3.0l 6-cyl 5v Engine Mechanical, Engine Code(s): Avk, Bgn Audi A4 B7

Engine identification

Note. Engine identification is visible first after preparations.

Scheme 1

1. Remove front engine cover (arrows).

Scheme 2

A sticker containing "engine code" and "production number" (arrow) is located on the housing for vacuum diaphragm for intake manifold adjustment.

If the sticker is not present and the "engine identification" is required, proceed as follows

Scheme 3

1. Remove rear engine cover (arrows).

Scheme 4

Engine codes are stamped on rear of cylinder block, left side (arrow).

Engine codes are also included on the vehicle data plate.

If the sticker is not present and the "engine identification" and "production number" is required, proceed as follows

Scheme 5

1. Remove bolts (arrows) and remove vacuum diaphragm for intake manifold adjustment.
2. Remove compression spring which is behind it and set off to side vacuum diaphragm with connected lines.

Scheme 6

The engine code -arrow- ("engine code" and "production number") are located at the front of the cylinder head, on top.

Engine specifications

1) Also Super-unleaded RON 95 is permissible, however with reduced performance.

Engine, removing and installing

Scheme 7

Special tools and equipment

1. 10-222A Engine support bridge
2. 2024A Engine Sling
3. 3147 Engine support adapter
4. 3299 Ribbed belt installation tool with 3299/1 claw for tensioner

1. VAG1306 Drip tray for VAG1202A
2. VAG1383A Engine/transmission hoist

Scheme 8

1. VAG1202A Workshop crane

or

1. VAS 6100 Workshop crane

Scheme 9

1. T10062 Support
2. Oil receptacle

Removing

Note. Engine is removed toward the front without transmission and with the lock carrier removed. All cable ties opened or cut during engine removal must be reinstalled at the same locations. Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine. Drained coolant must be stored in a clean container for disposal or reuse.

Vehicles with automatic transmission

1. Shift selector lever into position "N".

All

Scheme 10

1. Pull off rubber seal of plenum chamber cover in direction of arrow.
2. Remove cover -1- toward front.

See Caution before beginning repairs on the electrical system. Refer to Engine, removing and installing

Scheme 11

1. Disconnect battery Ground (GND) strap (arrow) with ignition switched off.

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

Scheme 12

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.

Scheme 13

1. Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.
2. Remove quick-release screws -3- and remove rear sound insulation, if present.

Scheme 14

1. Remove bracket for sound insulation (arrows).
2. Remove front bumper

Refer to

1. «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
2. «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Place VAG1306 drip tray beneath engine.

Vehicles with drain plug

Scheme 15

1. Turn radiator drain plug -2- counterclockwise, if needed attach accessory hose to connection flange and drain coolant.

Vehicles without drain plug

1. Remove retaining clamp for Engine Coolant Temperature (ECT) sensor (on radiator) -G83-.
2. Remove Engine Coolant Temperature (ECT) sensor from outlet and drain coolant.

All

1. Pull off retaining clip -1- for lower coolant hose and disconnect coolant hose from radiator.

Scheme 16

1. Disconnect left coolant hose from radiator (arrow).

Scheme 17

1. In addition, disconnect coolant hose at oil cooler (arrow) and drain remaining coolant.
2. Place oil pan underneath.

Scheme 18

1. Disconnect hydraulic lines to cooling coil at rear of bumper (arrows).

Vehicles with automatic transmission

Note. Observe the rules of cleanliness for working on automatic transmissions

Refer to

1. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
2. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

1. Place oil pan underneath.

Scheme 19

1. Remove union nuts -3- and disconnect ATF lines.
2. Remove bracket for ATF lines, to do so remove nuts -1- and -2-.

All

Scheme 20

1. Remove cover -1- in engine compartment (right side).

Scheme 21

1. Remove bolts (arrows).
2. Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
3. Remove air guide -2-.

Scheme 22

1. Remove cover -1- in engine compartment (left side).

Scheme 23

1. Disconnect top coolant hose -1- from radiator.
2. Remove electrical harness connector -2- for left and right airbag sensors on bumper.....
3. ....and move cables clear.

Scheme 24

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

Scheme 25

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

Scheme 26

1. Remove air guides from left and right of radiator (arrows).

Scheme 27

1. Unclip temperature sensor -2- for outside temperature display from bracket.
2. Unscrew bolts -3- and -4- and remove power steering cooling coil.
3. Disconnect harness connector -1- at High pressure sensor -G65-.

1. Remove condenser mounting bolts (arrows).

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

1. Carefully swing condenser downward and move aside.

Scheme 28

1. Remove bolts (arrows) on left and right sides of bumper.
2. Unhook hood cable from lock and move cable free.

Scheme 29

1. Unscrew bolts at impact absorbers (arrows) at left and right.

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

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

1. Remove rear engine cover (arrows).

Scheme 30

1. Remove bolts for holding plate -3- for solenoid valves (arrows).
2. Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
3. Remove hose -4- of crankshaft housing ventilation from air duct -2-.

Scheme 31

1. Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
2. Disconnect hose -1- from air guide if installed.

Note. Illustration depicts air guide with the removed engine from rear.

Scheme 32

1. Remove coolant hoses -1- and -2-.

Note. Coolant hose -3- remains connected.

1. Remove coolant reservoir (arrow)
2. Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.

Scheme 33

1. Disconnect ground (GND) -2-.
2. Disconnect vacuum hoses -1- and -3-.

Scheme 34

1. Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.

Vehicles with automatic transmission

Scheme 35

1. Disconnect electrical harness connector (arrow).

All

1. Place oil pan underneath.

Scheme 36

1. Disconnect hose -1- from power steering fluid reservoir.
2. Disconnect vacuum hose -2- to vacuum reservoir.

Scheme 37

1. Disconnect electrical harness connector (lower arrow) at Secondary Air Injection (AIR) pump motor -V101- and move cable free.
2. Disconnect hose at tube to combination valve for Secondary Air Injection (AIR) (upper arrow).

Vehicles up to 06.03

Scheme 38

1. Disconnect fuel supply line -1- and fuel return line -2- and set aside.

Vehicles as of 07.03

Scheme 39

1. Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and unscrew union nut -2-.

All

Scheme 40

1. Remove the following lines/harness connectors

1 - At Evaporative Emission (EVAP) canister purge regulator valve -N80

2 - Vacuum hose at Evaporative Emission (EVAP) canister purge regulator valve -N80

3 - at Mass Air Flow (MAF) sensor -G70

1. Disconnect hose connections, move wires free and remove air filter housing (arrows).

Note. Place a rag under the hydraulic pressure lines, to catch escaping hydraulic fluid.

Scheme 41

1. Unbolt hydraulic pressure line for power steering at rear coolant pipe -1- and disconnect line at height of right cylinder head -2-.

Scheme 42

1. Pry off both covers -3- using a screwdriver.
2. Loosen hex-nuts -4- by several turns.
3. Loosen wiper arm -2- by lightly tilting from wiper axle.
4. Remove hex nuts completely and remove wiper arms.

1. Disconnect securing clips -1- and remove cowl grill -5-.

Vehicles with automatic transmission

Scheme 43

1. Disconnect electrical harness connector (arrow) at Brake booster pressure sensor -G294-.

All

Scheme 44

1. Remove heater core E-box cover (arrows).

Scheme 45

1. Using a screwdriver, pry off retaining bracket (arrow).

Scheme 46

1. Disengage connector catches (arrows) and disconnect harness connectors -1- and -2- from Engine Control Module (ECM).

Vehicles with automatic transmission 01V

1. Unclip Transmission Control Module (TCM) retaining bracket.

Scheme 47

1. Disengage harness connector (arrow) and disconnect it from Transmission Control Module (TCM).

All

Scheme 48

1. Disconnect rear connectors -2- on connector strip and set wiring harness aside.
2. Unbolt electrical wire connection -1-.

Scheme 49

1. Disengage locking mechanisms (arrows) and remove secondary relay carrier in E-box toward top.
2. Unhook engine wiring harness at E-box and at bulkhead and move it free.
3. Remove heat shield for harness connectors at left of bulkhead, if installed.

Scheme 50

1. Remove harness connectors -1 to 4- from bracket at left of bulkhead.
2. Disconnect electrical harness connectors -1- and -4-.
3. Expose oxygen sensor wires.
4. Remove bracket for harness connectors.

Scheme 51

1. Remove harness connectors -1 to 4- from bracket at right of bulkhead.
2. Disconnect electrical harness connectors -1-, -3- and -4-.
3. Expose oxygen sensor wires.
4. Remove bracket for harness connectors.

Scheme 52

1. Remove nut -2- for left exhaust pipe/exhaust manifold which is accessible from top.

Note. Illustration is shown with engine removed.

Scheme 53

1. Remove nut -2- for right exhaust pipe/exhaust manifold which is accessible from top.

Note. Illustration is shown with engine removed.

1. Disconnect coolant hoses to heater core at rear coolant pipe and at right coolant pipe. To do so, remove wiring harness screw clip on right side of vehicle.
2. Remove upper mounting bolts for engine/transmission. One bolt remains tightened by hand.

1. Remove front engine cover (arrows).

Note. Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.

Scheme 54

1. Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using 3299 ribbed belt installation tool and 3299/1 claw for tensioner.
2. Remove ribbed belt from pulley of power steering pump.
3. Place engine oil drip tray beneath engine.
4. Drain engine oil.

Scheme 55

1. Remove oil filter -2-.
2. Place VAG1306 drip tray beneath engine.
3. Remove coolant hose -3- from oil cooler.
4. Remove oil cooler -1-.

Scheme 56

1. Unbolt bracket for refrigerant line at oil pan (arrow).

Note. Depicted in illustration for a vehicle with manual transmission.

Scheme 57

1. Disconnect harness connector -1- of electrical wire to A/C compressor clutch.

1. Unbolt A/C compressor from bracket (arrows).
2. Hang A/C compressor together with condenser with connected lines at right side of vehicle.
3. Disconnect electrical lines from generator.

Scheme 58

1. Unscrew bolts (arrows) and remove generator.

Scheme 59

1. Remove left and right heat shields for drive axles -1-.

Scheme 60

1. Remove electrical wires -1- and -2- from starter.
2. Disconnect Ground (GND) wire -3-.

Scheme 61

1. Remove heat shield -1- from solenoid.
2. Unscrew bolts -2- and -3- and remove starter.

Vehicles with automatic transmission 01V

Scheme 62

1. Unscrew 3 Torx bolts (arrow) of torque converter in opening of removed starter (turn crankshaft 1/3 rotation in each case).

Note. To loosen the torque converter bolts counterhold the main harmonic balancer bolt.

Scheme 63

1. Remove bolts for front vehicle floor crossmember -1- to -4-.

All

Note. Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.

Scheme 64

1. Disconnect exhaust system at double clamps (arrows).

1. Remove nuts -1- and -3- for front exhaust pipe/left exhaust manifold which are accessible from bottom.

Note. Illustration is shown with engine removed.

1. Pull front exhaust pipe off of left exhaust manifold.

1. Remove nuts -1- and -3- for front exhaust pipe/right exhaust manifold which are accessible from bottom.

Note. Illustration is shown with engine removed.

1. Pull front exhaust pipe off of right exhaust manifold.
2. Where installed, unbolt heat shield for engine speed (RPM) sensor.

Scheme 65

1. Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.

Vehicles with manual transmission

Scheme 66

1. Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire.

Note. Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.

Scheme 67

1. Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of transmission.

Note. Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.

Vehicles with automatic transmission 01J

Scheme 68

1. Disengage harness connector -A- in direction of arrow and disconnect it from transmission.
2. Move wiring harness clear.

Vehicles with automatic transmission 01V

Scheme 69

1. Swing securing lever and disconnect harness connector for transmission wiring harness -1-.
2. Disconnect harness connector -2- on Speedometer Vehicle Speed Sensor (VSS) -G22-.
3. Disconnect harness connector -3- from wire for multi-function switch.

All

Scheme 70

1. Mark installation positions for threaded assemblies -1- and positioning sleeves -2-.

Note. Different mounting holes are available depending upon the installed engine.

1. Remove lower nuts -1- on left and right engine mounts.

Scheme 71

1. Slightly loosen upper nuts (arrow) on left and right engine mounts.

Scheme 72

1. Unbolt torque support (arrows).

Scheme 73

1. Tighten T10062 support on threaded holes for torque support to 20 Nm.
2. Lift engine using VAG1383A engine/transmission jack just far enough so that lower connecting bolts at engine/transmission can be removed.

Note. When working on a vehicle with all wheel drive, make sure the front constant velocity joint of driveshaft is not damaged when lifting engine.

Scheme 74

1. Remove bottom engine/transmission connecting bolts (arrows).
2. Lower engine again.

Vehicles with manual transmission and automatic transmission 01J

Scheme 75

1. Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
2. Hook 3147 engine support adapter into bolt hole at left of transmission housing.
3. Connect 3147 engine support adapter and 10222A engine support bridge with 10222A/2 additional hook.

Note. Illustration is shown with engine removed. If the engine support adapter 3147 can not be inserted far enough into the hole on transmission bell housing due to a change in wire routing, use a long bolt M10 and additional hook 10-222 A/2 in place of engine support adapter.

Vehicles with automatic transmission 01V

Scheme 76

1. Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
2. Hook 3147 engine support adapter into middle bolt hole in transmission housing.
3. Connect engine support adapter 3147 using engine support bridge 10-222 A.

Note. Illustration is shown with engine removed.

All

Scheme 77

1. Hook in 2024A engine sling at engine and at VAS6100 or 1202A workshop crane as depicted in illustration.

Note. To properly balance assembly, mounting hooks must be inserted in rails as shown in illustration.

1. Remove final mounting bolt.

Note. Verify that all hoses and lines between engine and body have been disconnected.

1. Using VAS6100 or VAG1202A workshop crane, lift engine far enough until threaded bolts of engine mount are free.
2. Turn 10-222A engine support bridge shaft.

Note. Make sure no lines are damaged at bulkhead.

Vehicles with automatic transmission 01V

Scheme 78

1. Press transmission off engine, while pressing torque converter off of drive plate.

All

1. Pull engine off of transmission and lift it out of engine compartment toward front.

Vehicles with automatic transmission 01V

1. If necessary, secure torque converter in transmission from falling out using wire.

Installing

Installation is reverse of removal, note the following

Note. During installation, all cable ties must be re-installed at the same locations. Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine. Secure all hose connections using hose clamps appropriate for the model type Replace self-locking nuts and bolts during assembly work. Always replace bolts that are secured with tightening torque as well as O-rings and gaskets.

1. Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.
2. Slide intermediate plate or intermediate panel onto sleeves.

Vehicles with manual transmission

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. Check centering of clutch disc.
3. Check clutch release bearing for wear and replace if necessary.

Scheme 79

1. If plastic ring of release bearing is loose, adhere it to bearing ring again using adhesive AMV-195-KD1-01.

1. 3 rectangular tabs (arrows) of 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.

Vehicles with SAC clutch pressure plate

When installing a new clutch disc in combination with a used SAC pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips).

Refer to 30 CLUTCH

If the clutch disc is not replaced, the adjustment ring does not have to be turned back.

New SAC pressure plates are already pre-adjusted and must not be turned back.

Vehicles with automatic transmission 01V

Scheme 80

1. Drive plate is bolted to crankshaft with a centering bushing (arrow).
2. Use original bolts when securing torque converter to drive plate

Scheme 81

When torque converter is installed correctly, distance between lower contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 01V is approx. 23 mm.

If the torque converter is not inserted completely, this distance will be approx. 11 mm.

All

1. Carefully guide engine with transmission into chassis.
2. Set engine onto engine mounts.

1. Bolt transmission to engine, from. Refer to «Tightening torques»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__tightening-torques) .

1. Tighten T10062 support on threaded holes for torque support to 20 Nm.
2. Lift engine using VAG1383A engine/transmission jack just far enough so that lower connecting bolts at engine/transmission can be installed.

Note. When working on a vehicle with all wheel drive, make sure the front constant velocity joint of the driveshaft is not damaged when lifting the engine.

1. Tighten lower engine/transmission connecting bolts (arrows).
2. Lower engine again.
3. Install and align exhaust system free of tension. Refer to «Exhaust system, aligning free of stress (vehicles with front wheel drive)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__exhaust-system-aligning-free-of-stress) or «Exhaust system, aligning free of stress (vehicles with all wheel drive)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__exhaust-system-aligning-free-of-stress) .
4. Install starter.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

1. Install generator. Refer to «Ribbed belt for power steering pump, generator and A/C system»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
2. Install A/C compressor. Refer to «Ribbed belt for power steering pump, generator and A/C system»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
3. Install ribbed belt. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing) .
4. Install lock carrier. Refer to «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__lock-carrier-moving-into-service-position) .

Vehicles up to 06.03

1. Tighten union nut of fuel supply line -1- to 22 Nm.
2. Secure fuel return line -2- with a hose clamp.

Vehicles as of 07.03

1. Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and tighten union nut -2- to 22 Nm.

Vehicles with automatic transmission

1. Secure ATF lines

Refer to

1. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
2. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

All

1. Check harness connectors and routing

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

See Caution for connecting Telematics battery. Refer to Engine, removing and installing

1. Observe safety precautions after connecting battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

1. Check engine oil level before starting engine.
2. Top off coolant. Refer to «Filling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__filling) .

Note. Only reuse drained coolant if cylinder head or engine block were not replaced. Dirty coolant cannot be reused.

1. Fill up power steering fluid and bleed steering system

Refer to 48 - STEERING

Vehicles with automatic transmission

1. Check ATF level

Refer to

1. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
2. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

All

1. Adjust headlights

Refer to 94 LIGHTS, SWITCHES - EXTERIOR .

Tightening torques

Note. Tightening torques are valid only for nuts and bolts that are lightly greased, oiled, covered with a thin coat of phosphate or blackened. Other lubricants are permitted, e.g. engine oil or transmission fluid, however they may not contain graphite. Do not use any degreased parts. Tightening torque tolerance ± 15%.

Scheme 82

Securing engine/transmission for manual transmission

A: Alignment bushing

Securing engine/transmission with automatic transmission 01J

A: Alignment bushing

Securing engine/transmission with automatic transmission 01V

A: Alignment bushing

Engine, attaching to engine stand

Special tools and equipment

1. VAS 6095 Engine and transmission holding fixture

Procedure

Scheme 83

1. Secure engine to VAS6095 engine and transmission support as depicted in illustration.

Scheme 84

1 - 50 Nm

2 - 3369 support tool

1. Tighten to 10 Nm

3 - 10 Nm

4 - 10 Nm

5 - 10 Nm

6 - 10 Nm

7 - 3369 support tool

1. Tighten to 10 Nm

8 - 50 Nm

Lock carrier, moving into service position

Special tools and equipment

Scheme 85

1. 3369 Support tool

Removing

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.

1. Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.

1. Remove cover -1- in engine compartment (right side).

1. Remove bolts (arrows).
2. Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
3. Remove air guide -2-.

1. Remove cover -1- in engine compartment (left side).
2. Pull off hood seal from lock carrier and fender edges.
3. Remove front bumper

Refer to

1. «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
2. «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Remove bolts (arrows) on left and right sides of bumper.

Scheme 86

1. Thread 3369 support tool into empty holes at left and right.
2. Unscrew bolts at impact absorbers (arrows) at left and right.
3. Carefully pull lock carrier toward front.

Installing

Installation is reverse of removal, noting the following

1. Tighten bolts for lock carrier to longmembers to 50 Nm and at fenders to 10 Nm.

Scheme 87

1. Place impact for torque support on rubber buffer for torque support, letting it rest under its own weight and tighten bolts (arrows) to 28 Nm.
2. Install front bumper

Refer to

1. «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
2. «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Adjust headlights

Refer to 94 LIGHTS, SWITCHES - EXTERIOR .

Tightening torques

Scheme 88

Note. Before removing ribbed belt, note direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.

1 - Ribbed belt

1. Removing and installing. Refer to «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__ribbed-belt-removing-and-installing)
2. Check for wear

2 - 23 Nm

3 - Generator

1. Removing

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

4 - 45 Nm

5 - 23 Nm

6 - Bracket

1. For generator

7 - 40 Nm

8 - Ribbed belt tensioner

1. Removing and installing. Refer to «Ribbed belt tensioner, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

9 - 23 Nm

10 - Belt pulley

1. For power steering pump
2. Use 3212 spanner wrench to counterhold when removing and installing
3. Identification: Front

11 - Seal

1. Always replace

12 - Banjo fitting, 47 Nm

13 - Pressurized line

1. To power steering

14 - Power steering pump

1. Removing and installing

Refer to 48 - STEERING

15 - Bracket

1. For power steering pump

16 - 23 Nm

17 - 23 Nm

18 - Bracket

1. For A/C compressor

19 - 23 Nm

20 - 23 Nm

21 - 25 Nm

22 - A/C compressor

1. Do not unscrew or disconnect refrigerant lines
2. After removing, secure compressor to chassis (i.e. with wire) Do not hang on refrigerant lines

23 - Socket

1. For A/C compressor
2. 2x

24 - Harmonic balancer

1. Version dependent with/without thrust washer between harmonic balancer and toothed belt gear. Refer to «Vibration damper, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__vibration-damper-removing-and-installing)
2. Removing and installing. Refer to «Vibration damper, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__vibration-damper-removing-and-installing)

25 - 23 Nm

26 - 23 Nm

Ribbed belt, removing and installing

Special tools and equipment

Scheme 89

1. 3299 Ribbed belt installation tool with 3299/1 claw for tensioner

Removing

1. Remove cover -1- in engine compartment (left side).

1. Remove cover -1- in engine compartment (right side).

1. Remove bolts (arrows).
2. Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
3. Remove air guide -2-.

1. Remove front engine cover (arrows).

Note. Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.

1. Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using 3299 ribbed belt installation tool and 3299/1 claw for tensioner.
2. Remove ribbed belt from pulley of power steering pump.

Installing

Installation is reverse of removal, noting the following

1. First install ribbed belt on crankshaft pulley. Slide belt onto tensioning roller last.

Scheme 90

1 - Generator

2 - Ribbed belt

3 - Power steering pump

4 - A/C compressor

5 - Crankshaft

6 - Tensioner roller

Note. When installing ribbed belt, ensure correct seating on belt pulley.

1. Start engine and check path of belt.

Scheme 91

Special Tools and Equipment

1. 3299 ribbed belt installation tool with 3299/1 claw for tensioner
2. 3212 spanner wrench
3. T10115 pin

1. Lock carrier in service position. Refer to «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__lock-carrier-moving-into-service-position) .
2. Ribbed belt removed. Refer to «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__ribbed-belt-removing-and-installing) .

Scheme 92

1. Remove ribbed belt gear of vane pump (arrows) using 3212 spanner wrench as retainer.
2. Swing ribbed belt tensioner in direction of arrow using 3299 ribbed belt installation tool and 3299/1 claw for tensioner to secure, secure using T10115 pin and release installation tool.
3. Unscrew bolts -1- and -2- and remove the secured ribbed belt tensioner.

Installation is performed in the reverse order of removal.

Tightening torques

Vibration damper, removing and installing

1. Lock carrier in service position. Refer to «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__lock-carrier-moving-into-service-position) .
2. Ribbed belt removed. Refer to «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__ribbed-belt-removing-and-installing) .

Removing

Scheme 93

1. Remove 8 bolts -1-.
2. Remove harmonic balancer -2- and thrust washer -3-.

Note. Thrust washer -3- is only installed on toothed belt gear with part number 06C 105 063 A. No thrust washer must be installed for toothed belt gear with part number 06C 105 063 B.

Installing

Installation is reverse of removal, noting the following

1. Insert thrust washer in such a way that convex edge points toward harmonic balancer.

Note. When installing the harmonic balancer, make sure notches (arrows) in harmonic balancer are aligned with locating lugs on toothed belt sprocket.

Tightening torque

Scheme 94

1 - 10 Nm

2 - 10 Nm

3 - Front coolant pipe

1. Only remove bolts item -1- and item -2- to remove toothed belt guide
2. Coolant hoses remain connected at coolant pipe

4 - Toothed belt guard, front right

5 - Toothed belt guard, front left

6 - Socket

7 - 6 Nm

1. Self-locking
2. Always replace

8 - Lower toothed belt cover

9 - 10 Nm

Scheme 95

Note. Before removing toothed belt, note direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.

1 - 45 Nm

1. Self-locking
2. Always replace

2 - Washer

3 - 45 Nm

4 - Tensioner roller

5 - Tensioning lever

1. Insert shim item - 6

6 - Washer

1. For tensioner lever

7 - Toothed belt

1. Before removing, note direction of rotation using chalk or felt-tip marker
2. Check for wear
3. Removing. Refer to «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)
4. Installing (adjusting timing). Refer to «Installing (adjusting valve timing)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing-adjusting-valve-timing)

8 - 45 Nm

9 - Exhaust camshaft, toothed belt gear

1. For cylinder bank 1 (right) with vibration damper
2. With camshaft adjuster
3. Identification "Exhaust"

10 - Intake camshaft, toothed belt gear

1. For cylinder bank 1 (right)
2. With camshaft adjuster
3. Identification "Intake"

11 - 10 Nm

1. Self-locking
2. Always replace

12 - Bracket

1. For idler roller

13 - 10 Nm

1. Self-locking
2. Always replace

14 - Toothed belt guard, rear right

15 - Idler roller

16 - 10 Nm

17 - 10 Nm

18 - Mechanical coolant pump

1. Removing and installing. Refer to «Coolant pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__coolant-pump-removing-and-installing)

19 - Gasket

1. Always replace

20 - Intake camshaft, toothed belt gear

1. For cylinder bank 2 (left)
2. With camshaft adjuster
3. Identification "Intake"

21 - Toothed belt guard, rear left

22 - 10 Nm

1. Self-locking
2. Always replace

23 - Exhaust camshaft, toothed belt gear

1. For cylinder bank 2 (left) with vibration damper
2. With camshaft adjuster
3. Identification "Exhaust"

24 - 100 Nm

1. Use T40030 camshaft adjuster gauge when loosening or tightening

25 - O-ring

1. Always replace

26 - Cap

27 - Snap ring

28 - Diamond disc

1. For toothed belt gear
2. Replace after removing toothed belt

29 - Eccentric pulley

30 - 45 Nm

31 - Toothed belt gear for crankshaft

1. Replace diamond disc item - 28 after removal
2. Contact surface between toothed belt gear, diamond disc and crankshaft must be free of oil.
3. Installation only possible in one position
4. Version dependent with/without thrust washer. Observe note. Refer to «Vibration damper, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__vibration-damper-removing-and-installing)

32 - Central bolt, 200 Nm plus an addition 180° (1/2 turn)

1. Always replace
2. Do not oil additionally
3. Use T40026 locking pin when loosening or tightening
4. Thread in T40026 locking pin. Refer to «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

33 - Toothed belt tensioner

34 - 10 Nm

Scheme 96

Special tools and equipment

1. 3212 Spanner wrench
2. 3387 Pin wrench
3. T40011 Pin
4. T40026 Locking pin

1. T40028 Socket
2. T40030 Camshaft adjuster gauge

1. Lock carrier in service position. Refer to «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__lock-carrier-moving-into-service-position) .
2. Ribbed belt removed. Refer to «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__ribbed-belt-removing-and-installing) .
3. Ribbed belt tensioner removed. Refer to «Ribbed belt tensioner, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

1. Remove ribbed belt gear of power steering pump (arrows) using 3212 spanner wrench as retainer.

1. Remove 8 bolts -1-.
2. Remove harmonic balancer -2- and thrust washer -3-.

Note. Thrust washer -3- is only installed on toothed belt gear with part number 06C 105 063 A. No thrust washer must be installed for toothed belt gear with part number 06C 105 063 B.

Scheme 97

1. Unscrew bolts -1 to 12- and remove toothed belt guards.

1. Remove rear engine cover (arrows).

1. Remove coolant reservoir (arrow)
2. Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.
3. Tie coolant expansion tank with connected coolant hoses -1 to 3- to side.

Scheme 98

1. Remove air filter housing (arrows).
2. Disconnect electrical harness connector -1- at Mass Air Flow (MAF) sensor.
3. Remove air guide hose -2- together with Mass Air Flow (MAF) sensor.

Scheme 99

1. Remove bolts -1- and -3-.
2. Disconnect hose -4- from line of secondary air injection.
3. Pull out guide tube for oil dipstick 2 from the oil pan (upper part) toward top and swing it forward for removal.

Scheme 100

1. Remove bolts -5- and -6- at right cylinder head cover.
2. Disconnect electrical harness connectors -1- to -4-.
3. Remove ignition coils (arrows).

Scheme 101

1. Remove hose of crankshaft housing ventilation (arrow).
2. Unscrew bolts for right cylinder head cover in sequence -12- to -1-.
3. Remove cylinder head cover.

Scheme 102

1. Remove bolts -4- and -5- at left cylinder head cover.
2. Disconnect electrical harness connectors -1- to -3- and -6-.
3. Remove ignition coils (arrows).

Scheme 103

1. Remove hose of crankshaft housing ventilation (arrow).
2. Unscrew bolts for left cylinder head cover in sequence -12- to -1-.
3. Remove cylinder head cover.

Scheme 104

1. Turn engine until cams (arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder bank) point upward uniformly.

Note. Turn engine at crankshaft central bolt.

Scheme 105

1. Insert T40030 camshaft adjuster gauge at camshafts of right cylinder head.

Note. Slightly turn crankshaft back and forth so that the claw of T40030 camshaft adjuster gauge can properly grab the camshafts.

1. Spread T40030 camshaft adjuster gauge with threaded shaft (tightening torque 10 Nm) until it is seated without axial play.

Scheme 106

1. Insert T40030 camshaft adjuster gauge at left cylinder head in same manner.
2. If installed, disconnect electrical harness connector at after-run coolant pump.
3. Unscrew sealing plug of TDC mark at cylinder block.

Scheme 107

1. Thread T40026 locking pin into hole of removed sealing plug and tighten.

Note. Slightly turn crankshaft back and forth to do so.

Note. Catch escaping oil using a rag.

Scheme 108

1. Pry off securing rings -1- for caps -2- at all camshaft gears.

Scheme 109

1. Loosen but do not remove bolts -1- to -4- for camshaft gears.

Note. The bolts remain loosely threaded in.

Scheme 110

1. Using an 8 mm hex socket wrench, turn toothed belt tensioner in direction of arrow until tensioning lever pushes tensioner together far enough so that T40011 pin can be inserted into bore of pistons and housing.

Note. The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure. Mark rotational direction of toothed belt. Reversing the direction in which it runs can ruin it.

Scheme 111

1. Loosen bolt (arrow) of eccentric pulley.
2. Remove toothed belt.

Installing (adjusting valve timing)

1. Camshafts aligned using T40030 camshaft adjuster gauge
2. Crankshaft aligned using T40026 locking pin
3. Camshaft gears loosened.

Note. Replace gaskets, O-rings and self-locking bolts. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged.

1. Bolt in camshaft gears -1- to -4- far enough so they can still just be turned without canting.
2. Install toothed belt as depicted in illustration.

1. For exact valve timing adjustment, toothed belt must make exact contact with front edge of all toothed belt gears.

Scheme 112

1. Using 3387 pin wrench, turn eccentric pulley -1- in clockwise direction until handle of pin wrench is exactly above center axle of coolant pump gear -2-.
2. Hold pin wrench in this position and tighten bolt -3- to 45 Nm.

Scheme 113

1. Place torque wrench horizontally on socket-head of tensioning lever.
2. Turn with 45 Nm in direction of arrow to pre-tension toothed belt.

1. Using 8 mm socket head wrench, turn toothed belt tensioning roller in direction of arrow until T40011 pin can pulled out.

Scheme 114

1. Place torque wrench horizontally on socket-head of tensioning lever.
2. Turn with 25 Nm in direction of arrow to tension toothed belt.

Scheme 115

1. Insert T40028 socket at camshaft adjuster of exhaust camshaft on left cylinder bank.
2. Turn rotor of camshaft adjuster clockwise to 10 Nm up to stop (arrow).

Scheme 116

1. Turn rotor of camshaft adjuster at right cylinder bank clockwise to 10 Nm up to stop (arrow).
2. Tighten bolts for all four camshaft gears to 100 Nm.

1. Insert caps -2- with new O-rings -1- at camshaft gears and secure them with securing ring.
2. Remove T40030 camshaft adjuster gauge.
3. Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O-ring into cylinder block.

Installation is reverse of removal, noting the following

1. Install cylinder head covers. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for Left cylinder head cover or «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for Right cylinder head cover.
2. Install toothed belt guards. Refer to «Toothed belt cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
3. Install harmonic balancer. Refer to «Vibration damper, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__vibration-damper-removing-and-installing) .
4. Install ribbed belt. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing) .

Sealing flanges and flywheel/drive plate, removing and installing

Note. Servicing clutch.

Refer to

1. «30 CLUTCH»(ref-278899-S19483555462008020700000) for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
2. «30 CLUTCH»(ref-278900-S04360899032008020700000) for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
3. «30 CLUTCH»(ref-278901-S17002765632008020700000) for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
4. «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
5. «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
6. «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE

Scheme 117

1 - 10 Nm

2 - 30 Nm

1. Self-locking
2. Always replace

3 - Seal

1. For crankshaft
2. Removing and installing. Refer to «Seal for crankshaft (ribbed belt side), replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

4 - Locking bolt - 10 Nm

5 - Seal

1. Always replace

6 - O-ring

1. Always replace

7 - Chain tensioner

1. Removing and installing. Refer to «Drive chain or chain tensioner for oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__drive-chain-or-chain-tensioner-for)

8 - Washer

9 - 12 Nm

10 - 40 Nm

11 - Stop

1. For torque support

12 - 28 Nm

13 - Torque support

14 - Oil pan (upper part)

1. Removing and installing. Refer to «Oil pan (upper part), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

15 - 45 Nm

16 - M7 = 16 Nm, M8 = 22 Nm

17 - O-ring

1. Always replace

18 - Dual-mass flywheel or drive plate

1. Flywheel, removing and installing. Refer to «Flywheel and drive plate, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__flywheel-and-drive-plate-removing-and)
2. Drive plate, removing and installing. Refer to «Drive plate for automatic transmission 01V»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

19 - Special bolt

1. Always replace
2. Tightening torque. Refer to «Tightening torques»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for Dual-mass flywheel or flywheel for automatic transmission 01J or «Tightening torques»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for Drive plate for automatic transmission 01V

20 - Needle bearing

1. Removing and installing. Refer to «Dual-mass flywheel pilot needle bearing, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__dual-mass-flywheel-pilot-needle-bearing-removing)
2. Not for automatic transmission 01V
3. For automatic transmission 01V, a centering bushing is bolted into crankshaft instead of needle bearing. See «Centering bushing of drive plate for automatic transmission 01V»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__centering-bushing-of-drive-plate-for)

21 - 10 Nm

22 - Sealing flange rear with oil seal

1. Removing and installing. Refer to «Rear sealing flange, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__rear-sealing-flange-removing-and-installing)
2. Lightly oil lip of O-ring.
3. To install, slide guide sleeve from kit onto crankshaft

23 - Cylinder block

1. Crankshaft, removing and installing. Refer to «Crankshaft, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)
2. Pistons and connecting rods, disassembling and assembling. Refer to «Pistons and connecting rods, disassembling and assembling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

24 - 20 Nm

25 - Guide tube for oil dipstick

26 - Sheet metal screw

27 - Gasket

1. Always replace

28 - Sealing flange, front

1. Removing and installing. Refer to «Front sealing flange, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__front-sealing-flange-removing-and-installing)

Centering bushing of drive plate for automatic transmission 01V

For vehicles with an automatic transmission, the drive plate is bolted to the crankshaft with a centering bushing (arrow).

Scheme 118

Special tools and equipment

1. 3202/1 Pull sleeve
2. 3203 Seal remover
3. 3265 Seal installer

Removing

1. Engine installed.

1. Remove toothed belt. Refer to «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

Scheme 119

1. Remove center bolt -1- for crankshaft toothed belt gear -2-.
2. Remove toothed belt gear.
3. Remove diamond disc -3- from toothed belt gear.
4. Unscrew inner portion of 3203 seal remover six rotations from outer portion and secure with knurled-head screw.

Scheme 120

1. Oil threaded head of 2085 seal puller, position and with forced pressure screw into oil seal as far as possible.
2. Loosen knurled bolt and turn inner part against crankshaft until oil seal is removed.
3. Clamp seal puller into vise at flattened regions. Remove O-ring with pliers.

Installing

1. Clean contact surface and sealing surface.

Note. Do not oil sealing lip or outer edge of sealing ring before pressing in.

1. Slide on sealing ring using 3202/1 pull sleeve.

Scheme 121

1. Press in sealing ring using 3265 seal installer and central bolt up to stop.

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

Note. Contact surfaces between toothed belt gear, diamond disc and crankshaft must be free of oil. Do not additionally oil bolt for toothed belt gear for crankshaft.

1. Install toothed belt (adjust timing). Refer to «Installing (adjusting valve timing)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing-adjusting-valve-timing) .

Tightening torque

1) Always replace bolt

2) 180°= one half-turn

Front sealing flange, removing and installing

Special tools and equipment

Scheme 122

1. 3202/1 Pull sleeve

Scheme 123

1. 3265 Seal installer

1. Lock carrier in service position. Refer to «Lock carrier, moving into service position»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__lock-carrier-moving-into-service-position) .

1. Remove toothed belt. Refer to «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
2. Remove camshaft gears from right cylinder head.

Scheme 124

1. Unscrew bolts -1- and remove bracket with idler roller.
2. Unscrew bolts -2- and remove toothed belt guard at right rear.
3. Remove oil pan (upper part). Refer to «Oil pan (upper part), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

Scheme 125

1. Remove center bolt -1- for crankshaft toothed belt gear -2-.
2. Remove toothed belt gear and diamond disc -3-.

Scheme 126

1. Unbolt eccentric roller -3-, tensioning lever -2- with tensioning roller and tensioner -1-.

Scheme 127

1. Unscrew locking bolt from adjustment hole -3-.
2. Press chain tensioner -1- in direction of arrow until a 3 mm drill bit -2- can be slid into alignment hole of sealing flange and chain tensioner.

Scheme 128

1. Remove bolts -1- and -2-.
2. Remove front sealing flange.
3. Drive out sealing ring with the flange removed.

Note. Remove chain tensioner to replace sealing flange. Refer to Drive chain or chain tensioner for oil pump, removing and installing .

Installation is reverse of removal, noting the following

Note. Always replace seals, sealing rings and self-locking bolts.

1. Clean sealing surfaces before installing sealing flange.
2. Install front sealing flange with secured chain tensioner.

1. Replace bolt -2-.
2. Tighten bolts -1- to 10 Nm and bolt -2- to 30 Nm.
3. Do not oil sealing lip or outer edge of sealing ring before pressing in.
4. Slide on sealing ring using 3202/1 pull sleeve.

1. Press in sealing ring using 3265 seal installer and central bolt up to stop.

1. Install eccentric roller 3 loosely.

Note. Note washer below tensioning lever -2-.

1. Install tensioning lever -2- using tensioner roller and tensioner -1-.

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

Note. Contact surfaces between toothed belt gear, diamond disc and crankshaft must be free of oil. Do not additionally oil bolt for toothed belt gear for crankshaft.

1. Remove oil pan (upper part). Refer to «Removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
2. After installing oil pump, remove drill bit from adjusting hole and thread in locking bolt with new sealing ring.
3. Install toothed belt (adjust timing). Refer to «Installing (adjusting valve timing)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing-adjusting-valve-timing) .

1) Replace bolts.

2) 180°= one half-turn

Rear sealing flange, removing and installing

Required equipment

1. Drill with plastic brush attachment
2. Protective glasses
3. Silicone sealant

Removing

1. Engine removed

1. Remove flywheel. Refer to «Removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for Dual-mass flywheel or flywheel for automatic transmission 01J or remove drive plate. Refer to «Removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for Drive plate for automatic transmission 01V.
2. Remove oil pan (upper part). Refer to «Oil pan (upper part), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

Scheme 129

1. Unbolt rear sealing flange (arrow).

Scheme 130

1. Using rotating plastic brush, remove remaining sealant from rear sealing flange and at cylinder block.

1. Clean sealing surfaces so they are completely free of any oil or grease.

Installing

Installation is reverse of removal, noting the following

Note. The rear sealing flange must be installed within 5 minutes after application of silicon sealant.

Scheme 131

1. Cut tube nozzle at front marking (jet diameter approx. 1 mm).

Scheme 132

1. Apply silicone sealant bead to clean sealing surfaces of sealing flange as shown in illustration.

1. Thickness of sealant bead (arrows): approx. 1.5 mm

Note. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.

1. To install, slide guide sleeve from kit onto crankshaft.
2. Remove oil pan (upper part). Refer to «Removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
3. Install flywheel. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for Dual-mass flywheel or flywheel for automatic transmission 01J or install drive plate. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for Drive plate for automatic transmission 01V.

Tightening torque

Damper unit, removing and installing

Automatic transmission (CVT) 01J

With reciprocating engines, torsional vibrations are produced at the crankshaft due to irregularity of the combustion process.

The torsional vibrations are transmitted to the transmission where they cause resonant vibrations. This results in noise and excessive stress on the components.

In 6-cylinder engines the engine torque is transmitted to the transmission via a flywheel damper unit in order to prevent the torsional vibrations from entering the transmission.

Scheme 133

1. Unscrew bolts -1- and remove damper unit -A- from flywheel -B-.

Note. For removal and installation of the flywheel -B-. Refer to Flywheel and drive plate, removing and installing .

Install in reverse order, paying attention to following

Note. The part number of the damper unit is assigned to the transmission code letter.

1. Align damper unit -A- with flywheel -B-.

1. Two lugs -2- must line up with each other

1. Hand-tighten bolts -1- (9 pcs.).
2. Tighten bolts to 25 Nm in diagonal sequence.

Flywheel and drive plate, removing and installing

Special tools and equipment

Scheme 134

1. T40026 Locking pin

1. Transmission removed

1. Turn crankshaft via center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 3 marking.

Scheme 135

1. Notch -1- lines up with marking -2

1. If installed, disconnect electrical harness connector at after-run coolant pump.
2. Unscrew sealing plug of TDC mark at cylinder block.

1. Thread T40026 locking pin into hole of removed sealing plug and tighten.

Note. Slightly turn crankshaft back and forth to do so.

1. Remove clutch pressure plate.

Refer to

1. «30 CLUTCH»(ref-278899-S19483555462008020700000) for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
2. «30 CLUTCH»(ref-278900-S04360899032008020700000) for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
3. «30 CLUTCH»(ref-278901-S17002765632008020700000) for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
4. «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
5. «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
6. «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE

1. Remove damper unit: Refer to «Damper unit, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__damper-unit-removing-and-installing) .
2. Mark flywheel to engine.
3. Unbolt flywheel.

Installation is reverse of removal, noting the following

Note. Needle bearing is located in the flywheel and must be driven in when flywheel is replaced. Refer to Dual-mass flywheel pilot needle bearing, removing and installing

1. Replace bolts and tighten.
2. Install clutch pressure plate.

Refer to

1. «30 CLUTCH»(ref-278899-S19483555462008020700000) for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
2. «30 CLUTCH»(ref-278900-S04360899032008020700000) for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
3. «30 CLUTCH»(ref-278901-S17002765632008020700000) for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
4. «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
5. «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
6. «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE

1. Install damper unit: Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
2. Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O-ring into cylinder block.

1) 90° corresponds to one quarter-turn

2) Replace bolts.

3) 180° = one half-turn

1. Transmission removed

1. Turn crankshaft via center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 3 marking.

1. Notch -1- lines up with marking -2

1. If installed, disconnect electrical harness connector at after-run coolant pump.
2. Unscrew sealing plug of TDC mark at cylinder block.

1. Thread T40026 locking pin into hole of removed sealing plug and tighten.

Note. Slightly turn crankshaft back and forth to do so.

1. Mark drive plate to engine.
2. Remove drive plate.

Installation is reverse of removal, noting the following

1. Bolt drive plate to crankshaft with a centering bushing (arrow).
2. Replace bolts and tighten.
3. Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O-ring into cylinder block.

1) 90° = one quarter-turn

2) Replace bolts.

3) 180° = one half-turn

Dual-mass flywheel pilot needle bearing, removing and installing

Special tools and equipment

Scheme 136

1. 3264 Bearing driver

Scheme 137

1. Special tool Kukko 21/1 (Item -1-) and Kukko 22/1 (Item -4-)

Procedure

1. Transmission removed

1. Remove clutch pressure plate.

Refer to

1. «30 CLUTCH»(ref-278899-S19483555462008020700000) for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
2. «30 CLUTCH»(ref-278900-S04360899032008020700000) for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
3. «30 CLUTCH»(ref-278901-S17002765632008020700000) for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
4. «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
5. «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
6. «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE

Scheme 138

1. Pull out needle bearing using Kukko 21/1 and Kukko 22/1.

Scheme 139

1. Drive needle bearing into flywheel using 3264 bearing driver.

1. Installation depth. Refer to «Needle bearing installation depth»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

Scheme 140

1. To measure installation depth, place a metal ruler onto plastic ring -1- of dual-mass flywheel.

1. Measurement -x- = 0.5 mm.

Note. Plastic ring is sensitive to hits. If the plastic ring is damaged, dual-mass flywheel must be replaced.

Crankshaft, removing and installing

Note. For engine disassembly and assembly, mount engine to assembly stand using VAS6095 holding fixture. Refer to Engine, attaching to engine stand .

Scheme 141

1 - Bolt

1. For bearing cap
2. Always replace
3. Tightening sequence. (Scheme 147)

2 - Bushing

1. Insert in cylinder block

3 - Drive chain gear for oil pump

1. Removing and installing. Refer to «Drive chain gear for oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__drive-chain-gear-for-oil-pump)

4 - Bearing caps

1. Observe number markings. (Scheme 143)
2. Removing. (Scheme 144)
3. Installing. (Scheme 147)

5 - Nut

1. For bearing cap
2. Always replace
3. Tightening sequence. (Scheme 147)

6 - Thrust washer

1. Only on 4th crankshaft bearing
2. Lubricating grooves face outward
3. Check locating point
4. Measuring crankshaft axial clearance. Refer to «Axial and radial play, measuring»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__axial-and-radial-play-measuring)

7 - Bearing shell

1. For bearing cap without lubrication groove
2. Do not interchange run-in connecting rod bearing shells (mark)
3. Insert new bearing shells for cylinder block with proper color marking. (Scheme 146)

8 - Crankshaft

1. Measuring axial and radial clearance. Refer to «Axial and radial play, measuring»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__axial-and-radial-play-measuring)
2. Do not turn crankshaft when measuring radial play.
3. Crankshaft dimensions. Refer to «Crankshaft measurements»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__crankshaft-measurements)

9 - Thrust washer

1. Only on 4th crankshaft bearing
2. Lubricating grooves face outward
3. Measuring crankshaft axial clearance. Refer to «Axial and radial play, measuring»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__axial-and-radial-play-measuring)

10 - Bearing shell

1. For engine block with lubrication groove
2. Do not interchange run-in connecting rod bearing shells (mark)
3. Insert new bearing shells for cylinder block with proper color marking. (Scheme 145)

11 - Stud

12 - Bolt

1. For bearing cap
2. Always replace
3. Tightening sequence. (Scheme 147)

Scheme 142

1. Bearing 1 is located on the belt pulley side

Scheme 143

1. Unscrew bolts or nuts for crankshaft bearing caps.
2. Remove crankshaft bearing caps from cylinder block using T10055 extractor.

Scheme 144

Bearing shells with the correct thickness are allocated to the cylinder block in the factory. Colored dots on the bearing shells serve for identifying bearing shell thickness.

Note. The arrow points to the belt pulley side.

Application of bearing shells to cylinder block is marked by a letter beside the respective bearing.

Scheme 145

Bearing shells with the correct thickness are allocated to the bearing caps in the factory. Colored dots on the bearing shells serve for identifying bearing shell thickness.

Application of bearing shells to crankshaft is marked with a letter sequence at the crankshaft flank. The first digit, "1" (arrow) identifies the color coding for bearing 1.

Scheme 146

1. Replace bolts -A- and nuts -1- to -8-.
2. Inserting alignment bushings into cylinder block
3. Tighten bearing cap nuts or bolts in following sequence

1. - Screw in bolts -A- hand tight.

2. - Tighten nuts -1- to -8- to 35 Nm.

3. - Tighten nuts -1- to -8- 90° (1/4 turn) further using rigid wrench.

4. - Tighten bolts -A- to 20 Nm.

5. - Tighten bolts -A- 90° (1/4 turn) further using rigid wrench.

Crankshaft measurements

(Distance in mm)

Axial and radial play, measuring

Special tools and equipment

Scheme 147

1. VW387 Dial gauge holder
2. Dial gauge

Axial clearance

Scheme 148

1. Attach dial indicator together with VW387 dial gauge holder to cylinder block and set indicator against crankshaft counterweight.
2. Press crankshaft against dial indicator by hand, set indicator to 0.
3. Press crankshaft away from dial indicator.
4. Read clearance.

Radial clearance

Note. Never interchange used bearing shells. Bearing shells that are worn through the nickel coating must be replaced

Required equipment

1. Plastigage

1. Remove main bearing caps. Clean bearing caps and journals.
2. Place Plastigage over entire width of bearing journal or into bearing shells.

1. Plastigage must rest in center of bearing shell

1. Install main bearing caps and tighten to 30 Nm. DO NOT turn crankshaft.
2. Remove main bearing caps again.
3. Compare width of Plastigage with calibrated scale.
4. Read clearance.

Drive chain gear for oil pump, removing and installing

Special tools and equipment

Scheme 149

1. 30-100 Press tube

Removing

1. Remove front sealing flange. Refer to «Front sealing flange, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__front-sealing-flange-removing-and-installing) .

Scheme 150

1. Using claw remover -2-, remove crankshaft chain sprocket while protecting crankshaft end with appropriate washer -1-.

Installing

Installation is reverse of removal, noting the following

1. Warm chain sprocket in oven at 220°C for approx. 15 minutes.

Scheme 151

1. Using pliers install chain sprocket on crankshaft end and slide onto crankshaft to stop using 30-100 press tube.

Pistons and connecting rods, disassembling and assembling

Note. Oil injector jet for piston cooling. (Scheme 161)

Scheme 152

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

1. Always replace
2. Grease thread and contact surface
3. Tighten to 30 Nm when measuring radial clearance, but do not turn further

2 - Connecting rod bearing cap

1. Do not interchange
2. Mark allocation to cylinder using a color marker -B-. (Scheme 159)
3. Observe when installing bearing cap: Tabs at contact surfaces at face of connecting rod must be aligned -A
4. Installed position of connecting rod pairs. (Scheme 160)

3 - Bearing shell

1. Note installed position
2. Do not interchange run-in connecting rod bearing shells (mark)
3. Measuring radial play. Refer to «Connecting rod radial play, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__connecting-rod-radial-play-checking)
4. Tighten bolts item - 1 to 30 Nm when measuring radial clearance, but do not turn further

4 - Connecting rod

1. Replace only as a set
2. Mark allocation to cylinder using a color marker -B-. (Scheme 161)
3. Observe when installing bearing cap: Tabs at contact surfaces at face of connecting rod must be aligned -A
4. Installed position of connecting rod pairs. (Scheme 160)

5 - Snap ring

6 - Piston pins

1. In case of difficulty of movement, warm piston to approx. 60°C
2. When removing and installing, use VW222a Pilot drift

7 - Pistons

1. Installed position and allocation piston/cylinder. (Scheme 158)
2. Arrow on piston head points to belt pulley side
3. Checking. (Scheme 156)
4. Install with piston ring tension strip

1. Piston and cylinder dimensions. Refer to «Piston and cylinder measurements»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__piston-and-cylinder-measurements)
2. Checking cylinder bore hole. (Scheme 157)

8 - Piston rings

1. Offset gaps by 120°
2. Use piston ring pliers to remove and install
3. Marking or identification "TOP" i.e. marked side must face toward piston head
4. End play, checking. (Scheme 154)

1. Height play, checking. See «Checking piston ring side clearance»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

Scheme 153

1. Insert ring at right angle to cylinder wall from above to lower cylinder opening approx. 15 mm from cylinder edge. Use piston without rings to insert.

Scheme 154

1. Before measuring, clean piston ring groove

Scheme 155

Special tools and equipment

1. External micrometer 75-100 mm

1. Measure approx. 10 mm from lower edge, at a 90° angle to piston pin axis.

1. Deviation from nominal dimension: max. 0.04 mm

Specified dimension. Refer to Piston and cylinder measurements

Scheme 156

Special tools and equipment

1. Inner bore gauge 50-100 mm

1. Measure diagonally at 3 positions, horizontally -A- and lengthwise -B-.

1. Deviation from nominal dimension: max. 0.08 mm

Specified dimension. Refer to Piston and cylinder measurements

Scheme 157

1. Mark installed position and allocation to cylinder on piston head using chalk or waterproof felt pen.

Note. Do not use a center punch or scribe, since the piston head coating will be damaged.

1. Installed position

Arrow on piston head points to belt pulley side

Scheme 158

Note. Replace the connecting rods only as a set. Do not interchange the connecting rod bearings. Before removing, mark allocation of connecting rod and connecting rod bearing caps to each other and to cylinder using a color marker (arrow).

Scheme 159

1. Molded tabs (arrows) at the bevelled surfaces of the connecting rod pairs 1 and 2, 3 and 4 as well as 5 and 6 must point toward each other.

Scheme 160

1 - Bolt, 10 Nm

2 - Oil injector jet for piston cooling

Piston and cylinder measurements

1) Dimensions exclude graphite coating (thickness 0.02 mm). The graphite coating wears off.

Connecting rod radial play, checking

Special tools and equipment

1. Plastigage

Work sequence

1. Remove connecting rod bearing caps. Clean bearing caps and journals.
2. Place Plastigage over entire width of bearing journal or into bearing shells.
3. Install connecting rod bearing caps and tighten to 30 Nm. DO NOT turn crankshaft.
4. Remove connecting rod bearing caps again.

1. Compare width of Plastigage with calibrated scale.

1. Always replace connecting rod bolts.

Cylinder head, removing and installing

Note. Replace cylinder head bolts. Replace self-locking nuts and bolts during assembly work. Always replace bolts that are secured with tightening torque as well as O-rings and gaskets. After installing a replacement cylinder head with camshafts installed, oil contact surfaces between valve lifters and cam lubricating surfaces after installing cylinder head. Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head. When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced. If a cylinder head is replaced, a cap must be driven in on the front part of the respective head. see scheme 205 Cylinder heads with cracks between valve seats or between valve seat and spark plug thread can still be used without loss of service life if the cracks are minute (max. 0.3 mm width) or only the first four threads of a spark plug thread are cracked.

Scheme 161

1 - Intake manifold

1. Removing and installing. Refer to «Intake manifold, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

2 - Resonator

3 - 10 Nm

4 - O-Rings

1. Always replace

5 - Fuel return line

1. Only in vehicles up to 06.03

6 - Fuel supply line

1. For vehicles up to 06.03, tighten union nut to 22 Nm
2. Loosening and tightening union nut in vehicles as of 07.03. see scheme 206

7 - Socket

8 - 10 Nm

9 - Holding plate

1. For solenoid valves

10 - Fuel distributor

11 - Air duct

12 - 10 Nm

13 - O-ring

1. Always replace

14 - 10 Nm

15 - 10 Nm

1. Tighten diagonally in sequence

16 - Gasket

1. For intake manifold
2. Always replace

Scheme 162

1 - Cylinder head gasket

1. Replacing. Refer to «Left cylinder head, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__left-cylinder-head-removing)
2. Installed position: Part number to cylinder head
3. After replacing, replace coolant

2 - Cylinder head

1. Removing left cylinder head. Refer to «Left cylinder head, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__left-cylinder-head-removing)
2. Removing right cylinder head. Refer to «Right cylinder head, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__right-cylinder-head-removing)
3. Check for warpage. (Scheme 164)
4. Refacing dimension. (Scheme 165)

1. Sealing cap (core plug) in cylinder head, installing. see scheme 205
2. Installing. Refer to «Cylinder head, installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__cylinder-head-installing)
3. After replacing, replace coolant

3 - Lifting eye

4 - 23 Nm

5 - Cylinder head bolt

1. Always replace
2. Follow order of removal. Refer to «Left cylinder head, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__left-cylinder-head-removing) or «Right cylinder head, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__right-cylinder-head-removing)
3. Follow tightening order. Refer to «Cylinder head, installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__cylinder-head-installing)

6 - Centering pin

1. For intake manifold

7 - Special bolt, 10 Nm

1. Follow order of tightening. Refer to «Tightening torques»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) or «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

8 - Gasket

1. Replace if damaged or leaking

9 - Cap

10 - O-ring

1. Always replace

11 - Hose of crankcase housing ventilation

12 - Ignition coil

13 - Cylinder head cover

1. Left cylinder head cover, removing and installing. Refer to «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)
2. Right cylinder head cover, removing and installing. Refer to «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

14 - Cylinder head cover gasket

1. Replace if damaged or leaking

15 - 10 Nm

16 - Rear coolant pipe

17 - Combination valve for secondary air injection (AIR)

18 - 10 Nm

19 - Gasket

1. Always replace

20 - O-ring

1. Always replace

Scheme 163

1. Using straightedge and feeler gauge, check cylinder head for warpage at multiple points.

1. Maximum permissible warpage: 0.1 mm

Scheme 164

1. Refacing cylinder head can only be done to minimum dimension -a-.

1. Minimum dimension: a = 139.25 mm

Scheme 165

Special tools and equipment

1. VW295 Needle bearing drift

Cylinder heads which are supplied as replacement parts can be used on left or right and a cap must be installed on the respective front side.

1. Coat lip of sealing cap with sealant.

1. Sealant

1. Drive sealing cap flush into cylinder block using VW295 needle bearing drift.

Loosening and tightening union nut for fuel supply line in vehicles as of 07.03

Loosening

1. Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and unscrew union nut -2-.

Tightening

1. Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and tighten union nut -2- to 22 Nm.

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

1. Drain coolant. Refer to «Coolant, draining and refilling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

See Caution before beginning repairs on the electrical system. Refer to Cylinder head, removing and installing

1. Switch ignition off and disconnect battery Ground (GND) strap.

1. Remove rear engine cover (arrows).

1. Remove front engine cover (arrows).

1. Remove cover -1- in engine compartment (right side).

1. Remove bolts (arrows).
2. Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
3. Remove air guide -2-.

1. Remove air filter housing (arrows).
2. Disconnect electrical harness connector -1- at Mass Air Flow (MAF) sensor.
3. Remove air guide hose -2- together with Mass Air Flow (MAF) sensor.

Scheme 166

1. Disconnect vacuum hoses -2- and -3- at Intake manifold change-over valve -N156-.
2. Disconnect vacuum hose -6- from check valve.
3. Disconnect electrical harness connector -5-.
4. Set aside hose of crankshaft housing ventilation (arrow).

1. Remove bolts -1-, -4- and -7- for holding plate for solenoid valves.
2. Remove holding plate for solenoid valves.

Scheme 167

1. Disconnect electrical harness connector -1-.
2. Pull off vacuum hose -2- at T-connector.
3. Remove all harness connectors to injectors.

Scheme 168

1. Disconnect vacuum line at fuel pressure regulator and remove mounting bolts of fuel pressure regulator (arrows).
2. Remove fuel distributor together with fuel injectors from intake manifold simultaneously upward and place it on a clean rag in engine compartment.

Note. Carefully protect removed fuel injectors from contamination.

Scheme 169

1. Disconnect electrical harness connector -1- at Throttle valve control module -J338-.
2. Disconnect vacuum hoses -2- and -3-.

Scheme 170

1. Disconnect hose -1- from air duct.
2. Remove bolt -4- and disconnect air duct -2- at throttle valve control module.
3. If installed, disconnect vacuum hose -3- from air guide at bottom.

1. Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.

1. Remove bolts -1- and -3-.
2. Pull out guide tube for oil dipstick 2 from the oil pan (upper part) toward top and swing it forward for removal.

Note. Hose -4- remains connected.

Scheme 171

1. Remove bolts at right side of engine (arrows) at line for secondary air injection.

Scheme 172

1. Remove bolts -1- and -2- at lines of secondary air injection.
2. Remove bolts -3- and -5- and remove resonator -4-.

Scheme 173

1. Disconnect vacuum hose -1- at EVAP valve.
2. Remove coolant hoses -2- and -3-.

Scheme 174

1. Unbolt intake pipe (arrows) and remove.

Note. Plug intake channels in the cylinder heads with clean rags.

Installation is reverse of removal, noting the following

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

1. Bolt in intake manifold in diagonal sequence in stages (arrows).
2. Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).

See Caution for connecting Telematics battery. Refer to Cylinder head, removing and installing

1. Observe safety precautions after connecting battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

1. Top off coolant. Refer to «Filling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__filling) .

1. Remove rear engine cover (arrows).

1. Remove cover -1- in engine compartment (left side).

1. Remove coolant reservoir (arrow)
2. Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.
3. Tie coolant expansion tank with connected coolant hoses -1- to -3- to side.

1. Remove front engine cover (arrows).

Scheme 175

1. Unbolt toothed belt guard at front left from cylinder head cover (arrows).

1. Remove bolts -4- and -5-.
2. Disconnect electrical harness connectors -1- to -3- and -6-.
3. Remove ignition coils (arrows).

1. Remove hose of crankshaft housing ventilation (arrow).
2. Unscrew bolts for left cylinder head cover in the sequence -12- to -1-.
3. Remove cylinder head cover.

Installation is reverse of removal, noting the following

Note. Always replace self-locking bolts. Replace cylinder head cover gasket if damaged.

1. Tighten cylinder head cover in sequence -1- to -12-.

1) Replace bolts.

1. Remove rear engine cover (arrows).

1. Remove cover -1- in engine compartment (right side).

1. Remove bolts (arrows).
2. Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
3. Remove air guide -2-.

1. Remove air filter housing (arrows).
2. Disconnect electrical harness connector -1- at Mass Air Flow (MAF) sensor.
3. Remove air guide hose -2- together with Mass Air Flow (MAF) sensor.

1. Remove bolts -1- and -3-.
2. Disconnect hose -4- from line of secondary air injection.
3. Pull out guide tube for oil dipstick -2- from the oil pan (upper part) toward top and swing it forward for removal.

Scheme 176

1. Unbolt toothed belt guard at front right from cylinder head cover (arrows).

1. Remove bolts -5- and -6-.
2. Disconnect electrical harness connectors -1- to -4-.
3. Remove ignition coils (arrows).

1. Remove hose of crankshaft housing ventilation (arrow).
2. Unscrew bolts for right cylinder head cover in the sequence -12- to -1-.
3. Remove cylinder head cover.

Installation is reverse of removal, noting the following

Note. Always replace self-locking bolts. Replace cylinder head cover gasket if damaged.

1. Tighten cylinder head cover in sequence -1- to -12-.

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.

1. Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.
2. Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).

1) Replace bolts.

Left cylinder head, removing

Special tools and equipment

Scheme 177

1. 3452 Polydrive key

Removing

1. Engine installed.

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

1. Remove intake manifold. Refer to «Intake manifold, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

1. Remove cover -1- in engine compartment (left side).

1. Remove coolant hoses -1- to -3-.
2. Remove coolant reservoir (arrow).
3. Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.

Scheme 178

1. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) sensor 2 -G163- and Camshaft Position (CMP) sensor 4 -G301-.
2. Unbolt Ground (GND) wire at rear of cylinder head.
3. Toothed belt, removing. Refer to «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
4. Remove camshaft gears from left cylinder head.

Scheme 179

1. Unscrew bolts -1- and -2- and remove toothed belt guard at left rear.

Scheme 180

1. Remove front coolant pipe from cylinder head (arrows).

Vehicles with automatic transmission

Scheme 181

1. Disconnect vacuum hose to brake booster (arrows).

All

1. Remove heat shield for harness connectors at left of bulkhead, if installed.

Scheme 182

1. Remove bolts -1- at flange of combination valve for secondary air injection.
2. Unbolt coolant pipe at rear of cylinder head (bolts -2- and -3-).

Note. Coolant pipe and combination valve remain installed. Illustration is shown with engine removed.

1. Remove nut -2- for left exhaust pipe/exhaust manifold which is accessible from top.

Note. Illustration is shown with engine removed.

1. Remove front vehicle floor crossmember -1- to -4-.

Note. Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.

1. Disconnect exhaust system at left double clamp (left arrow).

1. Remove nuts -1- and -3- for front exhaust pipe/left exhaust manifold which are accessible from bottom.

Note. Illustration is shown with engine removed.

1. Press front exhaust pipe off of exhaust manifold.

Scheme 183

1. Follow sequence -1- to -8- when loosening cylinder head bolts.

1. Carefully remove cylinder head.

Right cylinder head, removing

Special tools and equipment

1. 3452 Polydrive key

Removing

1. Engine installed.

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

1. Remove intake manifold. Refer to «Intake manifold, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

Note. Place a rag under the hydraulic pressure lines, to catch escaping hydraulic fluid.

Scheme 184

1. Remove power steering pressure line from power steering pump at cylinder head and at rear of coolant pipe (arrows).
2. Lay pressure line to side.

Scheme 185

1. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) sensor -G40- and Camshaft Position (CMP) sensor 3 -G300-.
2. Toothed belt, removing. Refer to «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
3. Remove camshaft gears from right cylinder head.

1. Unscrew bolts -1- and remove bracket with idler roller.
2. Unscrew bolts -2- and remove toothed belt guard at right rear.

Scheme 186

1. Remove bolts -3- and remove combination valve for secondary air injection with flange from cylinder head.
2. Unbolt coolant pipe at rear of cylinder head (bolts -1- and -2-).

Note. Coolant pipe remains installed. Illustration is shown with engine removed.

1. Remove nut -2- for right exhaust pipe/exhaust manifold which is accessible from top.

Note. Illustration is shown with engine removed.

1. Remove front vehicle floor crossmember -1- to -4-.

Note. Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.

1. Disconnect exhaust system at right double clamp (right arrow).

1. Remove nuts -1- and -3- for front exhaust pipe/right exhaust manifold which are accessible from bottom.

Note. Illustration is shown with engine removed.

1. Press front exhaust pipe off of exhaust manifold.

1. Follow sequence -1- to -8- and loosen cylinder head bolts.

1. Carefully remove cylinder head.

Cylinder head, installing

Note. Replace cylinder head bolts. Replace self-locking nuts and bolts during assembly work. Always replace bolts that are secured with tightening torque as well as O-rings and gaskets. In case of repairs, carefully remove sealant residue from cylinder head and cylinder block. Avoid introducing any scratches or scoring. Thoroughly remove all sanding and grinding residue. Pocket holes in cylinder block for cylinder head bolts must be free of oil and coolant. Do not remove new cylinder head gasket from package until immediately before installing. Handle gasket with extra care. Damage in silicon layer and recessed area lead to leakage. Install cylinder head gasket onto guide sleeves. Marking "open" (top) or part number must face toward cylinder head. Secure all hose connections using hose clamps appropriate for the model type

Installation is reverse of removal, noting the following

1. Before installing cylinder head, set crankshaft and camshafts to TDC cylinder 3

1. T40030 camshaft adjuster gauge must be inserted at both cylinder heads...

1. .. and T40026 locking pin must be threaded in.

Scheme 187

1. Install cylinder head gasket.

1. Observe centering pins (arrows) in cylinder block.
2. Pay attention to installed position of cylinder head gasket, marking "open" (top) or part number must face toward cylinder head.

1. Install cylinder head.
2. Insert new cylinder head bolts and hand-tighten.

Scheme 188

1. Tighten cylinder head bolts in sequence, in two stages.

1. Tighten using torque wrench

1. 1. Stage: 40 Nm

1. Tighten using a solid wrench

1. 2. Stage: 180° (1/2 turn) further

Note. Two additional turns of 90° are permissible. It is not necessary to re-tighten the cylinder head bolts.

1. Install toothed belt (adjust timing). Refer to «Installing (adjusting valve timing)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing-adjusting-valve-timing) .

Note. After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

1. Install left front exhaust pipe with catalytic converter. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for vehicles with manual transmission and «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for vehicles with automatic transmission 01V.
2. Install right front exhaust pipe with catalytic converter. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for vehicles with manual transmission and «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) for vehicles with automatic transmission 01V.
3. Install exhaust system free of stress. Refer to «Exhaust system, aligning free of stress (vehicles with front wheel drive)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__exhaust-system-aligning-free-of-stress) and «Exhaust system, aligning free of stress (vehicles with all wheel drive)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__exhaust-system-aligning-free-of-stress) .
4. Install centering pin for intake manifold.

1. Install intake manifold. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

See Caution for connecting Telematics battery. Refer to Cylinder head, removing and installing

1. Observe safety precautions after connecting the battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

1. Replace coolant. Refer to «Filling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__filling) .
2. Fill up power steering fluid and bleed steering system

Refer to 48 - STEERING

Tightening torques

1) Replace bolts.

Compression pressure, checking

Special tools and equipment

Scheme 189

1. 3122B Spark plug removal tool

Scheme 190

1. VAG1381 or VAG1763 Compression tester

Requirements

1. Minimum engine oil temperature: 30°C
2. Battery voltage at least 12.7 V

Work sequence

1. Remove rear engine cover (arrows).

1. Remove cover -1- in engine compartment (left side).

1. Remove coolant reservoir (arrow)
2. Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.
3. Tie coolant expansion tank with connected coolant hoses -1 to 3- to side.

1. Remove cover -1- in engine compartment (right side).

1. Remove bolts (arrows).
2. Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
3. Remove air guide -2-.

1. Remove air filter housing (arrows).
2. Disconnect electrical harness connector -1- at Mass Air Flow (MAF) sensor.
3. Remove air guide hose -2- together with Mass Air Flow (MAF) sensor.

1. Remove bolts -4- and -5- at left cylinder head cover.
2. Disconnect electrical harness connectors -1- to -3- and -6-.
3. Remove ignition coils (arrows).

1. Remove bolts -5- and -6- at right cylinder head cover.
2. Disconnect electrical harness connectors -1- to -4-.
3. Remove ignition coils (arrows).
4. Using 3122B spark plug removal tool, remove spark plugs.

1. Remove all harness connectors to injectors.
2. Open throttle fully.
3. Test engine compression using VAG1381 or VAG1763 compression tester.

Note. Using VAG1381 or VAG1763 Compression Tester

Refer to Operating instructions

1. Activate starter until no further pressure increases are indicated by VAG1381 or VAG1763 compression tester.

Compression values

1. Install spark plugs and ignition coils.

The following work step must be performed after the engine compression test.

1. Check DTC and erasing if necessary.

Use VAS5051 tester.

Tightening torque

Valve train, servicing

Note. Cylinder heads with cracks between valve seats or between valve seat and spark plug thread can still be used without loss of service life if the cracks are minute (max. 0.3 mm width) or only the first four threads of a spark plug thread are cracked. After installing camshafts, do not start engine for at least 30 minutes. The hydraulic valve lifters have to settle (otherwise valves will strike the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting. Replace gaskets and O-rings. Illustration depicts the left cylinder bank.

Scheme 191

1 - 10 Nm

2 - Seals

1. Always replace. Refer to «Camshaft oil seals, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshaft-oil-seals-replacing)

3 - Housing

1. For camshaft adjustment valves

4 - Gasket

1. Always replace

5 - Exhaust camshaft

1. Checking axial clearance. Refer to «Camshaft axial play, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshaft-axial-play-checking)
2. Removing and installing. Refer to «Camshafts and camshaft adjusters, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshafts-and-camshaft-adjusters-removing-and)

Check radial clearance using Plastigage (hydraulic valve lifters removed)

1. Wear limit: 0.1 mm
2. Max. run-out: 0.01 mm

6 - Piston rings

1. For camshaft adjuster
2. Engage piston ring ends with each other. (Scheme 195)
3. If ring ends are not of locking ring type (cannot be locked together) align all ring gaps at top and install camshaft housing using a gentle side to side motion (do not rock top to bottom)

7 - Intake camshaft

1. Checking axial clearance. Refer to «Camshaft axial play, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshaft-axial-play-checking)
2. Removing and installing. Refer to «Camshafts and camshaft adjusters, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshafts-and-camshaft-adjusters-removing-and)

Check radial clearance using Plastigage (hydraulic valve lifters removed)

1. Wear limit: 0.1 mm
2. Max. run-out: 0.01 mm

8 - 10 Nm

1. Tighten in several stages from inside out

9 - Guide frame

1. With integrated camshaft bearings
2. Removing and installing. Refer to «Camshafts and camshaft adjusters, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshafts-and-camshaft-adjusters-removing-and)

10 - Sensor wheel

1. Note position (notch on camshaft)

11 - 23 Nm

12 - Hydraulic valve lifter

1. Checking. Refer to «Hydraulic valve lifters, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__hydraulic-valve-lifters-checking)
2. Removing and installing. Refer to «Valve stem oil seals, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)
3. Do not interchange
4. Install with journal surface facing down

1. Before installing, check axial play of camshaft. Refer to «Camshaft axial play, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshaft-axial-play-checking)
2. Oil contact surface

13 - Valve keepers

14 - Valve spring retainer

15 - Valve spring

16 - Valve stem oil seal

1. Always replace. Refer to «Valve stem oil seals, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

17 - Camshaft Position (CMP) sensor

1. Cylinder bank 1 (right) Camshaft Position (CMP) sensor -G40
2. Cylinder bank 2 (left) Camshaft Position (CMP) sensor 2 -G163

18 - 10 Nm

19 - Camshaft Position (CMP) sensor for exhaust camshaft

1. Cylinder bank 1 (right) Camshaft Position (CMP) sensor 3 -G300
2. Cylinder bank 2 (left) Camshaft Position (CMP) sensor 4 -G301

20 - O-ring

1. Always replace

21 - 10 Nm

22 - Camshaft Position (CMP) sensor housing

23 - Gasket

1. Always replace

24 - Cylinder head

1. Observe note. Refer to «Valve train, servicing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__valve-train-servicing)
2. Check valve guides, hand-lap valve seats. Refer to «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__valve-guides-checking)
3. Reface valve seats. Refer to «Valve seats, refacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__valve-seats-refacing)

25 - Intake valve

1. Do not reface, only hand-lapping is permitted
2. Mark installation position for reinstalling
3. Valve dimensions. See «Valve dimensions»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)
4. Check valve guides, hand-lap valve seats. Refer to «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__valve-guides-checking)

26 - Exhaust valves

1. Do not reface, only hand-lapping is permitted
2. Mark installation position for reinstalling
3. Valve dimensions. See «Valve dimensions»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)
4. Check valve guides, hand-lap valve seats. Refer to «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__valve-guides-checking)

Scheme 192

1 - Seals

1. Always replace. Refer to «Camshaft oil seals, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshaft-oil-seals-replacing)

2 - Housing

1. For camshaft adjustment valves

3 - O-Rings

1. Green
2. Between solenoid valve housing and solenoid valves
3. Always replace

4 - O-Rings

1. Black
2. Always replace

5 - O-Rings

1. Green
2. Always replace

6 - 4 Nm

7 - Camshaft adjustment valve - intake side

1. Cylinder bank 1 (right) Valve -1- for camshaft adjustment -N205
2. Cylinder bank 2 (left) Valve -2- for camshaft adjustment -N208
3. Do not interchange with a valve for camshaft adjustment (exhaust side)
4. Note identification 12. 100 338

8 - Gasket

1. Replace if damaged

9 - Connector adapter

1. Must be replaced after disconnecting from camshaft adjustment valves
2. Carefully press onto harness connectors of camshaft adjustment valves until they engage

10 - 4 Nm

11 - Camshaft adjustment valve - exhaust side

1. Cylinder bank 1 (right) Camshaft Adjustment Valve 1 (exhaust) -N318
2. Cylinder bank 2 (left) - Camshaft Adjustment Valve 2 (exhaust) -N319
3. Do not interchange with a camshaft adjustment valve (intake side)
4. Note identification 12. 100 339

12 - Gasket

1. Always replace

13 - 10 Nm

Scheme 193

Note. Valves must not be refaced. Only hand-lapping is permitted.

Scheme 194

1. Check whether piston rings at camshafts are installed and whether piston ring ends are engaged with each other.

Note. If ends of installed piston are not of the locking type (cannot be locked together)

1. Always orient the rings so that the gaps (of all three rings) are at the top of the camshaft prior to installation of the camshaft adjustment housing.

With all ring gaps aligned at the top of camshaft

1. Install camshaft adjustment housing using a gentle side to side motion (do not rock top to bottom).

Scheme 195

1. If necessary, engage ends of installed piston rings (arrows), as depicted in illustration.

Camshaft axial play, checking

Special tools and equipment

1. VW387 Dial gauge holder
2. Dial gauge

Work sequence

1. Remove camshafts. Refer to «Camshafts and camshaft adjusters, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshafts-and-camshaft-adjusters-removing-and) .
2. Remove hydraulic valve lifters.
3. Insert camshafts into cylinder head and install guide frame.

Scheme 196

1. Secure dial indicator to cylinder head using VW387 dial gauge holder.
2. Press camshaft to be checked against dial indicator by hand.
3. Set dial indicator to 0.
4. Press crankshaft away from dial indicator.

1. Read clearance.

Camshaft oil seals, replacing

Special tools and equipment

Scheme 197

1. VW681 Extractor lever

Scheme 198

1. T10053 Assembly tool

Removing

1. Remove toothed belt. Refer to «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
2. Mark installed position of camshaft gears for re-installation.
3. Remove camshaft gears.

Note. In case of leaks of one shaft seal, replace sealing rings at both cylinder heads. Be careful not to damage seating surface when pressing out sealing rings.

Scheme 199

1. Install camshaft sealing rings using VW681 extractor lever.
2. Clean seating surfaces.

Installing

Scheme 200

1. Press in sealing ring for camshaft gear flush to housing using T10053 assembly tool and bolt -1-.
2. Install toothed belt (adjust timing). Refer to «Installing (adjusting valve timing)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing-adjusting-valve-timing) .

Camshafts and camshaft adjusters, removing and installing

Special tools and equipment

Scheme 201

1. T10055 Extractor

Scheme 202

1. T40029 Locating pin
2. Drill with plastic brush attachment
3. Protective glasses
4. Sealants

1. Toothed belt, removing. Refer to «Toothed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
2. Remove respective camshaft gears.
3. Remove combination valve for Secondary Air Injection. Refer to «Left combination valve for secondary air injection, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__left-combination-valve-for-secondary-air) or «Right combination valve for secondary air injection, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__right-combination-valve-for-secondary-air) .

Right cylinder head

1. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) sensor -G40- and Camshaft Position (CMP) sensor 3 -G300-.

1. Unscrew bolts -1- and remove bracket with idler roller.
2. Unscrew bolts -2- and remove toothed belt guard at right rear.

Left cylinder head

1. Unscrew bolts -1- and -2- and remove toothed belt guard at left rear.

All

1. Remove T40030 camshaft adjuster gauge from camshafts.

Scheme 203

1. Unscrew bolts -1- to -6- and remove housing for camshaft adjustment valves.

Scheme 204

1. Unscrew bolts -1- to -6- and remove housing for Camshaft Position (CMP) sensor.

Scheme 205

1. Loosen bolts of guide frame in sequence of numbers and follow arrows.

Scheme 206

1. Press off guide frame with M6 bolts (arrows).
2. Carefully remove guide frame.

1. Using rotating plastic brush, remove remaining sealant from cylinder head and guide frame.
2. Clean sealing surfaces so they are completely free of any oil or grease.

Note. Replace gaskets and O-rings.

1. Crankshaft aligned using T40026 locking pin

1. Oil camshaft journal surface.

Left cylinder head

Scheme 207

1. Insert camshaft into cylinder head as depicted in illustration.

1. Cams at cylinder 5 point downward evenly (arrows).

Right cylinder head

Scheme 208

1. Insert camshaft into cylinder head as depicted in illustration.

1. Cams at cylinder 3 point upward evenly (arrows)

All

1. Cut tube nozzle at front marking (jet diameter approx. 1 mm).

Note. Sealant bead must be applied according to exact specifications, otherwise excess sealant could get into the camshaft bearings.

Scheme 209

1. Apply sealant to clean sealing surface of guide frame as depicted in illustration.

1. Thickness of sealant bead: Approx. 1.2 mm
2. Distance of sealant bead to camshaft bearings at specified locations -1- to -8-: at least 5 mm
3. In addition, sealing surfaces around spark plug holes obtain a sealant ring each, -9- to -11

Scheme 210

1. Immediately set guide frame in place and align using T40029 locating pin.

Note. Setting in place and tightening the guide frame should occur without interruptions since the sealant starts to harden immediately. After installing guide frame, allow sealant to dry for approx. 30 minutes.

Scheme 211

1. Tighten bolts of guide frame in sequence of numbers and follow arrows uniformly by hand.

1. Guide frame must make full contact with cylinder head surface

1. Tighten bolts of guide frame to final tightening torque (10 Nm).

Scheme 212

1. Using T10055 extractor, remove T40029 locating pin from cylinder head.

Left cylinder head

1. Insert T40030 camshaft adjuster gauge at camshafts.
2. Spread T40030 camshaft adjuster gauge with threaded shaft (tightening torque 10 Nm) until it is seated without axial play.

Right cylinder head

1. Install camshaft gear of exhaust camshaft.

Scheme 213

1. Turn exhaust camshaft (arrow -1-) and intake camshaft (arrow -2-) 30° in direction of arrow at same time...

1. ..until cams (arrows) of cylinder 3 at intake and exhaust camshafts are as shown in illustration.

1. Insert T40030 camshaft adjuster gauge at camshafts.
2. Remove exhaust camshaft gear again.

All

1. Install Camshaft Position (CMP) sensor housing and tighten bolts -1- to -6-.

1. Check whether piston rings at camshafts are installed and whether piston ring ends are engaged with each other.

Note. If ends of installed piston are not of the locking type (cannot be locked together)

1. Always orient the rings so that the gaps (of all three rings) are at the top of the camshaft prior to installation of the camshaft adjustment housing.

With all ring gaps aligned at the top of camshaft

1. Install camshaft adjustment housing using a gentle side to side motion (do not rock top to bottom).

1. If necessary, engage ends of installed piston rings (arrows), as depicted in illustration.

Note. If the camshaft sealing rings are being replaced, they must be removed from camshaft adjustment housing before installation, using T40017 lever. Installing camshaft sealing rings. Refer to Camshaft oil seals, replacing .

1. Install camshaft adjustment housing and tighten bolts -1- to -6-.

Installation is reverse of removal, noting the following

1. Install combination valve for Secondary Air Injection. Refer to «Left combination valve for secondary air injection, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__left-combination-valve-for-secondary-air) or «Right combination valve for secondary air injection, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__right-combination-valve-for-secondary-air) .
2. Install toothed belt (adjust timing). Refer to «Installing (adjusting valve timing)»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing-adjusting-valve-timing) .

Note. After installing camshafts, do not start engine for at least 30 minutes. The hydraulic valve lifters have to settle (otherwise valves will strike the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

1) Replace bolts.

Hydraulic valve lifters, checking

Special tools and equipment

1. Feeler gauge
2. Wooden or plastic wedge

Note. Hydraulic valve lifters cannot be serviced. Irregular valve noise when starting engine is normal.

Work sequence

1. Start engine and let run until coolant temperature reaches at least 80°C.
2. Increase RPM to 2500 for approx. 2 minutes, if necessary road test vehicle.

Note. If unusual valve noises disappear but then reappear during drive, replace oil retaining valve. Oil retaining valve, component location: Below cover at intake manifold. Refer to Oil check valves and spray jet valve, overview .

If hydraulic valve lifters are still loud, locate faulty valve lifter as follows

1. Remove cylinder head cover. Refer to «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) or «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.

1. Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.

1. Turn crankshaft at center bolt of toothed belt gear clockwise until cams of cylinder to be checked point upward (arrows).
2. Determine play between cams and valve lifters.

Scheme 214

1. Press valve lifter downward using wooden or plastic wedge. If 0.20 mm feeler gauge can be inserted between camshaft and valve lifter, replace valve lifter. Valve lifters, replacing. Refer to «Camshafts and camshaft adjusters, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshafts-and-camshaft-adjusters-removing-and) .

Note. After installing camshaft, do not start engine for at least 30 minutes. The hydraulic valve lifters have to settle (otherwise valves will strike the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Scheme 215

Special tools and equipment

1. Adapter T40012
2. 3122B Spark plug removal tool
3. 3364 Valve Seat Tool
4. 3365 Valve Stem Seat Fitting Tool

1. VAS 5161 Removal and installation device

Removing

1. Cylinder head installed

1. Remove camshafts. Refer to «Camshafts and camshaft adjusters, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshafts-and-camshaft-adjusters-removing-and) .

Note. Be careful not to switch valve lifters. Mark allocation of the valve lifters on back side using a waterproof felt-tip marker.

1. Remove valve lifters from guides and place aside with contact surface facing down.
2. Using 3122B spark plug removal tool, remove spark plugs.
3. Adjust piston of respective cylinder to BDC.

Scheme 216

1. Thread T40012 adapter into spark plug thread and apply constant pressure; at least 6 bar positive pressure.
2. Insert VAS5161/3 drift into valve lifter guide.
3. Loosen by hitting all stuck valve keys at all five valves using a plastic hammer.

Intake side

Scheme 217

1. Thread VAS5161/6 engaging device with VAS5161/5 engaging fork into one threaded hole at cylinder head.
2. At valve to be removed, slide VAS5161/13 guide bushing into valve lifter guide up to stop.

1. Installed position: Hatched areas point horizontally to direction of travel

1. Slide VAS5161/17 knurled spacer ring onto VAS5161/8 installation cartridge.
2. Slide installation cartridge into guide bushing.
3. Hook in VAS5161/2 pressure fork at VAS 5161/6 engaging device and press installation cartridge downward.
4. At same time, turn knurled bolt of installation cartridge toward right, until points engage in valve keys.

1. Lightly move knurled bolt back and forth, this causes valve keys to be pressed apart and captured in cartridge.

1. Release pressure fork.
2. Remove installation cartridge with spacer ring, guide bushing, valve plate and valve spring.

Exhaust side

Scheme 218

1. Thread VAS5161/6 engaging device with VAS5161/5 engaging fork into one threaded hole at cylinder head.
2. At valve to be removed, slide VAS5161/14 guide bushing into valve lifter guide up to stop.

1. Installed position: Hatched areas point horizontally to direction of travel

1. Slide VAS5161/17 knurled spacer ring onto VAS5161/8 installation cartridge.
2. Slide installation cartridge into guide bushing.
3. Hook in VAS5161/2 pressure fork at VAS 5161/6 engaging device and press installation cartridge downward.
4. At same time, turn knurled bolt of installation cartridge toward right, until points engage in valve keys.

1. Lightly move knurled bolt back and forth, this causes valve keys to be pressed apart and captured in cartridge.
2. Release pressure fork.
3. Remove installation cartridge with spacer ring, guide bushing, valve plate and valve spring.

All

Scheme 219

1. Remove valve stem oil seals using 3364 valve seat tool.

If due to limited space 3364 valve stem removal tool cannot be used at some valve stem oil seals, continue as follows

Scheme 220

1. Drive out spring dowel sleeve (arrow) at 3364 valve stem removal tool using a drift and remove impact extractor device.

Scheme 221

1. Position lower part of 3364 valve stem removal tool at valve stem oil seal.
2. Secure 3364 valve stem removal tool using a drift or cotter pin driver -1- as shown in illustration.
3. Position a lever at 3364 valve stem removal tool and remove valve stem oil seal (arrow).

Installing

Note. A plastic sleeve -A- supplements the new valve shaft seals.

Scheme 222

1. Place plastic sleeve -A- on valve stem to prevent damage to new valve stem oil seals -B-.
2. Lightly oil sealing lip of valve stem oil seal.
3. Slide valve stem oil seal onto plastic sleeve.
4. Carefully press valve stem oil seal onto valve guide using 3365 valve stem seal driver.

1. Remove plastic sleeve.

Scheme 223

1. If valve keepers were removed from installation cartridge, they must be inserted into VAS5161/18 insertion device next.

Note. The large diameter of the valve keepers points upward.

1. Press VAS5161/8 installation cartridge onto insertion device from top and take up valve keepers.

1. Set VAS5161/8 installation cartridge into VAS5161/13 guide sleeve or VAS5161/14.
2. Press down pressure fork and pull knurled bolt upward while turning left and right - valve keepers are inserted in this manner.
3. Release pressure fork with the knurled bolt still pulled.
4. Insert valve lifters.

1. Install camshafts. Refer to «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .

Note. After installing camshafts, do not start engine for at least 30 minutes. The hydraulic valve lifters have to settle (otherwise valves will strike the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Valve guides, checking

Special tools and equipment

1. VW387 Dial gauge holder
2. Dial gauge

Work sequence

Scheme 224

1. Insert valve into guide. Valve stem tip must seal with guide. Due to differences in valve stem diameter, make sure that only intake valves are used to check intake guides, and only exhaust valves are used to check exhaust guides.
2. Measure side play.

Wear limit

Note. If wear limit is exceeded, re-measure using new valves. If wear limit is still exceeded, replace cylinder head. Valve guides cannot be replaced. If valve is to be replaced during repair, use a new valve for measurement.

Valves, checking

1. Visual check for signs of wear at stem and at seating surface. Replace valves in case of significant signs of wear.

Valve seats, refacing

Note. If a perfect contact pattern is not created after hand-lapping valve seats, reface valve seats.

Special tools and equipment

1. Depth gauge
2. Valve seat refacing tool

Note. When servicing engines with leaking valves, refacing or replacing valve seats and valves is not sufficient. It is particularly important to check valve guides for wear on engines with higher running performance. Refer to Valve guides, checking . Only reface valve seats enough until a perfect contact pattern is obtained. Before refacing, determine maximum refacing dimension. If refaced dimension is exceeded, hydraulic valve lifter function is no longer guaranteed and cylinder head must be replaced.

Determining maximum allowable refacing dimension

1. Insert valve and press tightly against valve seat.

Note. If valve is replaced during repair, use new valve for measurement.

Scheme 225

1. Measure distance -a- between valve stem end (upper edge) and upper cylinder head surface using a depth gauge.
2. Determine maximum allowable refacing dimension using distance measured and minimum dimension.

Measured distance minus minimum dimension = max. permissible refaced dimension.

Note. If the maximum allowed refaced dimension is 0 mm or less than 0 mm, repeat measurement using new valve. If measurement result is still 0 mm or less than 0 mm, replace cylinder head.

Scheme 226

Valve seats, refacing

Camshaft adjustment, checking

The Engine Control Module (ECM) can adapt the instantaneous load- and RPM situation by adjusting the timing.

To do so, the total of four valves for camshaft adjustment allow more or less oil pressure to impact the mechanical adjustment mechanism.

While the exhaust camshafts only have control over a single stage adjustment, intake camshafts can be adjusted variably.

System test, initiating

Special tools and equipment

Scheme 227

1. VAS5051 Vehicle diagnosis, testing and information system with VAG5051/1 Adapter

Requirements

1. VAS5051 tester connected and vehicle On Board Diagnostic (OBD) -01 Engine electronics- selected.
2. Coolant Temperature at least 80°C.
3. Vehicles with automatic transmission selector lever in P or N.

Work sequence

1. Start engine, and let run at idle.

Scheme 228

Display on VAS5051

1. In selection -1-, click on the diagnostic function "04 - Basic setting".

Scheme 229

Display on VAS5051

1 - Enter display group

max. input value = 255

1. Select function "094" in button field -2- for "display group number 094" and press Q button to confirm input.

Scheme 230

Display on VAS5051

1. Activate basic setting by pressing button A.
2. Depress accelerator pedal and brake pedal at same time; engine speed increases to approx. 1900 RPM.

Requirement

1. Accelerator pedal and brake pedal depressed at same time, engine runs at approx. 1900 RPM.

1. Check specified values in display fields -3- and -4-.

1. Click on <-- button

Display on VAS5051

1 - Enter display group

max. input value = 255

1. Select function "096" in button field -2- for "display group number 096" and press Q button to confirm input.

Indicated on display of VAS 5051

1. Activate basic setting by pressing button -A-.
2. Depress accelerator pedal and brake pedal at same time, engine speed increases to approx. 1900 RPM.

Requirement

1. Accelerator pedal and brake pedal depressed at the same time, engine runs at approx. 1900 RPM.

1. Check specified values in display fields -3- and -4-.

1. Click on <-- button.
2. Switch over to Read measured value block.

Camshaft adjustment (exhaust), checking

Indicated on display of VAS 5051

1 - Enter display group

max. input value = 255

1. Select function "090" in button field -2- for "display group number 090" and press Q button to confirm input.

Scheme 231

Indicated on display of VAS 5051

Requirement

1. Engine running at idle.

1. Check specified values in display fields -2-, -3- and -4-.

1. Perform a road test.
2. Accelerate vehicle in 3rd gear at wide open throttle from 2000 RPM.
3. Check specified values in display fields -2-, -3- and -4-.

Note. If display field indicates a value between 3.0° crankshaft rotation and 19.0° crankshaft rotation during a road test, the electrical valve for camshaft adjustment is correctly switching the oil pressure to mechanical camshaft adjuster, but the mechanical camshaft adjuster cannot reach its end position (e.g. due to difficulty of movement).

Camshaft adjustment (intake), checking

Indicated on display of VAS 5051

1. Press s button to change into display group 091.

Requirement

1. Engine running at idle.

1. Check specified values in display fields -3- and -4-.

1. Perform a road test.
2. Accelerate vehicle in 3rd gear at wide open throttle from 2000 RPM.
3. Check specified values in display fields -3- and -4-.

Note. If display field only indicates a value between 3.0°crankshaft rotation and 39.0° crankshaft rotation during a road test, the electrical valve for camshaft adjustment is correctly switching the oil pressure to mechanical camshaft adjuster, but the mechanical camshaft adjuster cannot reach its end position (e.g. due to difficulty of movement).

Indicated on display of VAS 5051

1. Press s button to change into display group 092.

Requirement

1. Engine running at idle.

1. Check specified values in display fields -3- and -4-.

1. Perform a road test.
2. Accelerate vehicle in 3rd gear at wide open throttle from 2000 RPM.
3. Check specified values in display fields -3- and -4-.

Note. If display field only indicates a value between 3.0° crankshaft rotation and 39.0° crankshaft rotation during a road test, the electrical valve for camshaft adjustment is correctly switching the oil pressure to mechanical camshaft adjuster, but the mechanical camshaft adjuster cannot reach its end position (e.g. due to difficulty of movement).

Scheme 232

Special tools and equipment

1. VAG 1526 A Multimeter
2. VAG 1527 B Voltage tester
3. VAG 1594 A Connector test kit
4. VAG 1598/31 Test box

1. VAS 5051 Vehicle diagnosis, testing and information system with VAS 5051/1 Adapter

Requirement

1. VAS5051 tester connected and vehicle On Board Diagnostic (OBD) -01 Engine electronics- selected.

Valves for camshaft adjustment (intake), activating

1. Initiate output Diagnostic Test Mode (DTM) and activate valve for camshaft adjustment bank 1

Scheme 233

Display on VAS5051

A - Actuator test is waiting Advancing by switching required

5 - Bank 1, camshaft adjustment. Refer to -N205

1. Click on delta button

Display on VAS5051

A - Actuator test is running Advancing by switching allowed

1. This valve is activated for approx. 1 minute (clicks), unless delta button is pressed first to switch to the next actuator.

1. Click on delta button

Scheme 234

Display on VAS5051

A - Actuator test is waiting Advancing by switching required

6 - Bank 2, camshaft adjustment. Refer to -N208

1. Click on delta button

Display on VAS5051

A - Actuator test is running Advancing by switching allowed

1. This valve is activated for approx. 1 minute (clicks), unless delta button is pressed first to switch to the next actuator.

1. End function "03 - output Diagnostic Test Mode (DTM)" by pressing <-- button.

If one of the valves is not being activated (does not click).

1. Switch ignition off.
2. Perform an electrical test for valves for camshaft adjustment. Refer to «Electrical test of solenoid valve for camshaft adjustment»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__electrical-test-of-solenoid-valve-for) .

Valves for camshaft adjustment (exhaust), activating

1. Initiate output Diagnostic Test Mode (DTM) and activate valve for camshaft adjustment (exhaust) bank 1

Scheme 235

Display on VAS5051

A - Actuator test is waiting Advancing by switching required

7 - Bank 1, valve for camshaft adjustment (exhaust)

1. Click on delta button

Display on VAS5051

A - Actuator test is running Advancing by switching allowed

1. This valve is activated for approx. 1 minute (clicks), unless delta button is pressed first to switch to the next actuator.

1. Click on delta button

Scheme 236

Display on VAS5051

A - Actuator test is waiting Advancing by switching required

8 - Bank 2, valve for camshaft adjustment (exhaust)

1. Click on delta button

Display on VAS5051

A - Actuator test is running Advancing by switching allowed

1. This valve is activated for approx. 1 minute (clicks), unless delta button is pressed first to switch to the next actuator.

1. End function "03 - output Diagnostic Test Mode (DTM)" by pressing <-- button.

If one of the valves is not being activated (does not click).

1. Switch ignition off.
2. Perform an electrical test for valves for camshaft adjustment. Refer to «Electrical test of solenoid valve for camshaft adjustment»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__electrical-test-of-solenoid-valve-for) .

Electrical test of solenoid valve for camshaft adjustment

Cylinder bank 2 (left)

1. Remove cover -1- in engine compartment (left side).

1. Remove coolant reservoir (arrow)
2. Remove line from Engine Coolant Level (ECL) warning switch -F66- and lay coolant reservoir to side.

Note. Coolant hoses 1 to 3 remain connected.

Cylinder bank 1 (right)

1. Remove cover -1- in engine compartment (right side).

1. Remove bolts (arrows).
2. Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
3. Remove air guide -2-.

Scheme 237

1. Remove air filter housing (arrows).

Continuation for both cylinder banks

Scheme 238

1. Disconnect harness connector (arrow) from connector adapter.

Note. Illustration depicts cylinder bank 2 (left).

Checking internal resistance

Valve for camshaft adjustment (intake)

Scheme 239

1. Connect multimeter between terminals 1 and 2 for resistance measurement.

1. Specification: 7.4 to 8.2 ohms

Valve for camshaft adjustment (exhaust)

1. Connect multimeter between terminal 2 and 3 for resistance measurement.

1. Specification: 12.8 to 14.2 ohms

All

If specified value is not obtained

1. Replace valve.

If specified value is obtained

Checking voltage supply

Requirement

1. Fuse for valves for camshaft adjustment OK.

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

Scheme 240

1. Connect VAG1527B voltage tester as follows

1. Switch ignition on.

1. LED must light up

If LED does not light up

1. Check wire connection from terminal 2 of connector via fuse to Motronic Engine Control Module (ECM) power supply relay -J271- for open circuit

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

1. Repair open circuit if necessary.

If LED lights up

Checking activation

1. Connect VAG1527B voltage tester as follows

1. Initiate output Diagnostic Test Mode (DTM) and activate valve for camshaft adjustment.

1. LED must blink

If LED does not blink or if it remains constantly lit

Scheme 241

1. Connect VAG1598/31 test box to harness connectors of wiring harness (do not connect ECM). Connect Ground (GND) clip at test box (not visible in illustration) to Ground (GND).

Refer to 24 MULTIPORT FUEL INJECTION (MFI)

1. Check following wire connections for open circuit and short circuit to Ground (GND) and B+

1. Repair short circuit to Ground (GND) connection or open circuit if necessary.

If wire connection is OK

1. Replace Engine Control Module (ECM).

If no malfunctions are detected

1. Replace mechanical camshaft adjuster. Refer to «Valve train, servicing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) , i.e. camshafts, removing and installing: Refer to «Camshafts and camshaft adjusters, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__camshafts-and-camshaft-adjusters-removing-and) .

Lubrication system components, removing and installing

Note. If large quantities of metal shavings or abraded material are found in the engine oil while servicing the engine, the oil passages must be carefully cleaned to prevent resulting damage and the oil cooler must be replaced. Oil level must not exceed max. marking - risk of catalytic converter damage! Oil injector jet for piston cooling. see scheme 362

Viscosity classes and oil specifications

Refer to Additional Information, Fluid Capacity Chart

Scheme 242

1 - Seal

1. Always replace

2 - 10 Nm

1. Tighten diagonally in sequence

3 - Oil pan (lower part)

1. Removing and installing. Refer to «Oil pan (lower part), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__oil-pan-lower-part-removing-and)

4 - 10 Nm

5 - Front baffle plate

6 - 22 Nm

1. Always replace

7 - 20 Nm plus and additional 90° (1/4 turn)

1. Always replace
2. Insert a new diamond disc item - 9 between gear and chain sprocket.

8 - Gear for differential gear shaft drive

1. Insert a new diamond disc item - 9 between gear and chain sprocket.

9 - Diamond disc

1. Always replace

10 - Drive chain for oil pump

1. Removing and installing. Refer to «Drive chain or chain tensioner for oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__drive-chain-or-chain-tensioner-for)
2. Chain tensioner for drive chain. Refer to item - 16

11 - Drive chain gear for oil pump

1. Removing and installing. Refer to «Drive chain gear for oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__drive-chain-gear-for-oil-pump)

12 - Chain sprocket for oil pump

1. Installed position: Marking faces rear
2. Insert a new diamond disc item - 9 «Lubrication system components, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) between gear and chain sprocket.
3. Removing and installing. Refer to «Oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__oil-pump-removing-and-installing)

13 - Stud

1. Self-locking
2. Short threaded side to cylinder block

14 - 10 Nm

15 - O-ring

1. Always replace

16 - Oil tube

17 - O-Rings

1. Always replace

18 - Oil tube

19 - Bracket

1. For oil tubes

20 - 10 Nm

21 - O-ring

1. Always replace

22 - Oil pump

1. With differential shaft
2. Removing and installing. Refer to «Oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__oil-pump-removing-and-installing)

23 - Rear baffle plate

24 - 10 Nm

1. Self-locking
2. Always replace

25 - 20 Nm plus an additional 120° (1/3 turn)

1. Always replace
2. Insert with locking fluid
3. Locking fluid

26 - Seal

1. Always replace

27 - Oil drain plug, 30 Nm

28 - 10 Nm

29 - Oil level thermal sensor -G266

Scheme 243

1 - Torque support

2 - 40 Nm

3 - Stop

1. For torque support
2. Adjusting

1. Place impact for torque support on rubber buffer for torque support, letting it rest under its own weight and tighten bolts to 28 Nm.

4 - 28 Nm

5 - Seal

1. Always replace

6 - Oil pressure switch -F1-, 1.4 bar, 25 Nm

1. Black insulation
2. Checking. Refer to «Oil pressure and oil pressure switch, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)
3. Always replace O-ring

7 - 12 Nm

8 - Washer

9 - O-ring

1. Always replace

10 - Seal

1. Always replace

11 - Locking bolt, 10 Nm

12 - Seal

1. For crankshaft
2. Removing and installing. Refer to «Seal for crankshaft (ribbed belt side), replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

13 - 10 Nm

14 - 30 Nm

1. Self-locking
2. Always replace

15 - Sealing flange, front

1. Removing and installing. Refer to «Front sealing flange, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__front-sealing-flange-removing-and-installing)

16 - Chain tensioner

1. Removing and installing. Refer to «Drive chain or chain tensioner for oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__drive-chain-or-chain-tensioner-for)
2. Use a diameter 3 mm drill bit to secure

17 - Gasket

1. Always replace

18 - 20 Nm

19 - Guide tube for oil dipstick

20 - Sheet metal screw

21 - O-ring

1. Always replace

22 - Oil filter housing

1. Follow filter change intervals

Refer to

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

1. Use 3417 Oil filter wrench to remove
2. Follow installation notes found on oil filter
3. Tighten to 20 Nm

23 - 30 Nm

24 - Oil cooler

1. Observe note. Refer to «Lubrication system components, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

25 - Guide piece

1. With seal
2. Always replace

26 - 10 Nm

1. Self-locking
2. Always replace

27 - Top baffle plate

28 - 45 Nm

29 - M7 = 16 Nm, M8 = 22 Nm

30 - Oil pan (upper part)

1. Removing and installing. Refer to «Oil pan (upper part), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn)

Oil injector jet for piston cooling

1 - Bolt, 10 Nm

2 - Oil injector jet for piston cooling

Oil pan (lower part), removing and installing

Required equipment

1. Catch reservoir
2. Drill with plastic brush attachment
3. Protective glasses
4. Silicone sealant

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.

1. Remove bolts or quick-release screws -1- and -2- and remove front noise insulation.
2. Place engine oil drip tray beneath engine.
3. Drain engine oil.

Vehicles with automatic transmission

1. Remove bracket for ATF lines, to do so remove nuts -1- and -2-.

Note. Union nuts -3- of ATF lines must not be disconnected.

All

1. Unbolt bracket for refrigerant line at oil pan (arrows).

Note. Depicted in illustration for a vehicle with manual transmission.

Scheme 244

1. Disconnect electrical harness connector at Oil level thermal sensor (arrow) and move wiring clear.
2. Place engine oil drip tray beneath engine, since oil will escape again.

Scheme 245

1. Unbolt oil pan (lower part) -1- and carefully remove.

Scheme 246

1. Using rotating plastic brush, remove any remaining sealant from oil pan (lower part) and at upper part.

1. Clean sealing surfaces so they are completely free of any oil or grease.

Installation is reverse of removal, noting the following

Note. Replace gaskets and O-rings.

1. Cut tube nozzle at front marking (jet diameter approx. 1 mm).

Scheme 247

1. Apply silicon sealant bead to clean sealing surfaces of oil pan (lower part) as shown in illustration.

1. Thickness of sealant bead (arrow): approx. 1.5 mm

Note. The oil pan (lower part) must be installed within 5 minutes after application of silicon sealant. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.

1. Install oil pan (lower part) and pre-tighten all bolts diagonally to 5 Nm.
2. Tighten bolts of oil pan (lower part) in diagonal pattern to 10 Nm.
3. Add engine oil and check oil level.

Oil pump, removing and installing

Special tools and equipment

1. T10055 Extractor

1. T40026 Locking pin
2. Drill bit, 3 mm diameter
3. Sealants

1. Locking fluid

Removing

1. Remove oil pan (lower part). Refer to «Removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
2. Turn crankshaft via center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 3 marking.

1. Notch -1- lines up with marking -2

1. If installed, disconnect electrical harness connector at after-run coolant pump.
2. Unscrew sealing plug of TDC mark at cylinder block.

1. Thread T40026 locking pin into hole of removed sealing plug and tighten.

Note. To do so, turn crankshaft back and forth slightly.

Scheme 248

1. Unscrew bolts -3- and -6- and remove oil lines.

Note. Oil escapes from oil tubes when removing.

1. Unscrew bolts -1-, -2-, -4- and -5- and remove front baffle plate.

Scheme 249

1. Remove bolt -4- and remove gear -3- for differential gear shaft drive.
2. Remove diamond disc from toothed gear.
3. Remove bolts -1- and -2- and nuts -5- and -6-.

Scheme 250

1. Install T10055 extractor into M8 holes alternating (arrows) at oil pan and pull oil pump off of cylinder block.

Installing

Installation is reverse of removal, noting the following

Note. Always replace seals and gaskets.

Scheme 251

1. Clean threads of studs 3 of remaining locking fluid.
2. Replace O-ring (arrow -1-).
3. Coat circumference of hole (arrow -2-) with sealant.

1. Replace bolts -1- and -2- and nuts -5- and -6- for oil pump threaded connection.
2. Insert nuts -5- and -6- with locking fluid.
3. Bolt in oil pump uniformly at all mounting points, so that shear pin does not cant.
4. Tighten threaded connection to final torque.

1. Replace diamond disc on toothed gear -3- for differential gear shaft drive.
2. Insert collar of toothed gear for differential gear shaft drive through chain sprocket onto oil pump shaft.
3. Loosely thread in bolt -4-.

Note. To install toothed gear, press piston of chain tensioner back using a screwdriver (arrow).

Scheme 252

1. Turn differential shaft -2-, until a pin diameter 5 mm item -3- (e.g. drill bit) can be slid into alignment hole.
2. Tighten bolt -1-.
3. Remove pin (drill bit) from alignment hole.
4. Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O-ring into cylinder block.

1. Install front baffle plate -bolts -1-, -2-, -4- and -5-.
2. Install oil tubes -bolts -3- and -6-.
3. Install oil pan (lower part). Refer to «Oil pan (lower part), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__oil-pan-lower-part-removing-and) .

Tightening torques