disconnect coolant hoses to heater core on rear of engine.
3. Remove windshield wiper arms.
4. Remove cowl.

Scheme 417

1. Remove cover for E-Box in plenum chamber, by removing bolts - arrows -.

Scheme 418

1. Carefully pry off retainer bar with a screwdriver - arrow -.

Scheme 419

1. Remove electrical cable - 1 -.
2. Disconnect electrical connectors - 2 to 4 - in E-box.

Scheme 420

1. Unclip fuse carrier - arrows -.
2. Free up cable and lay it aside on engine with Engine Control Module (ECM) J623 connected.

Scheme 421

1. Remove threaded connections - 1 - of power steering pump through holes in belt pulley.

Scheme 422

1. Remove threaded connection - arrow - on backside of power steering pump.

Scheme 423

1. Disconnect connector - 1 and 2 - and free up cable.
2. Separate intake hose - 3 - for air filter/turbocharger.

Scheme 424

1. Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70.
2. Free up wiring harness on air filter housing and remove air filter housing - arrow -.

Scheme 425

1. Remove Ground (GND) strap - arrow - from right longitudinal member.

Scheme 426

1. Remove heat shield - 1 - for right drive axle.

Scheme 427

Note. Exhaust system decoupling element must not be bent more than 10 ° , otherwise it may be damaged.

1. Loosen clamping sleeve - arrow - and push it rearward.

Scheme 428

1. Separate front exhaust pipe/catalytic converter - arrows -.
2. Remove bolt - 1 - at bracket for front exhaust pipe and remove front exhaust pipe.

Scheme 429

1. Disconnect connector - arrow - from Back-Up Light Switch F4 and free up cable to wiring harness.

Scheme 430

1. Disconnect accessible engine/transmission threaded connections - 1 to 3 - and - 7 to 11 - from below.

Scheme 431

1. Remove starter and pivot it aside.
2. Disconnect electrical connector - 3 -.
3. Remove nut - 1 - for clamp.
4. Remove nut - 2 - and remove electrical wiring.

1. Remove starter.

Scheme 432

1. Mark installed position of threaded connections - 1 - and locating sleeves - 2 - on lower left and right engine mounts.

Note. Depending on engine version, different fastening holes are utilized.

1. Remove nuts - 1 - at bottom on left and right engine mounts.

Scheme 433

1. Loosen upper nut - arrow - on left engine mount several turns.

Scheme 434

1. Hook engine sling 2024 A onto engine and onto workshop crane VAS 6100 as shown in the illustration.

Note. To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.

1. Remove last engine/transmission connecting bolt.

Note. Verify that all hose and line connections between engine and body have been disconnected.

1. Lift engine until engine mount studs are free.
2. Lift floor jack until transmission is supported.
3. Pull engine off from transmission and lift it forward and out of engine compartment.

Engine, securing to assembly stand

Special tools, testers and auxiliary items required

Scheme 435

1. Engine and transmission holder VW 540

Scheme 436

1. Engine and transmission holder VAS 6095

Work procedure

1. Remove clutch, observe removal instructions --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
2. Remove dual-mass flywheel, observe removal instructions --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE

Scheme 437

1. For performing work, secure engine using holding fixture VW 540 on engine and transmission holder VAS 6095.

Engine, installing

Note. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings. Hose connections and charge air system hoses must be free of oil and grease before installing. Secure all hose connections using hose clamps . During installation, all cable ties must be re-installed at the same location.

Vehicles with manual transmission

1. When installing a new clutch disc in combination with a used SAC clutch pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise pressure plate works with decreased contact pressure (clutch slips) --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

Note. If clutch disc is not being replaced, the adjustment ring must not be turned back. New SAC-pressure plates are already pre-adjusted and must not be reset.

1. Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
2. If necessary, check centering of clutch drive plate.
3. Check clutch release bearing for wear and replace if necessary.

If plastic ring of clutch release bearing is loose

Scheme 438

1. Use adhesive AMV 195 KD1 01 to glue plastic ring of clutch release bearing to bearing ring.

1. 3 rectangular tabs - arrows - of the plastic ring reach into cutouts of bearing ring.
2. If grooves with depth of more than 0.5 mm are present, release bearing must be replaced.

1. A pilot needle bearing must be installed in crankshaft in engines for vehicles with manual transmission. Install needle bearing if necessary --> «Pulling out and driving in needle bearings from crankshaft»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__pulling-out-and-driving-in-needle) .

Vehicles with automatic transmission

1. Clean transmission input shaft splines and splines of damper unit on flywheel, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Remove all excess grease.

All

1. Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.

Scheme 439

1. Make sure that the intermediate plate is hooked in at sealing flange and is pushed onto alignment sleeves - arrows -.
2. Install intermediate plate between engine and transmission onto alignment sleeves.
3. Adjoin engine to transmission and install one bolt hand-tight.
4. Lower engine and at the same time guide threaded studs of engine mount into engine mount plates.

Note. Torque specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any degreased parts. Tolerance for torque specifications ± 15%.

Engine/manual transmission, fastening

Engine/multitronic transmission, fastening

All

The rest of installation is in reverse order of removal, note the following

1. Install exhaust system and align it free of stress --> «Exhaust system, installing tension free»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__exhaust-system-installing-tension-free) .
2. Install A/C compressor --> «87 AIR CONDITIONING»(/audi/a4/b7-2004-2009/remont/ac-compressor/#heating-air-conditioning) .
3. Install power steering pump --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
4. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .

Scheme 440

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
3. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
4. Fasten ATF lines --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .

1. Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.
2. Observe safety precautions after connecting battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

1. Check oil level --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .
2. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant must not be re-used.

1. Check power steering fluid level --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Note. Torque specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any degreased parts. Tolerance for torque specifications ± 15%.

Overview of component locations

Components A through O are not depicted in exploded view illustration.

Scheme 441

1 - Mass air flow (MAF) sensor G70

1. Refer to --> «Mass Air Flow (MAF) Sensor G70»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

2 - Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19

3 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29

1. «Oxygen sensors»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

4 - Engine coolant temperature (ECT) sensor G62

1. Refer to --> «Engine Coolant Temperature (ECT) Sensor G62»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

5 - Camshaft Adjustment Valve 1 N205

1. Refer to --> «Camshaft Adjustment Valve 1 N205 - 1 - and Fuel Pressure Regulator Valve N276 - 2»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

6 - Fuel Pressure Regulator Valve N276

1. and under «Camshaft Adjustment Valve 1 N205 - 1 - and Fuel Pressure Regulator Valve N276 - 2»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

7 - Single piston high pressure pump

8 - Low Fuel Pressure Sensor G410

1. 15 Nm

9 - Intake Flap Motor V157 with Intake Manifold Runner Position Sensor G336

10 - Engine Speed (RPM) Sensor G28

1. «Electrical harness connectors»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

11 - 6-pin harness connector Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 (brown connector)

12 - 6-pin harness connector

1. For Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 (black) «Electrical harness connectors»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

13 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 1 N80

14 - Engine Control Module (ECM) J623

1. Removing and installing --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)

15 - Charge Air Pressure Sensor G31

1. Refer to --> «Charge Air Pressure Sensor G31»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

16 - Throttle Valve Control Module J338 , Throttle Drive (for Electronic Power Control (EPC)) G186

1. Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) G187 and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) G188
2. After replacing Throttle Valve Control Module J338 , it must be adapted to Engine Control Module (ECM) J623 again (basic setting, display group 60) see "Guided Fault Finding"
3. Refer to --> «Intake Air Temperature (IAT) Sensor G42 Throttle Valve Control Module J338»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

17 - Intake Air Temperature (IAT) Sensor G42

1. Refer to --> «Intake Air Temperature (IAT) Sensor G42 Throttle Valve Control Module J338»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

18 - Fuel Pressure Sensor G247

1. Refer to --> «Fuel Pressure Sensor G247»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

19 - Camshaft Position (CMP) Sensor G40

1. Refer to --> «Camshaft Position (CMP) Sensor G40»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

20 - Ignition coils with power output stages

1. Ignition Coil 1 with Power Output Stage N70
2. Ignition Coil 2 with Power Output Stage N127
3. Ignition Coil 3 with Power Output Stage N291
4. Ignition Coil 4 with Power Output Stage N292

1. The ignition coils must be pulled out of cylinder head using Ignition Coil Puller T40039
2. Removing and installing --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)

21 - Turbocharger Recalculating Valve N249

1. Installed directly on turbocharger «Components on turbocharger»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

22 - Wastegate Bypass Regulator Valve N75

1. Installed directly on turbocharger «Components on turbocharger»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

A - Data Link connector (DLC)

1. In knee bolster on drivers side

B - Fuel Pump (FP) Control Module J538

1. Refer to --> «Fuel Pump (FP) Control Module J538»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

C - "EPC" indicator lamp

1. In instrument cluster

D - Exhaust Malfunction Indicator Lamp "MIL"

1. In instrument cluster

E - 8-pin harness connector for fuel injectors

1. «Component locations beneath intake manifold»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

F - Connector

1. For Camshaft Position (CMP) Sensor G40 and Fuel Pressure Sensor G247
2. «Component locations beneath intake manifold»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

G - Brake Light Switch F and Brake Pedal Switch F63

1. Refer to --> «Installed location Brake light switch F and Brake pedal switch F47 , Clutch pedal switch F36»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

H - Throttle position (TP) sensor G79 and Accelerator Pedal Position Sensor 2 G185

1. On accelerator pedal (both sensors are stored in one housing)

I - Clutch pedal switch F36

1. Refer to --> «Installed location Brake light switch F and Brake pedal switch F47 , Clutch pedal switch F36»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

J - Relay and fuse carrier in E-box

1. «Installed location in 4-socket relay carrier, plenum chamber E-box»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

K - Coolant Fan Control (FC) control module J293

1. Installed in left coolant fan, when facing driving direction

L - Fuel injector

1. In fuel rail pipe
2. Cylinder 1 Fuel Injector N30
3. Cylinder 2 Fuel Injector N31
4. Cylinder 3 Fuel Injector N32

1. Cylinder 4 Fuel Injector N33
2. Removing and installing --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)

Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under high pressure (max. approx. 120 bar).

M - Knock Sensor (KS) I G61

1. For cylinder 1 and 2
2. Torque specification: 20 Nm
3. «Component locations beneath intake manifold»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

N - Knock sensor 2 G66

1. For cylinder 3 and 4
2. Torque specification: 20 Nm
3. «Component locations beneath intake manifold»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

O - Oil Pressure Sensor G10

1. «Electrical harness connectors»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

Scheme 442

Scheme 443

Scheme 444

Scheme 445

Scheme 446

Scheme 447

Scheme 448

1 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 (brown connector)

2 - Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 (black connector)

Scheme 449

1 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29

2 - Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19

Scheme 450

Scheme 451

Scheme 452

1. Brake light switch F , Brake pedal switch F47
2. Clutch pedal switch F36

Note. To ensure that they are absolutely securely seated, the switches may only be installed once.

Scheme 453

1.1 - Not used

1.2

2 - Motronic Engine Control Module (ECM) Power Supply Relay J271

3 - Engine Component Power Supply Relay J757

A

B

C

Scheme 454

1 - Fuel pump (FP) relay J17

Scheme 455

1 - Oil Pressure Sensor G10

2 - 3-pin connection (gray) for engine speed (RPM) sensor G28

3 - Engine Speed (RPM) Sensor G28

Scheme 456

1 - Knock Sensor (KS) I G61

2 - Knock Sensor (KS) II G66

3 - Oil Pressure Sensor G10

4 - 3-pin connection (gray) for engine speed (RPM) sensor G28

5 - Electrical connection for Camshaft Position (CMP) Sensor G40 and Fuel Pressure Sensor G247

6 - 8-pin harness connector for fuel injectors

Scheme 457

Scheme 458

1 - Turbocharger

2 - Wastegate Bypass Regulator Valve N75

3 - Turbocharger Recalculating Valve N249

Lock carrier, moving into service position

Special tools, testers and auxiliary items required

Scheme 459

1. Support tool 3369

Work procedure

1. Remove both front wheels.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.

1. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Remove air duct from in front of charge air cooler at left and right - arrows -.

Scheme 460

1. Remove air duct hose - 1 - to charge air cooler at lower left on lock carrier.

1. Unhook refrigerant line from bracket - 2 -.

1. Remove bolts - arrows -.
2. Remove air duct - 1 - and - 2 -.

1. Remove electrical harness connectors - 1 - and - 2 - from bracket and free up electrical wiring.

1. Remove hood seal from lock carrier and fender edges.
2. Remove bolts - arrows - at left and right side of bumper.

Scheme 461

1. Thread support tool 3369 into empty bores at left and right.
2. Remove bolts - arrows - at left and right impact absorbers.
3. Carefully pull lock carrier toward front.

Installing

Installation is in reverse order of removal, note the following

Note. Hose connections and charge air system hoses must be free of oil and grease before installing. Do not use lubricant under any circumstances. Secure all hose connections using hose clamps .

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten the nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Ribbed belt, component overview

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions. When installing, make sure the belt is correctly seated in the belt pulley.

Scheme 462

1 - Ribbed belt

1. Ribbed belt routing --> «Ribbed belt, routing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
2. Check for wear
3. Do not kink
4. Removing and installing --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing)

2 - Pulley

1. For ribbed belt
2. Removing and installing --> «Crankshaft belt pulley, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__crankshaft-belt-pulley-removing-and-installing)

3 - Special bolt

1. Replace
2. Torque specification 10 Nm plus an additional 90 °

4 - 23 Nm

5 - Engine lift eye

6 - Belt tensioner for ribbed belt

1. To release tension on ribbed belt, pivot using open-end wrench.
2. Secure tensioner with special tool Locking Tool T40098

7 - 23 Nm

8 - Bushing

9 - Bracket for assemblies

1. Removing and installing --> «Accessory assembly bracket, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__accessory-assembly-bracket-removing-and-installing)

10 - 23 Nm

11 - Generator

1. Removing and installing --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)
2. To facilitate installing the generator, slightly drive back threaded bushings for retaining bolts on generator.

12 - 23 Nm

13 - Power steering pump

1. Removing and installing --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

14 - 45 Nm

1. Insert with locking fluid
2. Locking fluid
3. Observe tightening sequence --> «Accessory assembly bracket, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__accessory-assembly-bracket-removing-and-installing)

15 - Bushing

1. 2 pieces

16 - Air conditioner compressor

1. Removing and installing --> «87 AIR CONDITIONING»(/audi/a4/b7-2004-2009/remont/ac-compressor/#heating-air-conditioning)

17 - 25 Nm

18 - Idler roller for ribbed belt

1. Note installation position

19 - 20 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace

Scheme 463

1 - Vibration damper

2 - Belt tensioner for ribbed belt

3 - Ribbed belt

4 - Generator

5 - Power steering pump

6 - Idler roller

7 - Air conditioner compressor

Ribbed belt, removing and installing

Special tools, testers and auxiliary items required

Scheme 464

1. Locking Tool T40098

Removing

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

1. Mark direction of rotation of ribbed belt.

1. Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
2. Secure tensioning element using Locking Tool T40098.
3. Remove ribbed belt.

Installing

Note. Ribbed belt routing --> Ribbed belt, routing .

1. Hold tensioning element with a box-end wrench, remove Locking Tool T40098 and relieve tension on tensioning element.
2. Check ribbed belt for correct positioning.
3. Start engine and check belt running.

Crankshaft belt pulley, removing and installing

Removing

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__lock-carrier-moving-into-service-position) .
3. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing)

Scheme 465

1. Unfasten crankshaft belt pulley.

Note. To loosen and tighten the crankshaft belt pulley, counter-hold at the central bolt using a box-end wrench.

Installing

Installation is in reverse order of removal, note the following

Scheme 466

1. Only install crankshaft belt pulley with original bolts

1. Only possible to install in one position: The hole - arrow - in crankshaft belt pulley must be positioned over protrusion on toothed belt sprocket

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Accessory assembly bracket, removing and installing

Special tools, testers and auxiliary items required

1. Locking Tool T40098

Scheme 467

1. Spring-type clip pliers VAS 5024 A

Removing

1. Remove engine cover - arrows -.

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

1. Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
2. Secure tensioning element using Locking Tool T40098.
3. Remove ribbed belt.

Scheme 468

1. Remove ribbed belt tensioner with engine lifting eye - arrows -.
2. Remove generator --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.

1. Remove bracket for refrigerant line on oil pan - arrow -.

1. Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.

1. Remove air conditioning compressor from bracket - arrows -.

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Hang up A/C compressor with attached lines at bottom of vehicle.

Scheme 469

1. Remove accessory assembly bracket - bolts - 1 to 6 -.

Installing

Installation is in reverse order of removal, note the following

1. Then tighten bolts in sequence - 1 to 6 -.
2. Install generator --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)
3. Install A/C compressor --> «87 AIR CONDITIONING»(/audi/a4/b7-2004-2009/remont/ac-compressor/#heating-air-conditioning)
4. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .

1. Connect battery. Necessary measures --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

Torque specifications

Toothed belt drive, overview

Before removing ribbed belt, mark running direction with chalk or felt tip marker. A reversed turning direction can cause damage to belt under operating conditions.

Scheme 470

1 - 10 Nm

2 - Toothed belt cover, upper

3 - 50 Nm plus an additional 180 ° ( 1 / 2 turn)

1. Use Retainer 3036 for loosening and tightening «Loosening camshaft sprocket»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

4 - Camshaft sprocket

1. When removing and installing, remove toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing)
2. Camshaft sprocket, removing «Pulling off camshaft sprocket»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

5 - 10 Nm

1. Insert with locking fluid
2. Locking fluid

6 - Rear toothed belt cover

7 - Woodruff key

1. Check for secure seat

8 - 25 Nm

9 - Semi-automatic tensioning roller

10 - Coolant pump

1. Removing and installing --> «Coolant pump, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__coolant-pump-removing-and-installing)

11 - O-ring

1. Replace

12 - 25 Nm

13 - Damper roller

14 - 15 Nm

15 - 35 Nm

16 - Damper roller

17 - Sealing flange

1. Removing and installing --> «Front sealing flange, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

18 - Toothed belt gear diamond disc

1. Replace after removing toothed belt gear

19 - Crankshaft toothed belt sprocket

1. There must be no oil on contact surface between toothed belt sprocket and crankshaft
2. Only possible to install in one position

20 - 90 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. Do not oil
3. Fastening Counter Support 3415 «Crankshaft toothed belt sprocket, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

21 - Toothed belt

1. Before removing, mark direction of rotation using chalk or felt-tip marker
2. Check for wear
3. Removing --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing)
4. Installing (adjusting valve timing) --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing)

22 - Toothed belt cover, lower

23 - Cover for toothed belt guard

Scheme 471

1. When loosening and tightening centered bolt, use Retainer 3036.

Scheme 472

1. Remove camshaft sprocket using puller T40001 and Claw T40001/6 and Claw T40001/7.

Scheme 473

1. When loosening and tightening centered bolt, use Retainer 3415.

Toothed belt, removing and installing

Special tools, testers and auxiliary items required

Scheme 474

1. Toothed Belt Tensioner T10020

1. Locking Tool T40098

Removing

1. Remove engine cover - arrows -.

1. Open cap of coolant expansion tank.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__lock-carrier-moving-into-service-position) .

Scheme 475

1. Disconnect coolant pipe - arrow -.

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

1. Mark direction of rotation of ribbed belt.

1. Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
2. Secure tensioning element using Locking Tool T40098.
3. Remove ribbed belt.

Scheme 476

1. Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard.

1. Remove vibration damper/belt pulley.

Scheme 477

1. Remove bolts from lower toothed belt cover - arrows -.

Scheme 478

1. Remove remaining bolts from toothed belt guard - arrows - and remove toothed belt guard from engine.
2. Mark rotational direction of toothed belt.
3. Loosen tensioning roller and remove toothed belt.
4. Then, turn crankshaft back slightly.

Installing

Note. When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged. The engine must be no more than warm to touch.

1. Place toothed belt onto crankshaft sprocket (observe direction of rotation).
2. Secure lower toothed belt cover with two lower bolts.
3. Install vibration damper/belt pulley with new bolts.

1. Set crankshaft and camshaft to TDC at cylinder 1 - arrows -.

Scheme 479

1. Route toothed belt in sequence: Tensioning roller, camshaft gear, coolant pump and last over relay pulley - arrow -.

Scheme 480

Note. Be sure tensioning roller is properly seated in cylinder head.

Scheme 481

1. Tension toothed belt. Do this by turning hex key at eccentric toward right (in direction of - arrow -) until notch is positioned above tab.
2. Release tension on toothed belt again.
3. Now tension toothed belt until notch and tab align.
4. Tighten tensioning roller nut.

1. Turn crankshaft 2 revolutions further in direction of engine rotation until engine is positioned at TDC again. For this it is necessary that the last 45 ° ( 1 / 8 rotation) is turned without interruption.
2. Check tension of toothed belt again. Specified value: Tab and notch align.

1. Check valve timing again.

If markings do not match

1. Repeat valve timing adjustment.

If markings match

Scheme 482

1. Install toothed belt guard - arrows -.
2. Install crankshaft belt pulley --> «Crankshaft belt pulley, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__crankshaft-belt-pulley-removing-and-installing) .
3. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .
4. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .
4. Install noise insulation pan.

1. Install engine cover.

Torque specifications

Sealing flanges and flywheel/drive plate, removing and installing

Note. Servicing clutch: Observe clutch removal instructions --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE 30 CLUTCH ; Clutch mechanism, servicing

Scheme 483

1 - 15 Nm

2 - Seal

1. Replacing --> «Crankshaft seal - ribbed belt side, replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .
2. Do not oil

3 - Sealing flange, front

1. Must be located on dowel sleeves
2. Removing and installing --> «Front sealing flange, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

4 - Cylinder block

1. Removing and installing crankshaft --> «Crankshaft, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
2. Piston and connecting rod, disassembling and assembling --> «Piston and connecting rod, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

5 - Dual mass flywheel/drive plate bolt

1. Replace
2. Dual mass flywheel tightening torque «Torque specification»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Drive plate tightening torque «Torque specification»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

6 - Dual-mass flywheel/drive plate

1. Dual-mass flywheel, removing and installing --> «Dual-mass flywheel and drive plate, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
2. Drive plate, removing and installing --> «Dual-mass flywheel and drive plate, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Only possible to install in one position - Bores are offset

7 - Intermediate plate

1. Must be located on dowel sleeves
2. Do not damage or bend when doing assembly work
3. Is hooked in at sealing flange «Installing intermediate plate»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

8 - 15 Nm

9 - Sealing flange with rear oil seal

1. Only replaced as complete unit
2. To install, use provided guide sleeve
3. Do not oil or grease sealing lip of oil seal
4. Before installing, remove oil remains from crankshaft journal with a clean cloth

1. Guide sleeve may only be removed after sealing flange has been slid onto crankshaft pin.

Scheme 484

1. Hook in intermediate plate at sealing flange and push it onto alignment sleeves - arrows -.

Scheme 485

Special tools, testers and auxiliary items required

1. Seal Remover 3203
2. Counter-holder tool 3415
3. Assembly tool T10053
4. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

Removing

1. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .
2. Toothed belt, removing --> «Toothed belt drive, overview»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-drive-overview) .

Scheme 486

1. Loosen toothed belt crankshaft sprocket by holding sprocket with Counter Support 3415.

Scheme 487

1. Remove toothed belt crankshaft sprocket center bolt - 1 - and remove sprocket - 2 - and diamond disc - 3 -.

Scheme 488

1. To guide seal puller, thread center bolt into crankshaft by hand until stop.
2. Remove inner part of Seal Remover 3203 nine rotations (approx. 20 mm) from outer part and secure with knurled-head screw.

Scheme 489

1. Grease threaded head of Seal Remover 3203 , position and install into oil seal as far as possible with forceful pressure.
2. Loosen knurled screw and turn inner portion against crankshaft until oil seal is pulled out.
3. Secure seal remover in a vise at the flat spots. Remove seal using pliers

Installing

1. Clean running and sealing surface.
2. Before installing, remove oil remains from end of crankshaft with a clean cloth.

Scheme 490

1. Position guide sleeve T10053/1 of assembly tool T10053 on end of crankshaft.
2. Slide sealing ring over guide sleeve onto crankshaft pin.

Scheme 491

1. Press in seal using center bolt of toothed belt sprocket and pressure sleeve of assembly tool T10053 until it is flush.
2. Replace center bolt for toothed belt sprocket.

Note. There must be no oil on the contact surface between the toothed belt sprocket and crankshaft. Do not oil the bolt for crankshaft toothed belt sprocket.

1. Install crankshaft toothed belt gear - 2 - with new diamond disc - 3 - and new center bolt - 1 -.

1. Hold toothed belt crankshaft sprocket with Counter Support 3415 and tighten.

Installing toothed belt (Adjusting valve timing) --> Toothed belt, removing and installing

1. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .
2. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Scheme 492

Special tools, testers and auxiliary items required

1. Counter-holder tool 3415
2. Assembly tool T10053
3. Torque wrench V.A.G 1331
4. Torque wrench V.A.G 1332

1. Hand drill with plastic brush attachment
2. Protective glasses
3. Sealant

Removing

1. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .
2. Toothed belt, removing --> «Toothed belt drive, overview»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-drive-overview) .

1. Loosen toothed belt crankshaft sprocket by holding sprocket with Counter Support 3415.

1. Remove toothed belt crankshaft sprocket center bolt - 1 - and remove sprocket - 2 - and diamond disc - 3 -.

Scheme 493

1. Remove bolts - 1 to 10 -.
2. Pry off and remove front sealing flange.
3. Drive out seal from removed flange.

Installing

Note. Place a rag over open part of oil pan.

1. Carefully remove any sealant residue from cylinder block and oil pan.

Scheme 494

1. Remove sealant residue from sealing flange e.g. with a rotating plastic brush.
2. Clean sealing surfaces, they must be free of oil and grease.

Scheme 495

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Scheme 496

1. Apply a thin bead of sealant to edge between cylinder block and oil pan - arrow -.

Scheme 497

1. Apply a thin bead of sealant - arrow - to clean sealing surface of sealing flange, as shown in the illustration.

1. Thickness of sealant bead: 2 to 3 mm.

Note. The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

Scheme 498

1. Lightly coat lower sealing surface of sealing flange with sealant - shaded area -.

Note. The sealing flange must be installed within 5 minutes of being applied with sealant.

1. Carefully slide sealing flange onto reamed bolt at cylinder block.

Note. To install the sealing flange with installed seal, use the guide sleeve T10053/1.

1. Fasten bolts in specified order
2. Tighten bolts - 1 to 6 -.
3. Tighten bolts - 7 to 10 -.
4. Install crankshaft seal (belt pulley side) «Installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__installing) .

1. Replace center bolt for toothed belt sprocket.

Note. There must be no oil on the contact surface between the toothed belt sprocket and crankshaft. Do not oil bolt for crankshaft toothed belt sprocket.

1. Install crankshaft toothed belt gear - 2 - with new diamond disc - 3 - and new center bolt - 1 -.

1. Hold toothed belt crankshaft sprocket with Counter Support 3415 and tighten.

The rest of installation is in reverse order of removal, note the following

How to install toothed belt and adjust valve timing --> Toothed belt, removing and installing

1. Install crankshaft belt pulley --> «Crankshaft belt pulley, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__crankshaft-belt-pulley-removing-and-installing)
2. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .
3. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Note. The threads and shoulder must be free of oil and grease.

Dual-mass flywheel, removing and installing

Special tools, testers and auxiliary items required

Scheme 499

1. Counter-holder tool 3067

Removing

1. Engine or transmission removed.

1. Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

Scheme 500

1. Rotate dual-mass flywheel - A - so that bolts - B - stand centered to holes - arrows -.
2. When removing bolts - B - , make sure that bolt head does not contact dual-mass flywheel - arrows - and thereby cause damage when turning it further.

Scheme 501

1. Insert counter-holder 3067 into hole in cylinder block - B -.
2. Mark dual-mass flywheel to engine.
3. Remove dual-mass flywheel.

Installing

Installation is in reverse order of removal, note the following

1. Use new bolts when securing.

1. Insert counter-holder 3067 into hole in cylinder block - A -.

Torque specification

Drive plate, removing and installing

Special tools, testers and auxiliary items required

Scheme 502

1. Flywheel lock adapter VW 558
2. Hex bolt M8x45 and two M10 hex nuts
3. Depth gauge

Removing

1. Engine or transmission removed.

1. Mark drive plate to engine

Scheme 503

1. Secure flywheel lock adapter VW 558 with hex bolt M8x45 to drive plate. Insert two M10 hex nuts between flywheel lock adapter and drive plate. Installed location of flywheel retainer: - A - to loosen, - B - to tighten
2. Remove drive plate.
3. Remove shim from behind it.

Installing

Scheme 504

1. Set drive plate in place, using washer with notches - 1 -.
2. Insert new bolts - 3 - and tighten to 30 Nm.

Scheme 505

1. Check dimension - a - an three points and calculate mean value.

1. Specified value: 19.5 to 21.1 mm

Note. This is measured through the hole in the drive plate to the machined surface of the cylinder block.

If specification is not obtained

1. Remove driver plate and remove or add shim - 2 -.
2. Repeat measuring procedure by tightening drive plate to 30 Nm.

If specified value is achieved

1. Tighten bolt to torque specification.

Torque specification

Crankshaft, removing and installing

Note. Secure engine to assembly stand using engine and transmission holder VW 540 when performing repair work --> Engine, securing to assembly stand .

Scheme 506

1 - 65 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. When measuring radial clearance, tighten crankshaft to 65 Nm, but do not turn further

2 - Bearing cap

1. Bearing cap 1: Belt pulley side
2. Bearing cap 3 with notches for thrust washers
3. Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another

3 - 10 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. Replace sensor wheel every time bolts are loosened «Sensor wheel, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

4 - Needle bearing

1. For vehicles with manual transmission
2. Pulling out and driving in --> «Pulling out and driving in needle bearings from crankshaft»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__pulling-out-and-driving-in-needle)

5 - Sensor wheel

1. For engine speed (rpm) sensor G28
2. Only possible to install in one position - Bores are offset
3. Replace sensor wheel every time bolts are loosened
4. Removing and installing «Sensor wheel, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

6 - Crankshaft

1. Axial play new: 0.07 to 0.23 mm. Wear limit: 0.30 mm
2. Check radial clearance with Plastigage 0.02 to 0.04 mm Wear limit: 0.15 mm
3. Do not turn crankshaft when measuring radial play
4. Crankshaft dimensions --> «Crankshaft dimensions»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__crankshaft-dimensions)

7 - Thrust washers

1. For bearing 3
2. Observe locating point

8 - Bearing shell for cylinder block

1. With lubricating groove
2. Do not interchange used bearing shells (mark)
3. Insert bearing shells for cylinder block with proper color marking «Allocation of crankshaft bearing shells for cylinder block»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

9 - Chain sprocket

1. For chain for oil pump
2. Replacing --> «Chain sprocket, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__chain-sprocket-removing-and-installing) .

10 - Bearing shell for bearing cap

1. Without lubricating groove
2. Do not interchange used bearing shells (mark)
3. The crankshaft bearing shells in bearing caps are only available as a replacement part with a "yellow" color marking.

Scheme 507

1. Always replace sensor wheel - 2 - whenever bolts are removed - 1 -.

Note. After tightening a second time, the attachment point of the countersunk screws of the sensor wheel are so deformed that the screw heads lie on the crankshaft - 3 - - arrows - and the sensor wheel is loose underneath the screws. Installation of sensor wheel is only possible in one position - the bores are offset.

Torque specifications

Scheme 508

The cylinder block is allocated with bearing shells of the correct thickness in the factory. Colored spots serve to identify the bearing thicknesses.

Note. Arrow points in direction of travel.

The letters marked on lower sealing surface of cylinder block identify which bearing shell must be installed in which location.

Note. The crankshaft bearing shells in the bearing caps are only available as a replacement part with a "yellow" color marking.

Pulling out and driving in needle bearings from crankshaft

Note. A pilot needle bearing must be installed in the crankshaft in engines for vehicles with manual transmission. Install needle bearing if necessary.

Special tools, testers and auxiliary items required

Scheme 509

1. Drift VW 207 C 3176 or centering mandrel 3176

Scheme 510

1. 1 - Internal puller Kukko 21/1
2. 4 - Counter-support Kukko 22/1

Pulling out

Scheme 511

1. Pull out needle bearing using internal puller Kukko 21/1 and counter-support Kukko 22/1.

Driving in

Scheme 512

1. Drive in needle bearing using drift VW 207 C or centering mandrel 3176 until it is flush.

1. Side of needle bearing with writing on it must be readable when installed.

Crankshaft dimensions

(Dimensions in mm)

Chain sprocket, removing and installing

Special tools, testers and auxiliary items required

Scheme 513

1. Press tube 30 - 100

Scheme 514

1. Thrust piece 40 - 105
2. Two-arm puller, commercially available
3. Protective gloves

Removing

1. Remove oil pan with oil pump --> «Oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .
2. Remove front sealing flange --> «Front sealing flange, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Scheme 515

1. Pull off crankshaft chain sprocket with claw puller - 2 - e.g. Kukko 44-1, while protecting end of crankshaft with thrust piece 40 - 105.

Installing

Installation is in reverse order of removal, note the following

1. Heat up chain sprocket in an oven for approx. 15 minutes at 220 °C.

Note. Installed location: Wider shoulder of chain sprocket faces toward engine.

Scheme 516

1. Using pliers, install chain sprocket on crankshaft end and slide onto crankshaft to stop using press tube 30 - 100.
2. Install oil pan with oil pump --> «Oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Scheme 517

1 - Connecting rod bolt - 30 Nm plus an additional 1 / 4 (90 °)

1. Replace
2. Lubricate threads and contact surface
3. Use old bolt to measure radial play
4. Tighten to 30 Nm to measure radial play, do not turn further

2 - Pressure relief valve, 27 Nm

1. Opening pressure 1.6 to 1.9 bar

3 - Oil spray jet

1. For piston cooling

4 - Connecting rod bearing cap

1. Note installation position
2. Due to separation procedure (cracking) of connecting rod, cap only install in one position and only to corresponding connecting rod.
3. Affiliation to cylinder mark - B
4. Installed location: Markings - A - point to belt pulley side

5 - Bearing shells

1. Upper bearing shell with oil hole for piston pin lubrication
2. Installed location «Installed position of bearing shell»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Do not interchange used bearing shells (mark)
4. Axial play new: 0.10 to 0.35 mm. Wear limit: 0.40 mm

1. Measure radial clearance with Plastigage: New: 0.02 to 0.06 mm. Wear limit: 0.09 mm. Do not turn crankshaft when checking radial clearance

6 - Connecting rod

1. Only replace as set
2. Affiliation to cylinder mark - B
3. Installed location: Markings - A - point to belt pulley side
4. With oil hole for piston pin lubrication

7 - Circlip

8 - Piston pin

1. If difficult to move, heat piston to approx. 60 °C
2. Use pilot drift VW 222 A for removal and installation

9 - Piston

1. Checking «Checking piston»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
2. Mark installed position and cylinder allocation
3. Arrow on piston face points toward belt pulley side
4. Install with piston ring compressor

1. Piston and cylinder dimensions --> «Piston and cylinder dimensions»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__piston-and-cylinder-dimensions)
2. Cylinder bore, checking «Checking cylinder bores»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

10 - Piston rings

1. Offset gaps by 120 °
2. Use piston ring pliers for removal and installation
3. "TOP" mark must face up toward piston crown
4. Checking ring gap «Checking piston ring gap»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

1. Check piston ring groove clearance «Checking ring to groove clearance»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

Scheme 518

1. Push ring squarely from above down to approx. 15 mm from bottom end of cylinder. To do this use a piston without rings.

Scheme 519

1. Clean ring groove of piston before checking.

Scheme 520

1. Measure pistons approx. 10 mm from bottom edge and at points offset by 90 ° to piston pin axis.

1. Deviation from nominal dimension: max. 0.04 mm

Scheme 521

Special tools, testers and auxiliary items required

1. Internal dial gauge 50 to 100 mm

1. Measure diagonally at 3 positions transversely - A - and longitudinally - B -.

1. Deviation from nominal dimension: max. 0.08 mm

Scheme 522

Bearing shell - 1 - with connecting rod oil bore - arrow -.

Bearing shell - 2 - without connected rod cover oil bore.

1. Place bearing shells centrally into connecting rod and connecting rod cover.

Dimension - a - must be the same at left and right.

Piston and cylinder dimensions

Cylinder head, assembly overview

Note. Replace cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening torque as well as gaskets and O-rings. When installing a replacement cylinder head with camshafts installed, contact surfaces between roller rocker lever and cam running surfaces must be oiled. The plastic protectors installed to protect the open valves must only be removed immediately before installing the cylinder head. When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced.

Scheme 523

1 - Bolt

1. Tightening order «Cylinder head cover tightening sequence»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

2 - Cylinder head cover

1. Removing and installing --> «Cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__cylinder-head-cover-removing-and-installing)

3 - Gasket

1. Replace if damaged or leaking

4 - Valve housing

5 - Oil filler cap

6 - Gasket

1. Replace if damaged or leaking

7 - 4 Nm

8 - Cylinder head cover gasket

1. Replace if damaged or leaking

9 - Vacuum pump

10 - 4 Nm

11 - Camshaft Adjustment Valve 1 N205

1. Removing --> «Camshaft Adjustment Valve 1 N205 , removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

12 - Seal

1. Replace

13 - 10 Nm

14 - Cable bracket

15 - Seal

1. Replace if damaged or leaking

16 - 10 Nm

17 - Housing

18 - Gasket

1. Replace

19 - Transport strap

20 - 25 Nm

21 - 10 Nm

1. Stud bolt for intake manifold

22 - Partition plate

23 - Cylinder head gasket

1. Replace
2. Note installation position: Part number facing cylinder head

24 - 10 Nm

25 - Camshaft Position (CMP) sensor G40

26 - Seal

27 - 10 Nm

1. Stud bolt for tensioning roller

28 - 20 Nm

1. Stud bolt for exhaust manifold

29 - Cylinder head bolt

1. Replace
2. Observe sequence for loosening. Refer to --> Loosen cylinder head bolts, paying attention to sequence of cylinder head bolts. under «Cylinder head, removing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Observe sequence for tighten cylinder head in sequence indicated, in two stages as follows
4. Torque specification: 40 Nm plus an additional 1 / 2 turn (180 °)

Scheme 524

1. Tighten bolts to 10 Nm in sequence given

Scheme 525

1. Check cylinder head at multiple points for distortion, using straight edge and feeler gauges.

1. Max. permissible distortion: 0.05 mm

Scheme 526

1. Resurfacing cylinder head (face grinding) is only permissible to minimum dimension a.

1. Minimum dimension: a = 139.20 mm

Scheme 527

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1783
2. Torx bit assortment V.A.G 1766
3. Ratchet 1/4" VAS 6234
4. Spring-type clip pliers VAS 5024 A

Removing

Note. Always replace gaskets and seals.

1. Remove engine cover - arrows -.

Scheme 528

1. Separate electrical connector - 1 -.
2. Remove wiring harness bracket - arrow -.

Note. Do not pull out Camshaft Adjustment Valve 1 N205 at connector.

Scheme 529

1. Remove bolts - arrows - and remove Camshaft Adjustment Valve 1 N205 from housing.

Installing

Note. Camshaft Adjustment Valve 1 N205 as well as housing must be free of dirt and contamination. Remove new Camshaft Adjustment Valve 1 N205 from packaging only prior to installation.

1. Coat sealing ring with engine oil.
2. Carefully insert Camshaft Adjustment Valve 1 N205 into housing and press it in perpendicular to valve axle by hand as far as stop.
3. Install bolts and tighten to 4 Nm with Torque Wrench V.A.G 1783 , Ratchet Adapter 1/4 VAS 6234 , TORX-Bit T20 and Bithalter from TORX bit set V.A.G 1766.

The rest of assembly is basically a reverse of disassembling sequence.

Torque specifications

Cylinder head cover, removing and installing

Removing

Special tools, testers and auxiliary items required

Scheme 530

1. Ignition Coil Puller T40039

1. Remove engine cover - arrows -.

Scheme 531

1. Remove bolts - arrows -.

Scheme 532

1. Remove bolts - 1 -.
2. Disconnect connector - 2 - from ignition coils and free up cable.

Scheme 533

1. Remove ignition coils with power output stages - 2 - using Ignition Coil Puller T40039.

Scheme 534

1. Disconnect EVAP line from cylinder head cover - 1 -.
2. Remove the valve housing from the cylinder head cover - arrows -.

Scheme 535

1. Unfasten the crankcase ventilation line from the turbocharger - 1 -.
2. Disconnect the EVAP line to the turbocharger from the cylinder head cover - 2 -.
3. Loosen cylinder head cover from outside toward the inside.
4. Remove cylinder head cover.

Installing

Installation is performed in the reverse order of removal, noting the following

Note. Replace cylinder head cover gaskets if damaged.

1. Tightening order «Cylinder head cover tightening sequence»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
2. Observe the correct positioning of the upper toothed belt cover.

Torque specifications

Scheme 536

Special tools, testers and auxiliary items required

1. Drip tray for workshop crane VAS 6208
2. Retainer 3036
3. Puller T40001
4. Ignition Coil Puller T40039

1. Hose clamp pliers V.A.G 1921
2. Polydrive bit and drive socket T10070

Special tools, testers and auxiliary items required

1. Toothed Belt Tensioner T10020

1. Locking Tool T40098

Removing

1. Engine installed.

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing. Perform oil change if engine oil is contaminated --> 01 - MAINTENANCE 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET If using sealant, note current specifications

1. Note radio code (for vehicles equipped with coded anti-theft radio/radio navigation system), obtain if necessary.

1. Remove engine cover - arrows -.

1. Open cap of coolant expansion tank.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Remove toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing) .

1. Loosen bolt for camshaft sprocket using Retainer 3036.

1. Remove camshaft sprocket using two-arm puller T40001 and claw T40001/6 and claw T40001/7.

Scheme 537

1. Remove rear toothed belt housing - arrows - from cylinder head.

1. Unfasten Ground (GND) cable - 1 -.
2. Disconnect vacuum line to brake booster at bulkhead - 2 -.
3. Disconnect EVAP hose - 3 -.

1. Remove coolant hoses - 1 and 2 - and unfasten coolant expansion tank - arrow -.
2. Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.

1. Separate electrical connector from Charge Air Pressure Sensor G31 - 1 -.
2. Remove left charge air hose - 2 -.

1. Remove air duct hose - 1 - to turbocharger at bottom right.
2. Remove air duct hose - 2 - to charge air cooler at lock carrier.

1. Disconnect connector - 1 and 2 - and free up cable.

Scheme 538

1. Remove oil supply line for turbocharger at cylinder block - 1 -.
2. Remove bolt - 2 - of support for turbocharger.

Scheme 539

1. Remove oil supply line for turbocharger - arrows -.

Scheme 540

1. Disconnect oil return line - arrows - from turbocharger.

Scheme 541

1. Loosen bolt - 1 - of support for turbocharger by 2 turns.
2. Remove intake manifold --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)
3. Remove catalytic converter --> «Catalytic converter, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__catalytic-converter-removing-and-installing)
4. Remove cylinder head cover --> «Cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__cylinder-head-cover-removing-and-installing)

Scheme 542

1. Loosen cylinder head bolts, paying attention to sequence of cylinder head bolts.

Note. Verify that all hose and line connections between engine, transmission and body have been disconnected.

1. Remove cylinder head.

Cylinder head, installing

Note. Replace cylinder head bolts. Always replace self-locking nuts, bolts which have been tightened to tightening torque as well as gaskets and O-rings. Secure all hose connections using hose clamps of series-production status Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Carefully remove all grinding and sanding residue. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. Hot bolt paste

Note. Turning over the engine is performed at the center bolt of the crankshaft.

Scheme 543

1. Bring marking on camshaft gear to alignment with marking on toothed belt guard. Recesses - arrows - now point to each other vertically.
2. In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.
3. Set cylinder head gasket in place.

Scheme 544

Pay attention to centering pins in cylinder block - arrows -.

1. Observe cylinder head seal location, identification: Replacement part number must be visible from intake side

1. Set cylinder head in place.
2. Insert cylinder head bolts and tighten by hand.

Scheme 545

1. Tighten cylinder head in sequence indicated, in two stages as follows
2. Tighten with torque wrench

1. 1. Step: 40 Nm

1. Tighten using a solid wrench

1. 2. Step: 180 ° ( 1 / 2 turn) further (2 x 90 ° further is permissible)

Note. There is no requirement to retighten the cylinder head bolts after repairs.

1. Install cylinder head cover --> «Cylinder head, removing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .
2. Install toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing) .
3. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .
4. Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component Locations

1. Install intake manifold --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)
2. Connect battery --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)
3. Install fuel system --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)
4. Check oil level --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

1. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant must not be re-used.

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Scheme 546

Special tools, testers and auxiliary items required

1. Compression tester V.A.G 1763
2. Spark plug removal tool 3122 B
3. Ignition Coil Puller T40039
4. Spring-type clip pliers VAS 5024 A

Test sequence

Note. Engine oil temperature min. 30 °C Battery voltage at least 12.7 V

1. Remove engine cover - arrows -.

1. Remove bolts - 1 -.
2. Disconnect connector - 2 - from ignition coils and free up cable.

1. Remove ignition coils with power output stages - 2 - using Ignition Coil Puller T40039.
2. Remove spark plugs, using spark plug removal tool 3122 B.
3. Disconnect 8-pin connector from fuel injectors. Refer to 8-pin harness connector for fuel injectors under «Component locations beneath intake manifold»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
4. Check compression using compression tester V.A.G 1763 and adapter V.A.G 1763/6.

Note. Using tester: Operating instructions

1. Operate starter until tester shows no further pressure increase.

Compression pressure

1. Install spark plugs and ignition coils.
2. Read out ECM DTC memory Vehicle Diagnostic, Testing and Information System VAS 5051 in "Guided Fault Finding" function

Note. By separating the connections, DTCs are stored to memory. After the test, check fault memory and erase, if necessary.

Torque specifications

Valvetrain, servicing

Note. Cylinder head and guide frame may only be replaced together. After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons. Always replace gaskets and seals.

Scheme 547

1 - 50 Nm plus an additional 180 °

2 - Camshaft sprocket

3 - Seal

1. Replacing --> «Sealing ring for exhaust camshaft, replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

4 - Cylinder head

5 - Valve guide

1. Checking --> «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__valve-guides-checking)

6 - Valve stem seal

7 - Valve spring

8 - Top valve spring retainer

9 - Valve keepers

10 - Hydraulic valve play balancing element

1. Do not interchange
2. Lubricate contact surface

11 - Fitted key

1. Check for secure seat

12 - Exhaust camshaft

1. Check radial clearance using Plastigage (roller cam follower removed) wear limit: 0.1 mm
2. Run-out: max. 0.035 mm

13 - Bearing bracket

1. With integrated camshaft bearings
2. Clean sealing surface, reworking is not permitted.
3. Remove old sealant residue.

14 - 8 Nm plus an additional 90 °

1. Replace

15 - Camshaft adjuster

16 - 20 Nm plus an additional 45 °

1. Replace

17 - Intake camshaft

1. Check radial clearance using Plastigage (roller cam follower removed) wear limit: 0.1 mm
2. Run-out: max. 0.035 mm

18 - Chain tensioner

1. Removing --> «Camshaft adjuster, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) Camshaft timing adjusters, removing and installing
2. Before removing, secure with Locking Pin T10115

19 - Drive chain

1. Check for wear

20 - 10 Nm

21 - 10 Nm

22 - Phase sensor

23 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Valve dimensions «Valve dimensions»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Check valve guides --> «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__valve-guides-checking)

24 - Intake valve

1. Do not rework, only lapping is permitted
2. Valve dimensions «Valve dimensions»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Check valve guides --> «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__valve-guides-checking)

25 - Sealing cap

1. Replace
2. Removing: When guide frame is installed: Pierce through one side of cover with an awl and pry it out
3. Installing: Without sealant press in with thrust piece 3334 1 to 2 mm deep

Scheme 548

Note. Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.

Scheme 549

Special tools, testers and auxiliary items required

1. Multi-point socket T40080
2. Camshaft locator T10252
3. Toothed Belt Tensioner T10020
4. Locking Pin T10115

Removing

1. Remove high-pressure pump. --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)

1. Remove bolts - arrows -.
2. Remove cylinder head cover --> «Cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__cylinder-head-cover-removing-and-installing)
3. Remove vacuum pump.

Scheme 550

1. Remove camshaft adjuster housing - arrows -.

1. Bring marking on camshaft gear to alignment with marking on toothed belt guard. Recesses - arrows - now point to each other vertically.

Scheme 551

1. Install camshaft locator T10252 as shown and secure - arrows -.
2. Loosen mounting bolt from camshaft adjuster using socket insert T40080.

Scheme 552

1. Compress chain tensioner - arrow A - and secure it using Locking Pin T10115 - arrow B -.
2. Remove mounting bolt from camshaft adjuster and remove it with chain.

Installing

1. The camshafts must be fixed in place with camshaft locating tool T10252.

1. Place chain on to camshaft adjuster.

Scheme 553

1. Hold camshaft adjuster in front of exhaust camshaft so that the notch - A - and pin - B - are positioned across from one another.

Scheme 554

1. Place chain in this position on to chain sprocket of intake camshaft, first at top - arrow -.

Scheme 555

1. Slowly turn intake camshaft with Toothed Belt Tensioner T10020 in direction of - arrow A - until camshaft adjuster fits onto camshaft.

Note. If pin does not fit into notch: Remove chain and place chain on again.

1. Tighten camshaft adjuster screw. To do so, use socket insert T40080.

1. Remove Locking Pin T10115 - arrow B -.

The rest of assembly is basically a reverse of disassembling sequence.

1. Install intake manifold --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)
2. Install high pressure pump --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)
3. Install vacuum pump --> «47 - BRAKES - HYDRAULIC COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system) .

Torque specifications

Cylinder head, camshafts --> Cylinder head, camshafts, overview

Cylinder head, assembly overview --> Cylinder head, assembly overview

Camshafts, removing and installing

Special tools, testers and auxiliary items required

Scheme 556

1. Puller T40001

Scheme 557

1. Retainer 3036

Removing

Note. Sealing surfaces on guide frame at bottom and on cylinder head at top must not be worked. Camshaft bearings are integrated in cylinder head or in guide frame. Before removing guide frame, tension on toothed belt must be released. If guide frame was loosened, camshaft sealing ring and sealing cap must be replaced.

1. Remove cylinder head cover --> «Cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__cylinder-head-cover-removing-and-installing)
2. Remove camshaft adjuster --> «Camshaft adjuster, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Remove toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing)

Scheme 558

1. Loosen camshaft gear with Retainer 3036.

1. Pull off camshaft gear using puller T40001 , claw T40001/6 and claw T40001/7.
2. Remove toothed belt guard at rear of cylinder head.
3. Loosen bolts of guide frame evenly from outside toward inside and remove guide frame.
4. Carefully remove camshaft upward and place on a clean surface.

Scheme 559

1. Remove old sealant from guide frame groove and from sealing surfaces.
2. Prevent dirt and adhesive residue from entering cylinder head.

Installing

Note. Sealing surfaces must be completely free of oil and grease. The pistons must not be positioned at TDC. Make sure that all roller cam followers make contact correctly on valve stem ends.

1. Oil journal surfaces of camshafts.

1. Carefully insert camshafts into camshaft bearings of cylinder head. The cam lobes - A - of cylinder 4 must face toward one another.

1. Apply an even, light sealant bead into clean groove of guide frame.

Note. Sealant must not be applied too thickly. Attaching and bolting the guide frame should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces. Note the expiration date of the sealing compound.

Scheme 560

1. Set guide frame in place so that it can get by EGR Vacuum Regulator Solenoid Valve N18 - arrow -.
2. Replace guide frame bolts.
3. Gently tighten bolts from inside working toward outside in several stages.

Scheme 561

1. Finally, tighten bolts in sequence shown.
2. Drive in sealing cap with thrust piece 3334 approx. 1 to 2 mm deep.
3. Install camshaft seal --> «Sealing ring for exhaust camshaft, replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
4. Install rear toothed belt cover.

1. Insert fitting key into camshaft.

1. Install camshaft gear. To tighten bolt, hold camshaft gear in place using Retainer 3036.

Note. When turning camshaft, pistons may not be at TDC for any cylinder. Valves/pistons may be damaged. Be sure fitting keys are properly seated.

1. Install toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing)
2. Install camshaft adjuster --> «Camshaft adjuster, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Install cylinder head cover --> «Cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__cylinder-head-cover-removing-and-installing)
4. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

The rest of assembly is basically a reverse of disassembling sequence.

Torque specifications

Cylinder head, camshafts --> Cylinder head, camshafts, overview

Valve stem seals, replacing

(with cylinder head installed)

Scheme 562

Special tools, testers and auxiliary items required

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Adapter T40012

1. Torque wrench V.A.G 1331
2. Valve cotters assembly/disassembly device VAS 5161
3. Guide Plate F/2.0 Ltr FSI Engine VAS 5161/19A

Valve stem seals, removing

1. Remove camshafts --> «Camshafts, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__camshafts-removing-and-installing)

Note. To replace the valve stem seals of the exhaust valves for cylinder 3 and 4, the EGR Vacuum Regulator Solenoid Valve N18 must also be removed.

1. Remove roller rocker levers and place them on a clean surface. Make sure that roller cam followers are not interchanged.
2. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 563

1. Fasten Guide Plate F/2.0 Ltr FSI Engine VAS 5161/19A to cylinder as shown using Knurled Screws VAS 5161/12.
2. Adjust piston of respective cylinder to "Bottom Dead Center position".
3. Install adapter T40012 into spark plug thread and connect compressed air of at least 6 bar positive pressure.

Scheme 564

1. Using drift VAS 5161/3 and a plastic mallet, tap to loosen stuck valve keepers.

Scheme 565

1. Install Engaging Device VAS 5161/6 with Installation Fork VAS 5161/5 in Guide Plate F/2.0 Ltr FSI Engine VAS 5161/19A.
2. Insert Installation Cartridge VAS 5161/8 in Guide Plate F/2.0 Ltr FSI Engine VAS 5161/19A.
3. Engage pressure fork VAS 5161/2 on engaging device VAS 5161/6.

Scheme 566

Note. On the exhaust side, the pressure fork VAS 5161/2 must be hooked in, as shown.

1. Press down installation cartridge VAS 5161/8. At the same time, turn knurled bolt of installation cartridge VAS 5161/8 clockwise until points engage in valve keepers.
2. Lightly move knurled bolt back and forth, this causes the valve keepers to be pressed apart and captured in the installation cartridge.
3. Release pressure fork VAS 5161/2.
4. Remove installation cartridge VAS 5161/8.

Scheme 567

1. Remove valve stem seals using Valve Seal Removal Tool 3364.

Scheme 568

1. In the event valve stem seal driver 3364 cannot be used due to constrained spatial arrangements, drive out spring dowel sleeve - arrow - using a drift and remove impact device.

Scheme 569

1. Place lower part of valve seal removal tool 3364 onto valve stem seal.
2. Insert a drift - 1 - into bore in lower part of extractor device.
3. Place a lever at removal tool and pull out valve stem seal - arrow -.

Valve stem seals, installing

Scheme 570

1. Place plastic sleeve - A - on valve stem to prevent damage to new valve stem oil seals - B -.
2. Oil sealing lip of valve stem oil seal - B - , insert into valve stem seal driver 3365 and carefully slide onto valve guide.
3. Remove plastic sleeve - A -.
4. Insert valve spring and valve spring retainer.

1. Install valve cotter disassembly and assembly device VAS 5161 as shown.

Intake side

Exhaust side

Scheme 571

Note. If the valve keepers were removed from the installation cartridge, they must then be inserted into the insertion device VAS 5161/18. Press installation cartridge VAS 5161/8 onto insertion device from above and capture the valve keepers.

1. Press down installation cartridge VAS 5161/8 with pressure fork VAS 5161/2 and turn knurled screw of installation cartridge back and forth while pulling it upward at the same time.
2. Release pressure fork VAS 5161/2 with knurled bolt pulled.
3. Remove valve cotter assembly/disassembly device VAS 5161.

The rest of assembly is basically a reverse of disassembling sequence.

1. How to install camshafts --> «Camshafts, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__camshafts-removing-and-installing)

Valve guides, checking

Special tools, testers and auxiliary items required

Scheme 572

1. Dial gauge holder VW 387

Scheme 573

1. Dial gauge VAS 6079

Test sequence

Scheme 574

1. Insert valve into guide. Valve stem end must be flush with the guide. Due to the slight difference in stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust guide.
2. Determine tip clearance.

Wear limit

Note. If wear limit is exceeded, re-measure using new valves. If wear limit is still exceeded, replace cylinder head. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

Scheme 575

Special tools, testers and auxiliary items required

1. Seal remover 2085
2. Assembly tool 3066
3. Assembly tool T10071
4. Puller T40001

Special tools, testers and auxiliary items required

1. Toothed Belt Tensioner T10020

1. Locking Tool T40098

Removing

1. Remove engine cover - arrows -.

1. Open cap of coolant expansion tank.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Remove toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing)

1. Loosen camshaft sprocket, using Retainer 3036.

1. Remove camshaft sprocket using puller T40001 and claw T40001/6 and claw T40001/7.

Scheme 576

1. To guide seal puller, thread Adapter 2085/2 of seal puller 2085 into camshaft by hand up to stop.
2. Remove inner portion of seal puller 2085 two rotations (approx. 3 mm) from outer portion and secure with knurled-head screw.

Scheme 577

1. Grease threaded head of seal puller 2085 , position and screw into oil seal as far as possible with forceful pressure.
2. Loosen knurled bolt and turn inner part against camshaft until seal is removed.
3. Secure seal remover in a vise at flat spots. Remove seal using pliers

Installing

1. Do not oil sealing lip of sealing ring.

Scheme 578

1. Place Guide Sleeve T10071/1 from Assembly Tool T10071 on camshaft pin.
2. Slide oil seal over guide sleeve onto shaft pin.
3. Remove guide sleeve.

Scheme 579

1. Press sealing ring on as far as stop with Guide Sleeve T10071/3 and Screw T10071/4 from Assembly Tool T10071.
2. Install camshaft sprocket.

Scheme 580

1. Note installation position: Thin rib of camshaft gear points outward - arrows - and TDC marking cylinder 1 is visible.

1. Install bolt for camshaft sprocket using Retainer 3036.

Note. By turning the camshaft, the valves could contact the stationary pistons at TDC. Therefore, the pistons must not be at TDC. Valves/pistons may be damaged.

1. Install toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing) .
2. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Lubrication system components, removing and installing

Note. If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or connecting rod damage) are found in the engine oil, the oil passages must be cleaned thoroughly and the oil cooler replaced in order to prevent further damage from re-occurring.

Oil pressure, checking --> Oil pressure and oil pressure switch, checking

Viscosity classes and oil specifications: -->

1. «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures)
2. «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET

Note. The engine is filled at the factory with engine oil complying to VW standard 502 00. This engine oil is designed for long maintenance intervals. The engine oils listed below may also be used. The oil must be changed every 12 months or every 15,000 km and the Service Reminder Indicator (SRI) must be programmed accordingly. Procedure: --> 01 - MAINTENANCE 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET .

Part I oil pan, balance shaft module, component overview

Part II Balance shaft module, oil pump --> Part II balance shaft assembly with oil pump, component overview

Scheme 581

1 - 15 Nm

2 - Oil dipstick

1. Oil level must not be above max. mark!

3 - Inlet spout

4 - Guide tube

5 - Intermediate plate

6 - Balance shaft module with oil pump

1. With pressure relief valve 12 bar
2. Removing and installing --> «Balance shaft module with oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__balance-shaft-module-with-oil-pump)

7 - 15 Nm plus an additional 1 / 4 turn (90 °)

1. Replace
2. Note different length of bolts «Bolt allocation for balance shaft housing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

8 - 15 Nm

9 - Oil pan

1. Clean sealing surface before installing
2. Removing and installing --> «Oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

10 - 15 Nm

11 - Seal

12 - Oil drain plug, 30 Nm

1. With permanent sealing ring
2. Replace

13 - Chain sprocket

14 - 10 Nm

15 - Protective cap

16 - Oil Level Thermal Sensor G266

17 - Seal

1. Replace
2. Oil before assembling

18 - 20 Nm plus an additional 90 °

1. Replace

19 - Chain guard

20 - Chain

21 - Sealing flange

1. Must be located on dowel sleeves
2. Seal for crankshaft - belt pulley side, replacing --> «Crankshaft seal - ribbed belt side, replacing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

Part II balance shaft assembly with oil pump, component overview

Part I Oil pan, balance shaft assembly --> Part I oil pan, balance shaft module, component overview

Scheme 582

1 - Chain guard

2 - Chain

1. Mark direction of travel (installation position) using color marking before removing

3 - Alignment bushing

4 - Intermediate plate

5 - Balance shaft module with oil pump

1. Before installing, check to be sure both alignment bushings are present (for centering oil pump/cylinder block)
2. Removing and installing --> «Balance shaft module with oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__balance-shaft-module-with-oil-pump)

6 - 9 Nm

7 - Cover

1. Prevents engine oil from foaming up

8 - 40 Nm

9 - 8 Nm

10 - Oil intake pipe

1. Clean strainer if dirty

11 - O-ring

1. Replace

12 - 15 Nm plus an additional 1 / 4 turn (90 °)

1. Replace
2. Note different length of bolts «Bolt allocation for balance shaft housing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

13 - 15 Nm plus an additional 1 / 4 turn (90 °)

1. Replace
2. With seal
3. Note different length of bolts «Bolt allocation for balance shaft housing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

14 - Outer rotor

1. Check contact surfaces for groove build-up
2. Marking must be visible

15 - Inner rotor

1. Check contact surfaces for groove build-up

16 - Oil pump cover

17 - Chain sprocket

18 - 20 Nm plus an additional 90 °

1. Replace

19 - Chain tensioner with tensioning rail

1. Pre-load to install

20 - 15 Nm

Scheme 583

Special tools, testers and auxiliary items required

1. Engine support bridge 10-222 A
2. Multi-point socket T10058
3. Old oil collecting and extracting device V.A.G 1782
4. Shop crane VAS 6100

1. Insert pad for front fender T40045
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Remove engine cover - arrows -.
2. Remove rubber seal on fender attachment edges.

Scheme 584

1. To prevent damage to fender edges when using engine support bridge 10-222 A , place insert pad for front fender T40045 on both sides between fender attachment edge and web plate lying beneath.

Scheme 585

1. Position engine support bridge 10-222 A with adapters 10-222/3 on fender attachment edge.
2. Hook in spindles at engine lifting eyes, as shown.
3. Pretension engine slightly with spindles.
4. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing)

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
3. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.

Scheme 586

1. Remove bolts - arrows - and remove torque supports from oil pan.
2. Remove turbocharger oil return line - 1 - from oil pan.

1. Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor G266.

1. Remove bracket for refrigerant line on oil pan - arrow -.

1. Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.

1. Remove air conditioning compressor from bracket - arrows -.

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Hang up A/C compressor with attached lines at bottom of vehicle.

Scheme 587

1. Disconnect electrical harness connector - arrow - at Left Front Level Control System Sensor G78.

Scheme 588

1. Remove stabilizer bar mountings - 1 - and - 2 -.

Scheme 589

1. Support subframe with workshop crane VAS 6100 or V.A.G 1202 A.

Scheme 590

1. Cut through cable ties - arrows - , open starter harness retainer and take harness out.

Scheme 591

1. Remove lower nut - 3 - on engine mount.
2. Remove bolts - 4 - and - 5 - on engine mount plate.
3. Remove front bolt - 1 - for subframe and remove engine mount plate - 2 -.
4. Repeat work procedure on opposite side of vehicle.

1. Slowly lower subframe with workshop crane VAS 6100 or V.A.G 1202 A.
2. Lift engine slightly upward using spindles of engine support bridge 10-222 A , paying attention to clearance of shift linkage and exhaust system.

Scheme 592

1. Remove bolts - arrows - for transmission/oil pan.

Scheme 593

1. Remove M10 bolts - arrows -.
2. Loosen bolts - 1 to 18 - in a diagonal sequence.
3. Remove oil pan, and if necessary loosen by applying light strikes with a rubber hammer.

Installing

Installation is in reverse order of removal, note the following

Note. Replace seal. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location.

Scheme 594

1. Remove residual sealant from oil pan and at cylinder block, e.g. using a rotating plastic brush.

1. Clean sealing surfaces, they must be free of oil and grease.

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Scheme 595

1. Apply sealant bead as illustrated to clean sealing surface of oil pan.

1. Thickness of sealant bead: 2 to 3 mm.

Note. The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube. Apply a bead of sealant at the rear area of the sealing flange very carefully - arrows -. The oil pan must be installed within 5 minutes of being applied with sealant.

1. Install oil pan immediately and tighten bolts in described sequence
2. Pre-tighten bolts - 1 to 18 - in diagonal sequence to 5 Nm.
3. Tighten oil pan/transmission bolts to 45 Nm.
4. Tighten bolts M10 - arrows - to 40 Nm.

1. Tighten bolts - 1 to 18 - in diagonal sequence to 15 Nm.

Scheme 596

Note. When installing the oil pan - 3 - on a removed engine, make sure that the flywheel end of the oil pan is aligned flush with the intermediate plate - 1 - , therefore the oil pan must extend beyond the cylinder block - 2 - by dimension - a - 0.8 mm. After installing oil pan, allow sealant to dry for approx. 30 minutes. Only after then may the engine oil be replenished.

1. Install subframe --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Install A/C compressor --> «87 AIR CONDITIONING»(/audi/a4/b7-2004-2009/remont/ac-compressor/#heating-air-conditioning)
4. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .

1. Add engine oil and check oil level.

The rest of assembly is basically a reverse of disassembling sequence.

Torque specifications

Part I Oil pan, balance shaft assembly --> Part I oil pan, balance shaft module, component overview

Balance shaft module with oil pump, removing and installing

Special tools, testers and auxiliary items required

Scheme 597

1. Connecting Pin T10027

Removing

1. Remove oil pan --> «Oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Note. Turning over the engine is performed at the center bolt of the crankshaft.

1. Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard.

Scheme 598

1. Remove chain guard. Disengage locking lugs through openings - arrows - if necessary using a small screwdriver.

Scheme 599

1. Loosen bolt from oil pump chain sprocket. Counter-hold at center bolt for vibration damper.

Scheme 600

1. Release tension on chain rail using a screwdriver - arrow - and secure it using an Allen wrench - 1 - , across flats 3 mm.

Scheme 601

1. Remove chain sprocket of oil pump and disengage chain on differential shaft drive.

Scheme 602

1. Remove oil baffle, removing bolts - 1 and 2 -.

Scheme 603

1. Remove bolts - arrows - from balance shaft assembly from outside to inside and remove it.

Installing

1. Chain tensioner pre-tensioned

1. Replace all balance shaft assembly bolts.
2. Replace balance shaft assembly bolt gasket.

Scheme 604

1. Place intermediate plate as shown on to alignment bushings of differential shaft gear - arrows -.

1. Install balance shaft assembly with oil pump and intermediate plate. Tighten bolts - arrows - from inside toward outside.

Note. Observe the different lengths of bolts. Bolt allocation for balance shaft housing

Note. Pay attention to centering sleeves.

1. Install oil baffle, thereby inserting tabs into balance shaft assembly - arrows - and tightening bolt - 1 - to 21 Nm and bolts - 2 - to 9 Nm.

Note. Turning over engine is performed at the center bolt of the crankshaft.

1. Set engine to TDC at cyl. 1, by turning crankshaft in engine running direction at the central bolt of the crankshaft toothed belt sprocket. Marking on camshaft sprocket and marking on crankshaft must be positioned at TDC for cyl. 1 - arrows -.

Scheme 605

1. Set marking on chain sprocket of differential shaft - arrow - opposite alignment bore. Secure chain sprocket in this position using connecting pin T10027. Place chain on to differential shaft chain sprocket.
2. Install oil pump chain sprocket with new bolt and tighten bolt by hand.

Note. Oil pump chain sprocket fits only in one position. To install, only the oil pump must be turned.

1. Remove connecting pin T10027 and Allen wrench - 1 -. Secure chain sprocket of oil pump. Counter-hold at center bolt for vibration damper.

The rest of assembly is basically a reverse of disassembling sequence.

1. Install oil pan --> «Oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Scheme 606

A - Hex collar bolt M7x40

B - Hex collar bolt M7x70

C - Hex collar bolt M7x90

D - Hex collar bolt M7x55

E - Sealing plug with O-ring

Scheme 607

1. Pretension piston by hand - arrow -.

Scheme 608

1. Push chain rail in direction of - arrow - and secure it with an Allen wrench - 1 - , wrench diameter 3 mm.

Scheme 609

1 - Pipe

1. For crankcase ventilation

2 - Oil pressure switch F1

1. 1.4 bar - black
2. Checking --> «Oil pressure and oil pressure switch, checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Torque specification 21 Nm

3 - 15 Nm

1. With Ground (GND) wire for oil pressure switch

4 - Bracket

5 - 15 Nm

6 - Oil cooler

1. See note --> «Lubrication system components, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
2. Ensure sufficient clearance to surrounding components
3. Coolant hose connection diagram --> «Coolant hose connection diagram»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
4. Removing and installing --> «Oil cooler, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__oil-cooler-removing-and-installing)

7 - Gasket

1. Replace

8 - 15 Nm

9 - Seal

1. Replace
2. Lightly lubricate
3. Installed location «Sealing ring installation location»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

10 - Locking bolt

11 - Oil filter housing

1. Removing and installing with Oil Filter Wrench 3417 or with socket AF 36, e.g. Socket AF 36 T10125
2. Draining --> «Oil filter housing, draining»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__oil-filter-housing-draining)

12 - Oil filter element

1. Observe change intervals --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET

13 - Oil baffle

1. Installed location «Oil baffle installation location»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

14 - Gasket

1. Replace

15 - Oil filter bracket

1. With pressure relief valve, approx. 4 bar
2. Removing and installing --> «Oil filter bracket, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__oil-filter-bracket-removing-and-installing)

16 - Spring-type clip

Scheme 610

Scheme 611

1. Note position of service flag on sealing ring - arrow
2. Smooth side of sealing ring must face outward.

Oil filter housing, draining

Note. When installing the oil draining adapter T40057 , a valve in the oil filter housing is opened. If the oil draining adapter T40057 is removed, the valve closes again.

Special tools, testers and auxiliary items required

Scheme 612

1. Oil drain adapter T40057

Scheme 613

1. Remove dust cap from oil filter housing - arrow -.

Scheme 614

1. Hold hose of oil draining adapter T40057 in a catch pan and install oil draining adapter T40057 into oil filter housing.
2. Drain engine oil

Scheme 615

Special tools, testers and auxiliary items required

1. Oil pressure gauge V.A.G 1342
2. Voltage tester V.A.G 1527 B
3. Connector test set V.A.G 1594 C

Test requirements

1. Engine oil level OK, checking --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .
2. Oil pressure warning lamp must light up for approx. 3 seconds when ignition is switched on
3. On vehicles with Auto-Check-System, the indicator "O.K." must light up (check symbol).
4. Engine oil temperature at least 80 °C (radiator fan must start up once)

Note. Function test and servicing the optical and acoustic oil pressure indicator: wiring diagrams, "Function and Component Selection".

Test sequence

Scheme 616

1. Remove Oil Pressure Switch F1 - A - and install it into oil pressure gauge.
2. Thread oil pressure gauge into oil filter bracket in place of oil pressure switch.
3. Connect brown wire of tester to Ground (GND).
4. Connect voltage tester V.A.G 1527 B using adapter cables from connector test set V.A.G 1594 C to battery B+ and oil pressure switch F1 - B -. LED must not light up.

1. If LED lights up, replace 1.4 bar oil pressure switch.

If LED does not light up

1. Start engine and increase engine speed: LED must light up at 1.2 to 1.6 bar positive pressure, otherwise replace oil pressure switch F1.
2. Increase engine speed further. At 2000 rpm and an oil temperature of 80 °C, the oil pressure should be between 2.7 to 4.5 bar.

Torque specifications

Oil cooler, removing and installing

Special tools, testers and auxiliary items required

Scheme 617

1. Drip tray for workshop crane VAS 6208

1. Spring-type clip pliers VAS 5024 A

Removing

1. Open cap of coolant expansion tank.

1. Remove engine cover - arrows -.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
3. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
4. Remove intake manifold and fuel rail --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)

Scheme 618

1. Remove bracket for cable connector - arrows - from coolant pipe.

Scheme 619

1. Disconnect coolant hose - 1 -.
2. Remove bolts - 2 -.

Scheme 620

1. Disconnect coolant hoses - arrows - from coolant pipe.
2. Remove bolt - 1 - and remove coolant pipe.

Scheme 621

1. Remove oil cooler - arrows -.

Installing

Installation is in reverse order of removal, note the following

Note. Always replace gaskets and seals. Secure all hose connections using hose clamps appropriate for the model type .

1. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Torque specifications

Oil filter bracket, removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop crane VAS 6208

1. Spring-type clip pliers VAS 5024 A

1. Locking Tool T40098

Removing

1. Open cap of coolant expansion tank.

Removing

1. Remove engine cover - arrows -.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
3. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

1. Mark direction of rotation of ribbed belt.

1. Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
2. Secure tensioning element using Locking Tool T40098.
3. Remove ribbed belt.

1. Remove ribbed belt tensioner with engine lifting eye - arrows -.
2. Remove Generator --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)
3. Remove intake manifold and fuel rail --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)

1. Remove bracket for cable connector - arrows - from coolant pipe.

1. Disconnect coolant hose - 1 -.
2. Remove bolts - 2 -.

1. Disconnect coolant hoses - arrows - from coolant pipe.
2. Remove bolt - 1 - and remove coolant pipe.

1. Remove oil cooler - arrows -.

Scheme 622

1. Disconnect crankcase ventilation pipe - 1 -.
2. Remove Ground (GND) cable - 2 - for oil pressure switch.
3. Remove bolts - arrows - and remove oil filter bracket.

Installing

Installation is in reverse order of removal, note the following

Note. Always replace gaskets and seals. Secure all hose connections using hose clamps appropriate for the model type .

1. Install oil baffle
2. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .
3. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Torque specifications

Cooling system components, removing and installing

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Secure all hose connections using hose clamps appropriate for the model type . Hose clip pliers V.A.G 1921 or spring-type clip pliers VAS 5024 A are recommended for installing spring-type clamps. Always replace gaskets and seals. Arrows on coolant pipes and coolant hoses must line up across from each other.

Scheme 623

1 - Radiator

1. Removing and installing --> «Radiator, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__radiator-removing-and-installing)
2. Replace coolant after replacing

2 - Lower coolant hose

3 - Return hose from turbocharger

1. With bypass thermostat in hose

4 - Coolant pump

1. Removing and installing --> «Coolant pump, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__coolant-pump-removing-and-installing)

5 - Turbocharger

1. Removing and installing --> «Turbocharger, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__turbocharger-removing-and-installing)

6 - Map Controlled Engine Cooling Thermostat F265

1. Removing and installing --> «Map Controlled Engine Cooling Thermostat F265 , removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__map-controlled-engine-cooling-thermostat-f265)
2. Checking --> «Map Controlled Engine Cooling Thermostat F265 , checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__map-controlled-engine-cooling-thermostat-f265)

7 - Engine oil cooler

8 - Cylinder head/cylinder block

1. Replace coolant after replacing

9 - Water connection

10 - Bleeder hole

11 - Heater core of heater

1. Replace coolant after replacing

12 - Bleeder screw

1. Torque specification 20 Nm

13 - Expansion tank

1. With cap
2. Pressure relief valve in cap, checking --> «Cooling system, checking for leaks»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

14 - Coolant line

15 - Upper coolant hose

Scheme 624

Special tools, testers and auxiliary items required

1. Adapter V.A.G 1274/8
2. Pipe V.A.G 1274/10
3. Drip tray for workshop crane VAS 6208
4. Hose clamp pliers V.A.G 1921

1. Cooling system charge unit VAS 6096
2. Refractometer T10007

Draining

Note. Drained coolant must be stored in a clean container for disposal or reuse.

1. Open cap of coolant expansion tank.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.

1. Open drain plug - arrow - from lower left coolant hose and drain coolant.

Filling

Note. The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water. Only coolant additive G12+ can be used, in compliance with TL VW 774 F. Other coolant additives may above all reduce the corrosion protection effect significantly. The damage resulting from this may lead to loss of coolant and consequently to severe engine damage. Coolant additive G12+ can be combined with additives G11 and G12. G12+ and coolant additives with the designation "conforming to TL VW 774F " reduce frost and corrosion damage as well as lime deposits. They also raise the boiling point. For this reason the system must be filled all year round with frost and corrosion protection additives. Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates. Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%. If for climatic reasons a greater frost protection is required, the amount of G12+ can be increased, but only up to 60% (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced. Only clean drinking water may be used for mixing coolant. If the radiator, heater core, cylinder head and cylinder head gasket or cylinder block is replaced, completely replace the engine coolant. Dirty coolant must not be re-used. For coolant additive G12+, use refractometer T10007 to test frost protection in cooling system.

1. Close drain plug - arrow -.

Scheme 625

1. Fill coolant reservoir of cooling system filler unit VAS 6096 with at least 8 liters of pre-mixed coolant with correct mixture ratio

1. G12+ (40%) and water (60%) for frost protection to -25 °C
2. G12+ (50%) and water (50%) for frost protection to -35 °C
3. G12+ (60%) and water (40%) for frost protection to -40 °C

1. Install adapter V.A.G 1274/8 on expansion tank.
2. Assemble cooling system charge unit VAS 6096 on adapter V.A.G 1274/8.
3. Place air outlet hose - 1 - into a small container - 2 -. (A small amount of coolant is drawn off which should be reserved with discharged air.)
4. Close both valves - A - and - B - (lever perpendicular to direction of flow).

1. Connect hose - 3 - to pressurized air.

1. Pressure: 6 to 10 bar pressure

Scheme 626

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

A vacuum is created in cooling system by suction jet pump.

1. Needle on instrument display must travel into green region.

1. Briefly open valve - A - (lever in direction of flow), so that the hose of cooling system filler unit VAS 6096 is filled with coolant.
2. Close valve - A - again.
3. Let valve - B - remain open another 2 minutes.

A further vacuum is created in cooling system by suction jet pump.

1. Needle on instrument display must still remain in green region.

1. Close valve - B -.

1. Needle in display instrument must remain in green region, then sufficient vacuum in cooling system is obtained for upcoming filling.

If needle stands below green region, repeat procedure

If vacuum decreases, cooling system is leaking

1. Disconnect pressurized air hose.
2. Open valve - A -.

The vacuum in cooling system causes coolant to be extracted from cooling system filler unit VAS 6096 ; cooling system is filled.

1. Detach cooling system filler unit VAS 6096 from coolant expansion tank.

Scheme 627

1. Connect adapter for cooling system tester V.A.G 1274/10 to adapter V.A.G 1274/8.

Scheme 628

1. Loosen coolant hose to heater core and pull back hose sufficiently so that the bleeder hole - arrow - is no longer sealed by the connection.
2. Fill up coolant until it escapes from coolant hose bleeder hole without bubbles.
3. Push coolant hose onto connection and secure it with spring-type clamp.
4. If present, switch on auxiliary heater for about 30 seconds.

1. Twist cap for expansion tank closed.
2. Start engine.
3. Set heating air conditioning system to "HI" on both sides.
4. Let engine run at 2000 RPM for 3 minutes.

1. Let engine run at idle long enough until both large coolant hoses on main cooler are warm.
2. Let engine run at 2000 RPM for 1 minute.
3. Turn off engine and allow it to cool off.

Scheme 629

1. Check coolant level.

1. With cold engine, coolant level must be at MAX marking.
2. Coolant level may be above MAX marking with engine at operating temperature.

Scheme 630

1 - O-ring

1. Replace

2 - Coolant distribution housing

3 - O-ring

1. Replace

4 - Lower coolant line

5 - 10 Nm

6 - 15 Nm

7 - Seal

1. Replace

8 - Heating element connection

9 - Connector

10 - Map Controlled Engine Cooling Thermostat F265

1. Checking --> «Map Controlled Engine Cooling Thermostat F265 , checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__map-controlled-engine-cooling-thermostat-f265)
2. With connecting piece
3. Opening begins approx. 105 °C
4. Removing and installing --> «Map Controlled Engine Cooling Thermostat F265 , removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__map-controlled-engine-cooling-thermostat-f265)

Thermostat

Special tools and workshop equipment required

1. Drip Tray for VAS 6100 -VAS 6208
2. Hose Clip Pliers -V.A.G 1921
3. Locking Tool -T40098

Removing

Scheme 631

Scheme 632

Scheme 633

Scheme 634

1. With ignition switched off, disconnect battery Ground (GND) cable -arrow-. see scheme 361: Disconnecting Battery Ground (GND) Strap
2. Remove engine cover -arrows-. WARNING: Risk of scalding due to hot steam and hot coolant. When the engine is warm the cooling system is under pressure. To reduce pressure, cover coolant reservoir cap with cloth and carefully open. (Scheme 631): Removing Engine Cover
3. Open cap of coolant expansion tank.
4. Loosen quick-release fasteners -1 and 2- and remove front noise insulation. see scheme 363: Identifying Quick-Release Fasteners And Noise Insulation
5. Drain the coolant. Refer to «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt).
6. Remove oil pressure sensor electrical connector -1-.
7. Also remove lower coolant hose on coolant pipe -2- and allow remaining coolant to drain. (Scheme 632): Removing Oil Pressure Sensor Electrical Connector & Lower Coolant Hose On Coolant Pipe
8. Mark direction of rotation of ribbed belt.
9. Pivot the belt tensioner for ribbed belt in direction of -arrow- to relieve tension on ribbed belt. see scheme 365: Pivoting Belt Tensioner For Ribbed Belt To Relieve Tension On Ribbed Belt
10. Secure tensioning element using -T40098-.
11. Remove ribbed belt.
12. Remove the generator. Refer to «Generator (GEN)»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment).
13. Remove the coolant pipes. Refer to «Coolant pipe, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__coolant-pipe-removing-and-installing).
14. Remove the coolant pipe -arrow- from the intake manifold and move it to the side. (Scheme 633): Identifying Coolant Pipe
15. Remove the coolant hose -1- by lifting the retaining clip.
16. Remove the bolts -2 and 3- and remove the thermostat. (Scheme 634): Coolant Hose & Thermostat Bolts

1. Tightening specifications. Component Nm Thermostat to engine block 15 Accessory assembly bracket to cylinder block 45 1) Ribbed belt tensioner to accessory assembly bracket 23 1) Insert using locking compound

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

1. Clean and/or smooth O-ring sealing surface.
2. Coat new O-ring with coolant G12+.
3. Install the coolant pipes. Refer to «Coolant pipe, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__coolant-pipe-removing-and-installing) .
4. Fill with coolant. Refer to «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .
5. Install the generator. Refer to «Generator (GEN)»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .
6. Install the ribbed belt. Refer to Ribbed belt, removing and installing .
7. Connect battery. Necessary measures. Refer to «Battery»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .

Map Controlled Engine Cooling Thermostat F265 , removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop crane VAS 6208

Scheme 635

1. Hose clamp pliers V.A.G 1921

1. Locking Tool T40098

Removing

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

1. Remove engine cover - arrows -.

1. Open cap of coolant expansion tank.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

1. Remove oil pressure sensor electrical connector - 1 -.
2. Also remove lower coolant hose on coolant pipe - 2 - and allow remaining coolant to drain.

Scheme 636

1. Pull EVAP canister with connected lines upward in direction of - arrow - out of retainer and lay it aside.

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

1. Mark direction of rotation of ribbed belt.

1. Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
2. Secure tensioning element using Locking Tool T40098.
3. Remove ribbed belt.

1. Remove ribbed belt tensioner with engine lifting eye - arrows -.
2. Remove Generator --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

1. Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.

1. Remove air conditioning compressor from bracket - arrows -.

Note. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Hang up A/C compressor with attached lines at bottom of vehicle.

Scheme 637

1. Remove coolant hose - 2 - , thereby pull out retaining clip - 1 -.

1. Remove accessory assembly bracket - bolts - 1 to 6 -.

Scheme 638

1. Disconnect electrical connector - 1 -.
2. Remove Map Controlled Engine Cooling Thermostat F265 - arrows -.

Installing

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

1. Clean and/or smooth O-ring sealing surface.
2. Moisten new O-ring with coolant G12+.
3. Install accessory assembly bracket --> «Accessory assembly bracket, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__accessory-assembly-bracket-removing-and-installing)
4. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

1. Install generator. --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)
2. Install A/C compressor --> «87 AIR CONDITIONING»(/audi/a4/b7-2004-2009/remont/ac-compressor/#heating-air-conditioning)
3. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing)
4. Connect battery. Necessary measures --> «27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)

Map Controlled Engine Cooling Thermostat F265 , checking

Special tools, testers and auxiliary items required

Scheme 639

1. Connector test set V.A.G 1594C

1. Remove Map Controlled Engine Cooling Thermostat F265 --> «Map Controlled Engine Cooling Thermostat F265 , removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__map-controlled-engine-cooling-thermostat-f265) .

Note. How to drain coolant --> Cooling system, draining and filling . Always replace gaskets and seals. How to fill coolant --> Cooling system, draining and filling .

Scheme 640

1. Check thermostat when cold: Large valve plat must seal all around against connection flange.

If this is not the case

1. Replace Map Controlled Engine Cooling Thermostat F265.

Scheme 641

1. Connect contacts on Map Controlled Engine Cooling Thermostat F265 to battery with adapter leads from Connector Set V.A.G 1594C. Carefully insert it perpendicular to flange in a pot with hot coolant (mixture ratio: 50% G12+) using pliers.

The heating element also warms the wax in thermostat.

1. Observe whether minimum range of 7 mm - arrows - is reached after 10 minutes.

If range of 7 mm is reached

1. Disconnect voltage supply to battery.

Note. This test should not be performed in air. Damage to the expanding material element cannot be prevented!

If minimum range is not achieved

1. Replace Map Controlled Engine Cooling Thermostat F265.

Coolant pump, removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop crane VAS 6208

1. Spring-type clip pliers VAS 5024 A

Removing

1. Open cap of coolant expansion tank.

1. Remove engine cover - arrows -.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
3. Remove toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing)

Scheme 642

1. Remove coolant pump securing bolts - 1 - and remove coolant pump - 2 -.
2. Remove O-ring - 3 -.

Installing

Installation is in reverse order of removal, note the following

1. Clean and/or smooth O-ring sealing surface.

1. Moisten new O-ring - 3 - with coolant G12+.
2. Insert coolant pump - 2 -.

1. Installed location: Sealing plug in housing points downward

1. Tighten bolts - 1 - of coolant pump to 15 Nm.
2. Install toothed belt --> «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__toothed-belt-removing-and-installing) .
3. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__ribbed-belt-removing-and-installing) .
4. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Coolant pipe, removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop crane VAS 6208

1. Spring-type clip pliers VAS 5024 A

Removing

1. Open cap of coolant expansion tank.

1. Remove engine cover - arrows -.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
3. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)
4. Remove intake manifold --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)

1. Remove bracket for cable connector - arrows - from coolant pipe.

1. Disconnect coolant hose - 1 -.
2. Remove bolts - 2 -.

1. Disconnect coolant hoses - arrows - from coolant pipe.
2. Remove bolt - 1 - and remove coolant pipe.

Installing

Installation is in reverse order of removal, note the following

Note. Always replace gaskets and seals. Secure all hose connections using hose clamps appropriate for the model type .

1. Clean and/or smooth O-ring sealing surface before installing.
2. Moisten new O-ring with G12+ and push onto coolant pipe.
3. Install intake manifold --> - «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-fuel-injection-ignition-engine-codes-bpg-bwt)
4. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Torque specifications

Radiator, removing and installing

Special tools, testers and auxiliary items required

Scheme 643

1. Old oil collecting and extracting device V.A.G 1782 (only for vehicles with automatic transmission)

1. Drip tray for workshop crane VAS 6208

1. Spring-type clip pliers VAS 5024 A

Removing

Note. Drained coolant must be stored in a clean container for disposal or reuse.

1. Open cap of coolant expansion tank.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__lock-carrier-moving-into-service-position) .

1. Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
2. Open drain plug - arrow - from lower left coolant hose and drain coolant.

1. Disconnect lower coolant hose from radiator - arrow -.

Scheme 644

1. Disconnect coolant hose - 2 - at upper left of radiator.

Note. Ignore - 1 -.

1. Remove bolts - arrows -.
2. Remove air duct - 1 - and - 2 -.

Vehicles with automatic transmission

Scheme 645

Note. Observe the rules of cleanliness for working on automatic transmissions --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .

1. Place old oil collecting and extracting device V.A.G 1782 underneath.
2. Disconnect ATF-lines at top - arrow - and bottom of radiator --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
3. Tie ATF lines up to longitudinal member to prevent fluid from escaping.

All

1. Disconnect left and right electrical connectors - 3 - of horns - 2

Note. Ignore - 1 -.

1. Remove bumper - arrows -.

1. Remove left and right air guides at radiator - arrows -.

1. Unclip Outside Air Temperature Sensor G17 - 2 - from bracket.
2. Remove power steering cooling coil bolts - 3 - and - 4 - hydraulic hoses remain connected.
3. Pull off connector - 1 - from High Pressure Sensor G65.

1. Remove bolts - arrows - for condenser.

Note. Do not bend or stretch lines or hoses as A/C compressor and/or refrigerant lines/hoses may be damaged.

1. Pivot condenser downward with lines connected.

Scheme 646

1. Release both radiator retaining pins and remove by pulling upward - arrows -.
2. Pivot radiator forward, pull up and remove.

Installing

Installation is in reverse order of removal, note the following

1. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .

Note. Complete coolant must be replaced if the radiator was replaced.

Vehicles with automatic transmission

1. Fasten ATF lines --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
2. Check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .

Torque specifications

Fan shroud, removing and installing

Removing

1. Remove engine cover - arrows -.
2. Bring lock carrier into service position --> «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__lock-carrier-moving-into-service-position) .
3. Remove engine cover - arrows -.

1. Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
2. Free up electrical wiring.

Scheme 647

1. Remove bolts - arrows - and remove fan shroud upward and out.

Installing

Installation is in reverse order of removal, note the following

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

1. Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

Torque specifications

Coolant fan, removing and installing

Removing

1. Remove fan shroud --> «Fan shroud, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__fan-shroud-removing-and-installing) .
2. Free up electrical wiring.

Scheme 648

1. Remove screws - 1 to 8 -.
2. Remove coolant fan with control module.

Installing

Installation is in reverse order of removal, note the following

1. Install fan shroud --> «Fan shroud, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__fan-shroud-removing-and-installing) .

Torque specifications

Coolant fan motor, replacing

Special tools, testers and auxiliary items required

Scheme 649

1. Wiring harness repair kit VAS 1978

Work procedure

Note. The coolant fan control module and coolant fan motor are available as a replacement part without connector. Wiring harness and connector repairs must only be performed using wiring harness repair kit VAS 1978.

Scheme 650

The description of wiring harness repair kit VAS 1978 is explained in detail in the included operating instructions.

For example, repairs of open circuits and faulty connectors are also explained.

Scheme 651

Special tools, testers and auxiliary items required

1. Cooling system tester V.A.G 1274
2. Adapter V.A.G 1274/8
3. Adapter V.A.G 1274/9

Test conditions

1. Engine at operating temperature.

Test sequence

1. Open cap of coolant expansion tank.

Scheme 652

1. Attach cooling system tester V.A.G 1274 with adapter V.A.G 1274/8 to expansion tank.
2. Generate a positive pressure of approx. 1.0 bar using hand pump of cooling system tester.
3. If pressure decreases, search for leaking areas and repair malfunction.

Pressure relief valve in cap, checking

Scheme 653

1. Attach cooling system tester V.A.G 1274 with adapter V.A.G 1274/9 to expansion tank cap.
2. Operate hand pump.

1. Pressure release valve must open at a positive pressure of 1.4 to 1.6 bar

Note. Observe cleanliness rules Turbocharger . Secure all hose connections using hose clamps appropriate for the model type. Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces must only be lightly oiled with connector couplings --> Hose connections with connection couplings, assembly . Charge air system must be properly sealed. Replace self-locking nuts. Pliers for spring clamps VAS 5024A or Hose clamp pliers V.A.G 1921 are recommended for installing spring clamps. Add oil to turbocharger through oil feed line connecting piece. After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

Assembly of hose connections with connection couplings --> Hose connections with connection couplings, assembly

Hose connections with connection couplings, assembly

Removing

Scheme 654

1. Release connector coupling by pulling locking clip - arrow -. Separate hose/tube without assistance from tools.

Installing

1. When replacing sealing ring, lay ring in charge air hose groove. Ensure sealing ring sits completely in groove all the way around and is not turned.
2. Oil sealing surfaces and sealing ring.

Scheme 655

1. Bring securing clip into release position - 1 -.
2. Slide charge air hose into clutch as far as stop.
3. Bring securing clip into lock position - 2 - and then press charge air hose back again.
4. Check for correct seating and proper locking of connector by pulling on hose.

Part I

Part II Part II

Part III Part III

Part IV Part IV

Scheme 656

1 - Line for crankcase ventilation

2 - EVAP line

3 - Turbocharger and vacuum diaphragm

1. Removing and installing --> «Vacuum diaphragm for turbocharger, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__vacuum-diaphragm-for-turbocharger-removing-and)
2. Checking --> «Exhaust turbocharger vacuum diaphragm, checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__exhaust-turbocharger-vacuum-diaphragm-checking)
3. Adjusting --> «Vacuum diaphragm for turbocharger, adjusting»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__vacuum-diaphragm-for-turbocharger-adjusting)

4 - Seal

1. Replace

5 - Nipple

6 - Hose

7 - 8 Nm

8 - Hose

9 - 3 Nm

10 - Wastegate Bypass Regulator Valve N75

11 - Hose

12 - 7 Nm

13 - Bracket

14 - 7 Nm

15 - Turbocharger Recirculating Valve N249

1. Note installation position. Refer to --> «Installation position of Turbocharger Recirculating Valve N249»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

16 - Seal

1. Replace

17 - Turbocharger

1. Can only be replaced with exhaust manifold and pressure unit.
2. Removing and installing --> «Turbocharger, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__turbocharger-removing-and-installing)

18 - Gasket

1. Replace

19 - 9 Nm

Scheme 657

1. Note installation position - arrows -.

Part II

Part I Part I

Part III Part III

Part IV Part IV

Scheme 658

1 - Turbocharger

1. Can only be replaced with exhaust manifold and pressure unit.
2. Removing and installing --> «Turbocharger, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__turbocharger-removing-and-installing)

2 - Seal

1. Replace

3 - 35 Nm

4 - 9 Nm

5 - Coolant supply line

6 - 35 Nm

7 - 23 Nm

8 - Seal

1. Replace

9 - 9 Nm

10 - Gasket

1. Replace

11 - Oil return line

12 - 9 Nm

13 - Gasket

1. Replace

Part III

Part I Part I

Part II Part II

Part IV Part IV

Scheme 659

1 - Gasket

1. Replace

2 - 21 Nm

1. Replace
2. Coat stud bolts on exhaust manifold with hot bolt paste.
3. Hot bolt paste

3 - 35 Nm

4 - Seal

1. Replace

5 - Coolant return line

6 - 9 Nm

7 - Turbocharger

1. Removing and installing --> «Turbocharger, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__turbocharger-removing-and-installing)
2. Removing and installing --> «Turbocharger, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__turbocharger-removing-and-installing)

8 - 30 Nm

9 - Seal

1. Replace

10 - Oil supply line

11 - 9 Nm

12 - 30 Nm

13 - Seal

1. Replace

14 - 23 Nm

15 - Bracket

16 - Brace

17 - 30 Nm

1. Coat bolt with hot bolt paste
2. Hot bolt paste

18 - 30 Nm

1. Coat bolt with hot bolt paste
2. Hot bolt paste

19 - 30 Nm

1. Do not open when removing turbocharger
2. Replace
3. Coat stud bolts on exhaust manifold with hot bolt paste.
4. Hot bolt paste

20 - Fastening strip

Part IV

Part I Part I

Part II Part II

Part III Part III

Scheme 660

1 - Turbocharger

1. Can only be replaced with exhaust manifold and pressure unit.
2. Checking --> «Exhaust turbocharger vacuum diaphragm, checking»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__exhaust-turbocharger-vacuum-diaphragm-checking)
3. Removing and installing --> «Turbocharger, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__turbocharger-removing-and-installing)

2 - Turbocharger and vacuum diaphragm

1. Removing and installing --> «Vacuum diaphragm for turbocharger, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__vacuum-diaphragm-for-turbocharger-removing-and)
2. Adjusting --> «Vacuum diaphragm for turbocharger, adjusting»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__vacuum-diaphragm-for-turbocharger-adjusting)

3 - 10 Nm

4 - Securing plate

5 - 9 Nm

1. Secure with sealing wax
2. Sealing wax

6 - Knurled nut

Turbocharger, removing and installing

Special tools, testers and auxiliary items required

1. Spring-type clip pliers VAS 5024 A

Removing

1. Remove engine cover - arrows -.

1. Open cap of coolant expansion tank.
2. Drain engine coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt)

Scheme 661

1. Remove heat shield - arrows -.

Scheme 662

1. Remove crankcase ventilation line from turbocharger - 1 -.
2. Pull off crankcase ventilation line from the cylinder head cover - 2 - and remove it.
3. Disconnect EVAP line to turbocharger from cylinder head cover - 3 -.
4. Remove oil supply line from turbocharger - 4 -.

1. Remove catalytic converter --> «Catalytic converter, removing and installing»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__catalytic-converter-removing-and-installing)

Scheme 663

1. Remove coolant supply line to turbocharger - arrow -.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
2. Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.

1. Remove air duct hose - 1 - to turbocharger at bottom right.
2. Remove air duct hose to charge air cooler at lock carrier - 2

1. Disconnect connector - 1 and 2 - and free up cable.

1. Remove oil supply line for turbocharger at cylinder block - 1 -.
2. Remove bolt - 2 - of support for turbocharger.

1. Remove oil supply line for turbocharger - arrows -.

1. Disconnect oil return line - arrows - from turbocharger.

1. Loosen bolt - 1 - of support for turbocharger by 2 turns.

1. Disconnect coolant pipe - arrow -.

Scheme 664

1. Remove coolant pipe - 1 - , if present, from cylinder head.

Note. Nuts on bottom of fastening strip do not need to be opened

1. Remove upper nuts - arrows -.
2. Remove turbocharger/exhaust manifold upward.

Installing

Installation is in reverse order of removal, note the following

Note. Always replace seals, gaskets and self-locking nuts. Add oil to turbocharger through oil feed line connecting piece. Hose connections and charge air system hoses must be free of oil and grease before installing. Secure all hose connections using hose clamps appropriate for the model type .

1. Install exhaust system and align it free of tension --> «Exhaust system, installing tension free»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt__exhaust-system-installing-tension-free) .
2. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) .
3. Check oil level --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET

Note. After installing turbocharger, let engine idle for approx. 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

Torque specifications

Exhaust turbocharger vacuum diaphragm, checking

Special tools, testers and auxiliary items required

Scheme 665

1. Hand vacuum pump VAS 6213

Test conditions

1. Hose from exhaust turbocharger over Wastegate Bypass Regulator Valve N75 must have continuity to vacuum diaphragm.
2. Wastegate Bypass Regulator Valve N75 OK.

Work procedure

Scheme 666