3.2l v6 4v Engine Mechanical, Engine Code(s): Bkh Audi A4 B7

Engine number and engine data

Engine number

Scheme 357

1. Remove front engine cover - arrows -.

Scheme 358

1. The engine number ( "engine code" and "serial number" ) is located at front on cylinder block, below right cylinder head - arrow 1 -.
2. Additionally, a sticker - arrow 2 - is affixed to front coolant line with "engine code" and "serial number".
3. The engine code is also located on the vehicle data plate.

Engine data

Safety precautions

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

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

Rules of cleanliness for performing work on fuel injection system

Even minor contaminations can lead to malfunctions in the fuel injection system. Therefore when working on the fuel supply/injection system, pay careful attention to the following rules of cleanliness

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

1. When system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
2. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention!

The fuel injection system is separated into a high-pressure section (max. approx. 110 bar) and a low-pressure section (approx. 6 bar).

Before opening the high-pressure section - e.g. removing the high-pressure pump, fuel rail, fuel injectors, the motor for intake manifold runner control valve or any other component or fuel line that is located in the high-pressure section of the fuel injection system - the fuel pressure in the high-pressure section must be relieved to a residual pressure of approx. 8 bar. The procedure for this is as follows.

1. Start engine and run at idle speed.

Scheme 359

1. Connect Vehicle Diagnosis, Testing and Information System VAS 5051 with diagnostic cable VAS 5051/5 A.

Scheme 360

Display on VAS 5051

1. In selection - 1 - , press "On Board Diagnostic (OBD)" system and activate by pressing --> button.

Scheme 361

Display on VAS 5051

1. In selection - 1 - , press "01 - Engine electronics" vehicle system and activate by pressing --> button.

Scheme 362

Display on VAS 5051

1. In selection - 1 - , press diagnostic function "006 - Basic setting" and activate by pressing --> button.

Scheme 363

Display on VAS 5051

1. In button field - 1 - , press buttons 1 4 0 for "Display group 140" and confirm entry by pressing Q button.

Scheme 364

Display on VAS 5051

Example

1. 42%
2. 39.76 bar
3. 40.63 bar
4. Inactive

Scheme 365

1. Activate basic setting by pressing button A.

Display on VAS 5051

Example

1. 0%
2. 0 bar
3. 5.46 bar
4. Lower

The fuel rail will continue to be filled with fuel, but it will no longer be under high pressure.

Now components or lines can be opened. A clean rag must be placed around connection points. Escaping fuel must be absorbed.

1. In operating mode "Guided Fault Finding" , generate readiness code for engine control module (ECM).

Contact corrosion!

Contact corrosion can occur if appropriate connecting elements (bolts, nuts, washers, etc.) are not used.

For this reason, only install connecting elements that are treated with a special coating.

Also, rubber or plastic parts and adhesive consist of non-conductive materials.

Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. Audi accessories are recommended. Damage due to contact corrosion is not covered by warranty.

Scheme 366

Special tools, testers and auxiliary items required

1. Pry lever 80-200
2. Hose Clamps Up to 25 mm dia. 3094
3. Drip tray for workshop crane VAS 6208 or V.A.G 1306
4. Hose clamp pliers V.A.G 1921

1. Step ladder VAS 5085
2. Scissor Lift Table VAS 6131 with Support Set VAS 6131/10 and VAS 6131/11

Note. If engine and transmission are to be separated after removal, the Supplementary Set Audi A6 (C6) VAS 6131/12 will also be required.

Work procedure

Note. With lock carrier installed, engine is removed downward with transmission and subframe. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. Drained coolant must be stored in a clean container for disposal or reuse.

1. Discharge refrigerant circuit Refrigerant R134a - Servicing.

Scheme 367

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

Scheme 368

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

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

Scheme 369

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

Scheme 370

1. Loosen quick-release fasteners - 1 through 3 - and remove front and rear noise insulation.
2. Place drip tray for workshop crane VAS 6208 under engine.

Scheme 371

1. Disconnect coolant hose - arrow - from oil cooler and drain coolant.

Scheme 372

1. Disconnect lower right coolant hose from radiator - arrow - and drain residual coolant.

Scheme 373

1. Remove bolts - arrows - at torque support stop.

Scheme 374

1. Remove bolts - arrows - for torque support.

Note. The torque support and torque support stop will later be removed.

Scheme 375

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

Scheme 376

1. Disconnect brake booster vacuum hose from grommet - arrow - on bulkhead.

Scheme 377

1. Remove Ground (GND) strap - arrow - at bulkhead.

Scheme 378

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

Scheme 379

1. Remove coolant hose - arrow - from front coolant line.

Scheme 380

1. Remove left front coolant hose in engine compartment - arrows -.

Scheme 381

1. Remove coolant hose - arrow - from front coolant line.

Scheme 382

1. Disconnect vacuum hose - arrow - to leak detection pump.

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

Scheme 383

1. Remove hydraulic pressure line - 2 - at power steering pump and set it aside on top of longitudinal member.
2. Clamp off hydraulic hose - 1 - for power steering pump with a Hose Clamps Up to 25 mm dia. 3094.
3. Remove hydraulic hose from power steering pump.

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

Scheme 384

1. Remove bolts - arrows -.

Note. The refrigerant lines will be removed from air conditioning compressor at a later point in time.

Scheme 385

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

Scheme 386

1. Separate fuel line - arrow - and lay aside.

Scheme 387

1. Disconnect check valve - 1 - from connection at air duct hose.
2. Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

Scheme 388

1. Remove pin from spreader clips - arrow -.
2. Remove air filter housing.

Scheme 389

1. Remove vacuum hose - arrow - to EVAP canister at Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.

Scheme 390

1. Remove coolant hose - arrow - to heater core on rear of engine.

Scheme 391

1. Remove nuts and remove left bracket for harness connectors - 1 - and - 2 - from bulkhead.

Scheme 392

1. Remove rubber seal - 2 - for plenum chamber cover.
2. Remove plenum chamber cover - 1 -.

Scheme 393

1. Remove nut - 1 - and remove fuse strip on plus wire terminal clamp.
2. Disconnect positive wire - 2 - on battery positive terminal.
3. Pull positive wire through bulkhead toward front.
4. Free up wiring harness lay it aside on engine.

Note. Ignore - 3 -.

Scheme 394

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

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

Scheme 395

1. Remove cover for E-Box in plenum chamber - arrows -.

Scheme 396

1. Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from E-Box.

Note. Engine Control Module (ECM) remains connected at wiring harness.

Scheme 397

1. Release retaining hooks - arrows - toward outside and remove retaining bracket.

Scheme 398

1. Disconnect all electrical harness connectors on connector station - 2 -.
2. Remove electrical wire connection - 1 -.

Scheme 399

1. Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
2. Disengage engine wiring harness at E-Box and bulkhead.
3. Set wiring harness on engine and secure Engine Control Module (ECM) against falling down.
4. Have a second technician press brake pedal.

Scheme 400

1. Remove collar bolt - 2 - at left and right drive axles - 1 -.

Scheme 401

1. Remove heat shield - 1 - for left and right drive axles.
2. Remove left and right drive axles from flange shafts of transmission.

Note. The drive axles will be removed at a later time.

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

Scheme 402

1. Remove bracket for refrigerant lines at right on oil pan - arrow -.
2. Remove refrigerant lines at A/C compressor.
3. Tie up refrigerant line, that runs to catch reservoir at right of vehicle, to body.
4. Seal open connections on A/C compressor using clean plugs.

Scheme 403

1. Remove bolts and nuts - arrows - uniformly at left and right.
2. Remove stabilizer.

Scheme 404

1. If equipped, disconnect electrical harness connector at Left Front Level Control System Sensor G78.
2. Unclip actuator rod for Left Front Level Control System Sensor G78 at bottom on link - arrow -.

Scheme 405

1. Remove suspension strut from link - arrow -.

Scheme 406

1. Remove nuts - 1 - and - 2 - for fastening link and guide link.

Note. The bolts will be removed from the subframe at a later point in time.

1. Repeat procedure on opposite side of vehicle.

Scheme 407

1. Loosen clamping sleeves - arrows -.

Scheme 408

1. Remove heat shield - A - for drive shaft - arrows -.
2. Remove bolts at transmission/drive shaft flange.
3. Push drive shaft together with rear final drive. The constant velocity (CV) joints can move axially.
4. Lay aside drive shaft on exhaust system.

Scheme 409

Prepare scissor lift platform

1. Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 and VAS 6131/11 as follows

1. Install attachments on scissor lift table by hand first.
2. Place scissor lift platform VAS 6131 in horizontal position.

1. Note bubble level (sight glass) on support platform.

1. Drive scissor lift platform VAS 6131 under engine/transmission subassembly.

Scheme 410

1. Position support elements from VAS 6131/10 at front on engine as shown in illustration.
2. Make sure that the threaded spindles are completely installed.

Scheme 411

1. Position support elements from VAS 6131/10 at left and right on subframe as shown in illustration.

Scheme 412

1. Position support elements from VAS 6131/10 and VAS 6131/11 at left and right on tunnel cross member as shown in illustration.
2. Twist all spindles of support elements upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

Scheme 413

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

Scheme 414

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

Scheme 415

1. Mark installation position of subframe and of both engine mount plates to long members using a felt-tip marker.
2. Remove bolts - 1 to 4 - in diagonal sequence and in stages.
3. Remove left and right engine mount plate.

Note. Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected. While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.

Scheme 416

1. First lower engine/transmission assembly using scissor lift platform VAS 6131 only approx. by dimension - a -.

1. Dimension - a - = 80 mm.

1. Remove bolts at guide link - 1 - and at link - 2 - from subframe.

Scheme 417

1. Pivot guide link - 1 - and link - 2 - outward.

1. Pivot wheel bearing housing outward and remove drive axle.
2. Repeat work procedure on opposite side of the vehicle.

Scheme 418

1. Disconnect connecting rod - 2 - of shift rod.
2. Remove socket head bolt of pivot rod - 1 -.

Scheme 419

1. Remove nut - arrow - and remove lever from selector shaft.

Scheme 420

1. Remove clutch slave cylinder - arrow - , do not disconnect lines.
2. Tie up clutch slave cylinder together with shift rods.
3. Push scissor lift platform VAS 6131 approx. 20 mm back and remove torque support and torque support stop.
4. Push scissor lift platform VAS 6131 back into removal position and lower scissor lift platform VAS 6131 completely.

1. Push scissor lift platform VAS 6131 with engine/transmission subassembly under vehicle.

Engine and manual transmission, separating

Special tools, testers and auxiliary items required

1. Support set for Audi VAS 6131/10 , VAS 6131/11 and VAS 6131/12

Work procedure

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Engine/transmission assembly removed and placed on Scissor Lift Table VAS 6131.

1. Twist spindles of support elements at left and right at subframe completely downward.
2. Remove support pins from spindles.
3. Remove subframe to side.
4. Remove both base plates of subframe support elements on scissor lift table VAS 6131.

Note. The support points for front of engine and tunnel cross member remain unchanged.

1. Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 , VAS 6131/11 and VAS 6131/12 as follows

Scheme 421

1. Position support elements from VAS 6131/10 and VAS 6131/12 at left on engine as shown in illustration.

Scheme 422

1. Position support elements from VAS 6131/10 and VAS 6131/11 at right on engine as shown in illustration.
2. Twist spindles of attachments upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

1. Disconnect electrical harness connector - 1 - for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 and free up wire.

Note. In the illustration, the electrical harness connector is depicted as installed. Ignore - 2 -.

Scheme 423

1. Remove nut - 2 - at left bracket for front exhaust pipe.

Note. Ignore - 1 -.

Scheme 424

1. Remove nuts - 1 to 3 -.
2. Remove left front exhaust pipe with catalytic converter.

Scheme 425

1. Disconnect electrical harness connector - 2 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and free up wire.

Note. In the illustration, the electrical harness connector is depicted as installed. Ignore - 1 -.

Scheme 426

1. Disconnect electrical harness connector - arrow - for Back-Up Light Switch F4 and free up electrical wire.

1. Disconnect electrical harness connector - 2 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and free up wire.

Note. In the illustration, the electrical harness connector is depicted as installed. Ignore - 1 -.

Scheme 427

1. Remove nut - 2 - at right bracket for front exhaust pipe.

Note. Ignore - 1 -.

Scheme 428

1. Remove nuts - 1 to 3 -.
2. Remove right front exhaust pipe with catalytic converter.

Scheme 429

1. Disconnect electrical connector - arrow - on Engine Speed (RPM) Sensor G28.

Scheme 430

1. Remove engine/transmission threaded connections - 1 to 10 -.

Scheme 431

1. Loosen clamping bolts - 1 - on side of scissor lift table VAS 6131 and pull rear table section with transmission rearward - arrow -.

Scheme 432

Special tools, testers and auxiliary items required

1. Lifting tackle 2024 A
2. Engine and transmission holder VAS 6095 with bracket VAS 6095/1-5
3. Shop crane VAS 6100
4. Lift arm extension for workshop crane VAS 6101

Work procedure

1. Engine separated from transmission.

Scheme 433

1. Hook engine sling 2024 A onto engine and onto workshop crane VAS 6100 with lift arm extension for workshop crane VAS 6101 as shown in the illustration.

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

Scheme 434

1. Remove bolts - arrows - and remove left and right engine support.

Note. Ignore - 1 -.

Scheme 435

1. Secure engine on Engine and Transmission Holder VAS 6095 with bracket for V6 FSI engine VAS 6095/1-5 as shown in illustration.

Engine, installing

Note. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location.

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

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

1. Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
2. If necessary, check centering of clutch drive plate.
3. Check clutch release bearing for wear and replace if necessary.
4. Check clutch release bearing for wear and loose plastic ring --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

1. Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
2. Install intermediate plate between engine and transmission onto alignment bushings.
3. Bolt transmission to engine.

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

Engine/transmission, fastening

Further installation is in reverse order of removal, note the following.

1. Install front exhaust pipes: Left --> «Left front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-front-exhaust-pipe-with-catalytic) ; right --> «Right front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-front-exhaust-pipe-with-catalytic) .
2. Always clean threaded drive shaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.

1. Rotate attachment spindles at left of engine/transmission assembly downward.
2. Remove both base plates for left support element on scissor lift platform VAS 6131.

1. Rotate attachment spindles at right of engine/transmission assembly downward.
2. Remove both base plates for right support element on Scissor Lift Table VAS 6131.

Note. The support points for front of engine and tunnel cross member remain unchanged.

1. Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 and VAS 6131/11 as follows

1. Position subframe on both Attachments VAS 6131/10-8.
2. Twist spindles of support elements upward on both sides.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

1. Carefully guide engine/transmission assembly from below into body using Scissor Lift Table VAS 6131 far enough so distance between subframe and body is dimension - a -.

1. Dimension - a - = 80 mm.

1. Place torque support with torque support stop between lock carrier and engine.

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

1. Install lever for selector shaft - arrow -.

1. Install connecting rod - 2 - of shift rod.
2. Install socket head bolt of pivot rod - 1 -.

1. Loosely bolt guide link - 1 - and link - 2 - to subframe.

Note. Bolts must first be tightened once the vehicle is sitting on its wheels on the floor.

1. Align subframe, engine bearing plates and tunnel cross member according to markings applied on long members during removal.
2. Tighten bolts for subframe, engine mount plates as well as tunnel cross member only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

1. 65 Nm
2. 110 Nm
3. 110 Nm
4. 75 Nm

Further installation is in reverse order of removal, note the following

1. Vehicles with all wheel drive: Install drive shaft --> 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING 39 FINAL DRIVE, DIFFERENTIAL for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 39 FINAL DRIVE, DIFFERENTIAL for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «39F - FRONT FINAL DRIVE, DIFFERENTIAL»(ref-278905-S08726399372008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «39 FINAL DRIVE, DIFFERENTIAL»(ref-278904-S16737983372008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
2. Align exhaust system free of tension --> «Exhaust system, installing free of tension»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__exhaust-system-installing-free-of-tension) .
3. Install refrigerant lines --> «87 AIR CONDITIONING»(/audi/a4/b7-2004-2009/remont/ac-compressor/#heating-air-conditioning) .
4. Install drive shafts --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Install guide link, stabilizer bar and suspension strut --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Tighten bolts - arrows - for torque support.

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

1. Mount wiper arms and adjust --> «92 WINDSHIELD WIPER WASHER SYSTEM»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .
2. Check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .
3. Bleed fuel system --> «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
4. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

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

1. Fill power-steering system oil and bleed steering system --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Align subframe and both engine mount plates --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Perform axle alignment --> «44 - WHEELS, TIRES, VEHICLE ALIGNMENT»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Fill refrigerant circuit Refrigerant R134a - Servicing.

Torque specifications

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

Engine, removing

Special tools, testers and auxiliary items required

1. Pry lever 80-200
2. Hose Clamps Up to 25 mm dia. 3094
3. Drip tray for workshop crane VAS 6208 or V.A.G 1306
4. Hose clamp pliers V.A.G 1921

1. Step ladder VAS 5085
2. Scissor lift table VAS 6131 with support set VAS 6131/10 and adapters VAS 6131/10-12

Special tools, testers and auxiliary items required

Scheme 436

1. Old oil collecting and extracting device V.A.G 1782

Note. If engine and transmission are to be separated after removal, the Supplementary Set Audi A8 (D3) VAS 6131/11 and VAS 6131/12 will also be required.

Work procedure

Note. With lock carrier installed, engine is removed downward with transmission and subframe. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. Drained coolant must be stored in a clean container for disposal or reuse.

1. Shift selector lever to position "N".
2. Discharge refrigerant circuit Refrigerant R134a - Servicing.

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

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

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

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

1. Loosen quick-release fasteners - 1 through 3 - and remove front and rear noise insulation.
2. Place drip tray for workshop crane VAS 6208 under engine.

1. Disconnect coolant hose - arrow - from oil cooler and drain coolant.

1. Disconnect lower right coolant hose from radiator - arrow - and drain residual coolant.

1. Remove bolts - arrows - at torque support stop.

1. Remove bolts - arrows - for torque support.

Note. The torque support and torque support stop will later be removed.

Scheme 437

Note. Observe the rules of cleanliness for working on automatic transmissions --> 00 - GENERAL, TECHNICAL DATA for 5 SPD. AUTOMATIC TRANSMISSION 01V 00 - GENERAL, TECHNICAL DATA for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING 00 TECHNICAL DATA for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Loosen union nuts - 3 - and disconnect ATF lines.

Note. Ignore - 1 - and - 2 -.

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

1. Disconnect brake booster vacuum hose from grommet - arrow - on bulkhead.

1. Remove Ground (GND) strap - arrow - at bulkhead.

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

1. Remove coolant hose - arrow - from front coolant line.

1. Remove left front coolant hose in engine compartment - arrows -.

1. Remove coolant hose - arrow - from front coolant line.

1. Disconnect vacuum hose - arrow - to leak detection pump.

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

1. Remove hydraulic pressure line - 2 - at power steering pump and set it aside on top of longitudinal member.
2. Clamp off hydraulic hose - 1 - for power steering pump with a Hose Clamps Up to 25 mm dia. 3094.
3. Remove hydraulic hose from power steering pump.

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

1. Remove bolts - arrows -.

Note. The refrigerant lines will be removed from air conditioning compressor at a later time.

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

Scheme 438

1. Disconnect vacuum hose - 1 - at vacuum pump.
2. Remove bolts - arrows - and remove vacuum pump.

1. Separate fuel line - arrow - and lay aside.

1. Disconnect check valve - 1 - from connection at air duct hose.
2. Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

1. Remove pin from spreader clips - arrow -.
2. Remove air filter housing.

1. Remove vacuum hose - arrow - to EVAP canister at Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.

1. Remove coolant hose - arrow - to heater core on rear of engine.

1. Remove nuts and remove left bracket for harness connectors - 1 - and - 2 - from bulkhead.

1. Remove nuts and remove right bracket for harness connectors - 1 - and - 2 - from bulkhead.

1. Remove rubber seal - 2 - for plenum chamber cover.
2. Remove plenum chamber cover - 1 -.

1. Remove nut - 1 - and remove fuse strip on plus wire terminal clamp.
2. Disconnect plus wire - 2 - on battery positive terminal.
3. Pull plus wire through bulkhead toward front.
4. Free up wiring harness lay it aside on engine.

Note. Ignore - 3 -.

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

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

1. Remove cover for E-Box in plenum chamber - arrows -.

1. Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from E-Box.

Note. Engine Control Module (ECM) remains connected at wiring harness.

1. Release retaining hooks - arrows - toward outside and remove retaining bracket.

1. Disconnect all electrical connectors on connector station - 2 -.
2. Remove electrical wire connection - 1 -.

1. Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
2. Disengage engine wiring harness at E-Box and bulkhead.
3. Set wiring harness on engine and secure Engine Control Module (ECM) against falling down.
4. Have a second technician press brake pedal.

1. Remove collar bolt - 2 - at left and right drive axles - 1 -.

1. Remove heat shield - 1 - for left and right drive axles.
2. Remove left and right drive axles from flange shafts of transmission.

Note. The drive axles will be removed at a later time.

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

1. Remove bracket for refrigerant lines at right on oil pan - arrow -.
2. Remove refrigerant lines at A/C compressor.
3. Tie up refrigerant line, that runs to catch reservoir at right of vehicle, to body.
4. Seal open connections on A/C compressor using clean plugs.

1. Remove bolts and nuts - arrows - uniformly at left and right.
2. Remove stabilizer.

1. If equipped, disconnect electrical harness connector at Left Front Level Control System Sensor G78.
2. Unclip actuator rod for Left Front Level Control System Sensor G78 at bottom on link - arrow -.

1. Remove suspension strut from link - arrow -.

1. Remove nuts - 1 - and - 2 - for fastening link and guide link.

Note. The bolts will be removed from the subframe at a later point in time.

1. Repeat procedure on opposite side of the vehicle.

1. Loosen clamping sleeves - arrows -.

Vehicles with all wheel drive

1. Remove heat shield - A - for drive shaft - arrows -.
2. Remove bolts at transmission/drive shaft flange.
3. Push drive shaft together with rear final drive. The constant velocity (CV) joints can move axially.
4. Lay aside drive shaft on exhaust system.

Prepare scissor lift platform

1. Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 as follows

1. Install attachments on scissor lift table by hand first.
2. Place scissor lift platform VAS 6131 in horizontal position.

1. Note bubble level (sight glass) on support platform.

1. Drive scissor lift platform VAS 6131 under engine/transmission subassembly.

1. Position support elements from VAS 6131/10 at front on engine as shown in illustration.
2. Make sure that the threaded spindles are completely installed.

1. Position support elements from VAS 6131/10 at left and right on subframe as shown in illustration.

Scheme 439

1. Position support elements from VAS 6131/10 at rear on transmission as shown in illustration.
2. Twist all spindles of support elements upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

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

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

Scheme 440

1. Remove bolts - 1 -.
2. Mark installation position of subframe and of both engine mount plates to long members using a felt-tip marker.
3. Remove bolts - 2 - , - 3 - and - 4 - in diagonal sequence and in stages.
4. Remove left and right engine mount plate.

Note. Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected. While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.

1. First lower engine/transmission assembly using scissor lift platform VAS 6131 only approx. by dimension - a -.

1. Dimension - a - = 80 mm.

1. Remove bolts at guide link - 1 - and at link - 2 - from subframe.

1. Pivot guide link - 1 - and link - 2 - outward.

1. Pivot wheel bearing housing outward and remove drive axle.
2. Repeat work procedure on opposite side of vehicle.

Note. Mark the installation position of bracket for selector lever cable using a felt-tip marker.

Scheme 441

1. Press ball socket - 1 - of selector lever cable from selector shaft lever.
2. Remove bracket on transmission - arrows -.
3. Move selector lever cable clear.

Note. Do not bend or kink selector lever cable. To improve clarity, the transmission supports are shown removed in the illustration.

1. Push scissor lift platform VAS 6131 approx. 20 mm back and remove torque support and torque support stop.
2. Push scissor lift platform VAS 6131 back into removal position and lower scissor lift platform VAS 6131 completely.
3. Push scissor lift platform VAS 6131 with engine/transmission subassembly under vehicle.

Engine and automatic transmission 09L, separating

Special tools, testers and auxiliary items required

1. Support set for Audi VAS 6131/10 , VAS 6131/11 and VAS 6131/12

Scheme 442

1. Adapter T40058

Work procedure

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Engine/transmission assembly removed and placed on Scissor Lift Table VAS 6131.

Scheme 443

1. Remove bolts - arrows - for left and right transmission mount.

1. Twist spindles of support elements at left and right at subframe completely downward.
2. Remove support pins from spindles.
3. Remove subframe to side.
4. Remove both base plates of subframe support elements on scissor lift table VAS 6131.

Note. The support points for front of engine and rear of transmission remain unchanged.

1. Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 , VAS 6131/11 and VAS 6131/12 as follows

Scheme 444

1. Position support elements from VAS 6131/10 and VAS 6131/12 at left on engine as shown in illustration.

Scheme 445

1. Position support elements from VAS 6131/10 and VAS 6131/11 at right on engine as shown in illustration.
2. Twist spindles of attachments upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

1. Disconnect electrical harness connector - 1 - for Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131 and free up wire.

Note. In the illustration, the electrical harness connector is depicted as installed. Ignore - 2 -.

Scheme 446

1. Remove bolt - 1 - at left bracket for front exhaust pipe.

Note. Ignore - 2 -.

1. Remove nuts - 1 to 3 -.
2. Remove left front exhaust pipe with catalytic converter.

1. Disconnect electrical harness connector - 2 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and free up wire.

Note. In the illustration, the electrical harness connector is depicted as installed. Ignore - 1 -.

Scheme 447

1. Remove bolt - 1 - at right bracket for front exhaust pipe.

Note. Ignore - 2 -.

1. Remove nuts - 1 to 3 -.
2. Remove right front exhaust pipe with catalytic converter.

Note. Observe the rules of cleanliness for working on automatic transmissions --> 00 - GENERAL, TECHNICAL DATA for 5 SPD. AUTOMATIC TRANSMISSION 01V 00 - GENERAL, TECHNICAL DATA for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING 00 TECHNICAL DATA for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .

Scheme 448

1. Remove bracket - arrow - for ATF lines on oil pan.

Scheme 449

1. Remove bracket - arrow - for ATF lines at bottom on transmission.

Note. Place a rag under the ATF lines to catch escaping ATF.

Scheme 450

1. Remove bolt - arrow -.
2. Disconnect ATF lines from transmission.

1. Disconnect electrical connector - arrow - on Engine Speed (RPM) Sensor G28.

Scheme 451

1. Disconnect electrical harness connector on transmission, to do this swing twist lock counterclockwise - arrow -.

Scheme 452

1. Disconnect electrical harness connector - 1 - at right engine mount.
2. Remove bolts - arrows - and remove right engine mount.

Scheme 453

1. Disconnect electrical wires - 2 - and - 3 - on starter.
2. Remove bolts - 1 - and - 4 - and remove starter.

Scheme 454

1. Insert guide pin of adapter T40058 so that large diameter - arrow 1 - points to engine. Small diameter - arrow 2 - points to adapter.

Scheme 455

1. To loosen torque converter bolts, counter hold crankshaft using adapter T40058.

Note. Disregard - arrow -.

Scheme 456

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

1. Remove engine/transmission threaded connections - 3 to 10 -.

1. Loosen side clamping screws - 1 - on scissor lift platform VAS 6131 and pull rear platform top with transmission toward rear - arrow - , simultaneously push torque converter through opening of drive plate.
2. Secure torque converter in transmission to prevent it from falling out.

Engine, securing to assembly stand

Special tools, testers and auxiliary items required

1. Lifting tackle 2024 A
2. Engine and transmission holder VAS 6095 with bracket VAS 6095/1-5
3. Shop crane VAS 6100
4. Lift arm extension for workshop crane VAS 6101

Work procedure

1. Engine separated from transmission.

1. Hook engine sling 2024 A onto engine and onto workshop crane VAS 6100 with lift arm extension for workshop crane VAS 6101 as shown in the illustration.

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

1. Disconnect electrical harness connector - 1 - at left engine mount.
2. Remove bolts - arrows - and remove left engine mount.

1. Secure engine on Engine and Transmission Holder VAS 6095 with bracket for V6 FSI engine VAS 6095/1-5 as shown in illustration.

Special tools, testers and auxiliary items required

1. Depth gauge

Work procedure

Note. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location.

Scheme 457

Installation dimension for torque converter, checking

When torque converter is installed correctly, distance between contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 09L is approx. 19 mm.

1. Before connecting engine and transmission, rotate torque converter and engine drive plate so that one hole or one threaded hole stands at height of opening of removed starter - arrow -.
2. To secure torque converter to drive plate, use new original ribbed bolts .
3. Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
4. Install intermediate plate between engine and transmission onto alignment bushings.

1. Bolt transmission to engine.

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

Engine/transmission, fastening

1. Fasten ATF lines --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
2. Install front exhaust pipes: Left --> «Left front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-front-exhaust-pipe-with-catalytic) ; right --> «Right front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-front-exhaust-pipe-with-catalytic) .
3. Vehicles with all wheel drive: Always clean threaded drive shaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.
4. Rotate attachment spindles at left of engine/transmission assembly downward.

1. Remove base plate for left support element on scissor lift platform VAS 6131.

1. Rotate attachment spindles at right of engine/transmission assembly downward.
2. Turn spindle of right support element on engine downward.
3. Remove base plate for right support element on scissor lift platform VAS 6131.

Note. The support points for front of engine and rear of transmission remain unchanged.

1. Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 as follows

1. Position subframe on both attachments VAS 6131/10-8.
2. Twist spindles of support elements upward on both sides.

1. Fasten transmission mount to subframe - arrows -.

1. Carefully guide engine/transmission assembly from below into body using Scissor Lift Table VAS 6131 far enough so distance between subframe and body is dimension - a -.

1. Dimension - a - = 80 mm.

1. Place torque support with torque support stop between lock carrier and engine.

1. Press ball socket - 1 - of selector lever cable onto selector shaft lever.
2. Install mounting bracket according to marking on transmission - arrows -.
3. Insert drive axles into spines of left and right wheel bearing housings.

1. Loosely bolt guide link - 1 - and link - 2 - to subframe.

Note. Bolts must first be tightened once the vehicle is sitting on its wheels on the floor.

1. Align subframe according to markings on longitudinal members made during removal.
2. Tighten bolts for subframe and engine mount plates only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

1. 65 Nm
2. 110 Nm
3. 110 Nm
4. 75 Nm

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

1. Install drive shaft --> 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING 39 FINAL DRIVE, DIFFERENTIAL for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 39 FINAL DRIVE, DIFFERENTIAL for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «39F - FRONT FINAL DRIVE, DIFFERENTIAL»(ref-278905-S08726399372008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «39 FINAL DRIVE, DIFFERENTIAL»(ref-278904-S16737983372008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
2. Align exhaust system free of tension --> «Exhaust system, installing free of tension»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__exhaust-system-installing-free-of-tension) .
3. Install refrigerant lines --> «87 AIR CONDITIONING»(/audi/a4/b7-2004-2009/remont/ac-compressor/#heating-air-conditioning) .
4. Install vacuum pump for brake booster --> «Vacuum pump for brake booster, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__vacuum-pump-for-brake-booster-removing) .

1. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install guide link, stabilizer bar and suspension strut --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Tighten bolts - arrows - for torque support.

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

1. Mount wiper arms and adjust --> «92 WINDSHIELD WIPER WASHER SYSTEM»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) .
2. Check selector lever cable adjustment --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
3. Check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .
4. Bleed fuel system --> «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) .

1. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

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

1. Fill power steering system oil and bleed steering system --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Check ATF level --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
3. Align subframe and both engine mount plates --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
4. Perform axle alignment --> «44 - WHEELS, TIRES, VEHICLE ALIGNMENT»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Fill refrigerant circuit Refrigerant R134a - Servicing.

Torque specifications

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

Scheme 458

1 - Ribbed belt

1. Check for wear
2. Before removing, mark direction of rotation using chalk or felt-tip marker. Reversing direction of rotation of a run-in belt can destroy belt
3. Removing and installing --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
4. When installing, make sure it is seated correctly on pulleys

2 - 30 Nm

3 - 22 Nm

4 - Generator

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

5 - Cap for idler pulley

6 - Idler roller for ribbed belt

1. Tighten to 40 Nm

7 - 20 Nm

8 - Ribbed belt pulley for coolant pump

9 - 9 Nm

10 - Coolant pump

1. Removing and installing --> «Coolant pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__coolant-pump-removing-and-installing)

11 - Cap for tensioning element

12 - Tensioning element for ribbed belt

1. Tighten to 40 Nm

13 - 20 Nm

14 - 20 Nm

15 - Bracket for power steering pump

16 - 20 Nm

17 - Power steering pump

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

18 - 20 Nm

19 - Belt pulley for power steering pump

1. Identification: "Vorne/Front"

20 - 20 Nm

21 - 25 Nm

22 - Air conditioner compressor

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

23 - Alignment bushing

1. 2 pieces

24 - Bracket for air conditioning compressor

25 - Vibration damper

1. With belt pulley for ribbed belt
2. Removing and installing --> «Vibration damper, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__vibration-damper-removing-and-installing)

Removing

1. Remove front engine cover - arrows -.

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

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

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation. Rear section of noise insulation remains installed.
2. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Bring lock carrier into service position --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

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

Scheme 459

1. Pivot tensioning device in direction of - arrow - to relieve tension on ribbed belt.
2. Remove ribbed belt and release tensioning device.

Installing

Installation is in reverse order of removal, note the following

Scheme 460

1. Place ribbed belt over belt pulley as shown in the illustration.
2. Generator
3. Idler roller
4. Coolant pump

1. Power steering pump
2. Air conditioner compressor
3. Tensioning device for ribbed belt
4. Crankshaft

Note. When installing the ribbed belt, make sure it is seated correctly on the pulleys.

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Start engine and check belt running.
3. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Vibration damper, removing and installing

Note. Different vibration dampers are allocated to the various engine versions .

1. Remove front engine cover - arrows -.

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

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

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation. Rear section of noise insulation remains installed.
2. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Bring lock carrier into service position --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

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

1. Pivot tensioning device in direction of - arrow - to relieve tension on ribbed belt.
2. Remove ribbed belt and release tensioning device.

Scheme 461

1. Mark vibration damper for re-installation.
2. Remove bolts - 1 -.
3. Remove vibration damper.

Installation is in reverse order of removal, note the following

1. Install ribbed belt «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__installing) .
2. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Torque specifications

Front sealing flange with crankshaft seal, removing and installing

Special tools, testers and auxiliary items required

Scheme 462

1. Pin wrench 3212

Scheme 463

1. Assembly tool T40048
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

1. Remove vibration damper --> «Vibration damper, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__vibration-damper-removing-and-installing) .
2. Remove ribbed belt pulley from coolant pump.

Scheme 464

1. When loosening bolts use spanner wrench 3212 to counter-hold.

Scheme 465

1. Remove bolts - arrows -.
2. Remove front sealing flange.

Installing

1. Remove sealant from sealing flange groove and from sealing surfaces.

Scheme 466

1. Using rotating plastic brush, remove any sealant residue from sealing flange, cylinder block and upper part of oil pan.
2. Clean sealing surfaces so they are completely free of any oil or grease.

Scheme 467

1. Cut tube nozzle at front marking (jet dia. approx. 2 mm).

Scheme 468

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

1. The groove - arrow - of sealing surface must be completely filled with sealant.
2. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.

Note. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer. The front sealing flange must be installed within 5 minutes of being applied with sealant.

Scheme 469

1. Insert assembly device T40048/1 onto pull sleeve T40048/2 and slide sealing flange - 1 - onto pull sleeve.
2. Remove assembly device.

Scheme 470

1. Place sealing flange - 1 - with inserted pull sleeve T40048/2 onto crankshaft.

1. Fasten bolts - arrows - in a diagonal sequence and in steps.

Further installation is in reverse order of removal, note the following

1. Install vibration damper «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Install ribbed belt «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__installing) .
3. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
4. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .

Torque specifications

Dual mass flywheel (vehicles with manual transmission), component overview

Note. Servicing clutch --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

Scheme 471

1 - Dual mass flywheel

1. Removing and installing --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual)

2 - Special bolt

1. Replace
2. Tightening torque «Torque specifications»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

3 - Needle bearing

1. Only on vehicles with manual transmission
2. Pulling out and driving in --> «Needle bearing on dual mass flywheel (vehicles with manual transmission), pulling out and driving in»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

4 - Sealing ring for crankshaft (timing chain side)

1. Replacing --> «Crankshaft seal, timing chain side, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__crankshaft-seal-timing-chain-side-replacing) .

5 - Crankshaft

Dual mass flywheel (vehicles with manual transmission), removing and installing

Special tools, testers and auxiliary items required

Scheme 472

1. Counter-holder tool 10-201

Removing

1. Remove transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
2. Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
3. Mark dual-mass flywheel to engine.

Scheme 473

1. Insert counter hold tool 10-201 to loosen bolts.

Scheme 474

Note. To prevent damage to dual-mass flywheel when removing, bolts - B - must not be removed using an air-powered or impact wrench. Only removing bolts by hand is permitted.

1. Rotate dual-mass flywheel - A - so that bolts stand centered to holes - arrows -.
2. When removing bolts, make sure that no bolt head makes contact on dual-mass flywheel because it will otherwise be damaged when further removing the bolt.

Installing

Installation is in reverse order of removal, note the following

Note. Needle bearing is located in the flywheel and must be driven in when flywheel is replaced --> Needle bearing on dual mass flywheel (vehicles with manual transmission), pulling out and driving in .

1. Use new bolts when securing.
2. Re-position counter hold tool 10-201 to tighten bolts.
3. Install clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
4. Install transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

Torque specifications

Scheme 475

Special tools, testers and auxiliary items required

1. Centering mandrel 3176
2. Bearing driver 3264
3. Depth gauge VAS 6082
4. 1 - Internal puller Kukko 21/2

1. 4 - Counter-support Kukko 22/1

Work procedure

1. Remove transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
2. Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

Scheme 476

1. Measure depth - dimension x - that the needle bearing is driven into dual-mass flywheel and note this for later re-installation.

Scheme 477

1. Pull out needle bearing using internal puller Kukko 21/2 and counter-support Kukko 22/1.

Note. The plastic ring in the dual-mass flywheel is affected by impacts. If plastic ring is damaged, the dual-mass flywheel must be replaced.

Scheme 478

1. Drive needle bearing into dual-mass flywheel using bearing driver 3264.

Scheme 479

1. Using backside of centering mandrel 3176 , press needle bearing further in until previously measured depth is achieved.

1. Afterwards, verify depth - dimension x - that the needle bearing is driven into dual-mass flywheel.
2. Install clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
3. Install transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

Drive plate (vehicles with automatic transmission), removing and installing

Special tools, testers and auxiliary items required

1. Counter-holder tool 10-201

Removing

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

Scheme 480

1. Insert counter hold tool 10-201 to loosen bolts.
2. Mark drive plate to engine.
3. Remove drive plate.
4. Remove centering washer from behind it.

Installing

Installation is in reverse order of removal, note the following

Scheme 481

1. Install drive plate with centering washer - arrow - and backing plate.
2. Use new bolts when securing.
3. Turn over counter hold tool 10-201 to tighten bolts.
4. Install automatic transmission --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .

Torque specifications

Crankshaft seal, timing chain side, replacing

Special tools, testers and auxiliary items required

Scheme 482

1. Pulling fixture T10122

Scheme 483

1. Extractor lever T20143/2

Work procedure

1. Remove transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
2. Vehicles with manual transmission: Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE and dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) .
3. Vehicles with automatic transmission: Remove drive plate --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) .

Scheme 484

1. Pry out sealing ring using extractor lever T20143/2.
2. Clean operating and sealing surfaces.

Scheme 485

1. Insert assembly device T10122/1 onto pull sleeve T10122/2 and slide seal - A - onto pull sleeve.
2. Remove assembly device T10122/1.

Scheme 486

1. Install pull sleeve T10122/2 with sealing ring - 1 - onto crankshaft.

Scheme 487

1. Press in sealing ring all around evenly and flush using pressure sleeve T10122/3.

Further installation is in reverse order of removal, note the following

1. Vehicles with manual transmission: Install dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) and clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
2. Vehicles with automatic transmission: Install drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .
3. Install transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .

Scheme 488

1 - M6, 9 Nm; M8, 20 Nm

1. Observe sequence for tightening: Vehicles through 04.2005 Set lower timing chain cover in place, guiding cover at an angle from below onto sealing surface of cylinder block and cylinder head. under «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and) , vehicles from 05.2005

2 - Sealing ring for crankshaft (timing chain side)

1. Replacing --> «Crankshaft seal, timing chain side, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__crankshaft-seal-timing-chain-side-replacing) .

3 - Alignment bushing

1. 2 pieces

4 - Lower timing chain cover

1. Removing and installing --> «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and)

5 - Left cylinder head gasket

6 - 5 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. Observe sequence for tightening: Position left timing chain cover and tighten bolts in sequence under «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) ; Position right timing chain cover and tighten bolts in sequence under «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

7 - Left timing chain cover

1. Removing and installing --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers)

8 - 5 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. Observe sequence for tightening Position right timing chain cover and tighten bolts in sequence under «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

9 - Right timing chain cover

1. Removing and installing --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers)

10 - Right cylinder head gasket

11 - Alignment bushing

1. 2 pieces

Left and right timing chain covers, removing and installing

Special tools, testers and auxiliary items required

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

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

Left timing chain cover

1. Remove coolant expansion tank - arrow -.
2. Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

1. Remove electrical harness connectors - 1 - and - 2 - from bracket.
2. Free up wiring harness.
3. Remove nuts and remove left bracket for harness connectors from bulkhead.

Note. Place a rag under oil filter housing to catch escaping engine oil.

Scheme 489

1. Remove cap - arrow - for oil filter housing.
2. Remove oil filter element.

Rest-of-world vehicles

Scheme 490

1. Remove crankcase ventilation hose - arrow - at left cylinder head cover.

US./Can. -model vehicles

1. Remove left cylinder head cover and lay aside with crankcase ventilation hose connected --> «Left cylinder head cover, US./Can. vehicles, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-uscan-vehicles) .

All

Scheme 491

1. Disconnect electrical harness connectors.

1. Camshaft position (CMP) sensor 2 G163
2. Camshaft Adjustment Valve 2 N208
3. Camshaft Adjustment Valve 2 (exhaust) N319
4. Camshaft position (CMP) sensor 4 G301

1. Remove bolts - arrows - and separate electrical connections at ignition coils.
2. Set electrical wiring harness aside.

Scheme 492

1. Disconnect electrical harness connectors - 1 to 3 -.
2. Remove nut - arrow -.
3. Remove retainer for connection - 3 -.
4. Remove double-bolt lying beneath.

1. Remove retainer for connections - 1 - and - 2 -.

Scheme 493

1. Remove bolts - 1 to 8 - and remove left timing chain cover.

Right timing chain cover

1. Disconnect check valve - 1 - from connection at air duct hose.
2. Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

1. Remove pin from spreader clips - arrow -.
2. Remove air filter housing.

1. Remove nuts and remove right bracket for harness connectors - 1 - and - 2 - from bulkhead.

Scheme 494

1. Disconnect electrical harness connectors.

1. Camshaft Adjustment Valve 1 (exhaust) N318
2. Camshaft Position (CMP) sensor G40
3. Intake Manifold Runner Position Sensor G336
4. Camshaft position (CMP) sensor 3 G300

1. Remove bolts - arrows - and separate electrical connections at ignition coils.
2. Set electrical wiring harness aside.

Scheme 495

1. Separate electrical connector - 1 -.
2. Remove bolt - arrow - and remove retainer for connection.

Scheme 496

1. Remove bolts - 1 to 8 - and remove right timing chain cover.

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

1. Using e.g. a rotating plastic brush, remove sealant residue on covers for timing chain and on cylinder block and head.

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

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

Note. Covers for timing chain must be installed within 5 minutes after applying sealant.

Scheme 497

1. Apply sealant bead - arrow - , as shown in illustration, on clean sealing surfaces of left cover for timing chain.

1. The groove of sealing surface must be completely filled with sealant.
2. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.

1. Position left timing chain cover and tighten bolts in sequence - 1 to 8 -.

1. Apply sealant bead - arrow - , as shown in illustration, on clean sealing surfaces of right cover for timing chain.

1. The groove of sealing surface must be completely filled with sealant.
2. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.

1. Position right timing chain cover and tighten bolts in sequence - 1 to 8 -.

Further installation is in reverse order of removal, note the following

1. Check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .

Torque specifications

Lower timing chain cover, removing and installing

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

1. Remove transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
2. Vehicles with manual transmission: Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE and dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) .
3. Vehicles with automatic transmission: Remove drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .

Note. After removing transmission, the engine is supported by engine support bridge 10-222 A and the torque support stop is loosened.

1. To remove transmission, remove attached engine support bridge 10-222 A from engine.

1. Tighten torque support stop to 28 Nm - arrows -.
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .

Scheme 498

Note. Place a rag under oil filter housing to catch escaping engine oil.

1. Disconnect electrical harness connector from Oil Pressure Switch F1 - arrow -.
2. Remove oil pressure switch.
3. Extract engine oil using old oil collecting and extracting device V.A.G 1782 from oil filter housing.

Scheme 499

1. Remove bolts - arrows -.
2. Remove oil filter housing.
3. Place old oil collecting and extracting device V.A.G 1782 under engine.
4. Drain engine oil.

Scheme 500

1. Remove bolts - arrows -.
2. Remove bolts - 1 to 8 - and remove lower timing chain cover.
3. Press rear crankshaft seal out of lower timing chain cover.

Installing

Note. Replace gaskets, seals and O-rings.

Scheme 501

1. Pull alignment bushing out of top right of cylinder block.
2. Chamfer alignment bushing with a file, as shown in the illustration.

1. Dimension - x - = 6.5 mm.
2. Dimension - y - = 8 mm.

1. Install alignment bushing into cylinder block so that the chamfered side faces upward.

Note. The chamfer simplifies installation of the lower timing chain cover with cylinder head installed.

1. Using e.g. a rotating plastic brush, remove sealant residue on timing chain cover, cylinder block and head.

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

Scheme 502

1. Clean old sealant from holes - arrow - in cylinder head gaskets.

Note. With the cylinder head installed only half of the holes in the cylinder head gasket are visible.

Scheme 503

1. Bend ends of cylinder head gaskets very slightly downward - arrows - until upper sealing surface of gasket and cylinder head can be cleaned.
2. Clean both cylinder head gaskets, top and bottom, so they are completely free of any oil or grease.

1. Cut tube nozzle at front marking (jet dia. approx. 2 mm).

Note. The sealant must be applied to several places on the engine, as described in the following. The curing time for the sealant after application is only approx. 5 minutes.

1. Coat sealing surfaces of cylinder head gaskets, top and bottom, with a thin layer of sealant, slightly bending cylinder head gaskets downward again.
2. To coat surface between cylinder head and gasket, use a flat object, e.g. a feeler gauge.

1. Fill cleaned holes - arrow - in cylinder head seal with sealant.

Vehicles through 04.2005

Scheme 504

1. Apply sealant beads - 1 to 6 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.

1. The groove of sealing surface must be completely filled with sealant.
2. Sealant beads must stand 1.5 to 2.0 mm above sealing surface.
3. The sealant bead - 3 - must be pulled through as shown in the illustration even though groove is intermittent.

1. Lay O-ring - arrow - in lower timing chain cover groove.
2. Secure O-ring with some sealant.

1. Set lower timing chain cover in place, guiding cover at an angle from below onto sealing surface of cylinder block and cylinder head.
2. When installing, make sure that the cylinder head gaskets do not become damaged. A damaged gasket must be replaced.
3. Tighten bolts as follows

Vehicles from 05.2005

Scheme 505

1. Apply sealant beads - 1 to 5 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.

1. The groove of sealing surface must be completely filled with sealant.
2. Sealant beads must stand 1.5 to 2.0 mm above sealing surface.
3. The sealant bead - 2 - must be pulled through as shown in the illustration even though groove is intermittent.

1. Insert seals - arrows - in lower timing chain cover grooves.

Scheme 506

1. Set lower timing chain cover in place, guiding cover at an angle from below onto sealing surface of cylinder block and cylinder head.
2. When installing, make sure that the cylinder head gaskets do not become damaged. A damaged gasket must be replaced.
3. Tighten bolts as follows

All

Further installation is in reverse order of removal, note the following

1. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-filter-housing-removing-and-installing) .
2. Install left and right timing chain covers «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install crankshaft seal, timing chain side --> «Crankshaft seal, timing chain side, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__crankshaft-seal-timing-chain-side-replacing) .
4. Vehicles with manual transmission: Install dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) and clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

1. Vehicles with automatic transmission: Install drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .
2. Install transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .

Torque specifications

Camshaft drive

Note. Crankshaft and camshafts must only be rotated when chain drive is installed completely. Otherwise the valves impact on the pistons danger of damage to valves/piston heads.

Camshaft timing chain, component overview

Note. Before removing camshaft timing chain, mark direction of travel with paint. Reversing the rotation direction of a used chain can destroy it.

Scheme 507

1 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

2 - Camshaft bolt

1. Replace
2. Initial tightening torque: 40 Nm
3. Final tightening torque: 80 Nm plus an additional 90 ° ( 1 / 4 turn)

3 - Camshaft bolt

1. Replace
2. Initial tightening torque: 40 Nm
3. Final tightening torque: 80 Nm plus an additional 90 ° ( 1 / 4 turn)

4 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

5 - Left camshaft timing chain

1. Removing and installing --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

6 - 9 Nm

7 - Chain tensioner for left camshaft timing chain

1. Removing and installing --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

8 - Oil strainer

1. Set into chain tensioner
2. Observe locating tabs on circumference

9 - Gasket

1. Replace
2. Clipped onto chain tensioner

10 - Mounting bracket for drive sprocket

11 - 8 Nm plus an additional 45 ° ( 1 / 8 turn)

1. Replace
2. To be oiled for installation

12 - Drive sprocket for left camshaft timing chain

13 - Thrust washer for drive sprocket

14 - 6 Nm plus an additional 60 ° ( 1 / 6 turn)

1. Replace

Scheme 508

1 - Drive sprocket for right camshaft timing chain

2 - Mounting bracket for drive sprocket

3 - 30 Nm plus an additional 90 ° ( 1 / 4 turn)

4 - Right camshaft timing chain

1. Removing and installing --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

5 - Camshaft bolt

1. Replace
2. Initial tightening torque: 40 Nm
3. Final tightening torque: 80 Nm plus an additional 90 ° ( 1 / 4 turn)

6 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

7 - Chain tensioner for right camshaft timing chain

1. Removing and installing --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

8 - Oil strainer

1. Set into chain tensioner
2. Installed location: Locating tabs on circumference

9 - Gasket

1. Replace
2. Clipped onto chain tensioner

10 - 9 Nm

11 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

12 - Camshaft bolt

1. Replace
2. Initial tightening torque: 40 Nm
3. Final tightening torque: 80 Nm plus an additional 90 ° ( 1 / 4 turn)

13 - Thrust washer for drive sprocket

Scheme 509

Special tools, testers and auxiliary items required

1. Counter-holder T10172 with pin T10172/2
2. Adapter T40058
3. Locking pin T40069
4. Camshaft locator T40070 (qty. 2)

1. Securing pin T40071 (qty. 2)

Special tools, testers and auxiliary items required

Scheme 510

1. Multi-point socket T10035

Note. According to the following description, the timing chains for camshafts remain on engine. If the timing chains for camshafts are to be completely removed, the lower timing chain cover must also be removed --> Lower timing chain cover, removing and installing .

1. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .

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

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation. Rear section of noise insulation remains installed.

1. Insert guide pin of adapter T40058 so that large diameter - arrow 1 - points to engine. Small diameter - arrow 2 - points to adapter.

1. Using socket T40058 , rotate crankshaft in direction of engine rotation - arrow - to TDC.

Scheme 511

1. The threaded holes - arrows - in camshafts must face upward.

Scheme 512

1. Mount camshaft locating tool T40070 to both cylinder heads and tighten bolts - arrows - to 20 Nm.

1. The camshaft locating tool T40070 is correctly positioned when holes for cylinder head bolts remain free.

Scheme 513

1. Unfasten left and right stabilizer bar mountings - 1 - and - 2 -.

Scheme 514

1. Remove sealing plug - arrow - from cylinder block.

Scheme 515

1. Install crankshaft holder T40069 into hole - 1 - to 10 Nm, if necessary rotate crankshaft very slightly back and forth to completely center holder.
2. Mark running direction of left camshaft timing chain with paint.

Scheme 516

1. Remove bolts - 1 - and - 2 - for camshaft adjuster using multipoint socket T10035.
2. Remove both camshaft adjusters.

Scheme 517

1. Remove bolts - 1 - and - 2 - and remove chain tensioner.
2. Mark running direction of right camshaft timing chain with paint.

Scheme 518

1. Remove bolts - 1 - and - 2 - for camshaft adjuster using multipoint socket T10035.
2. Remove both camshaft adjusters.

Scheme 519

1. Remove bolts - 1 - and - 2 - and remove chain tensioner.

Note. Always replace bolts that are tightened to torque as well as O-rings and gaskets. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged. Drive chain for timing mechanism installed --> Drive chain for timing mechanism, removing and installing . Secure crankshaft in TDC position using crankshaft holder T40069. Camshaft locating tool T40070 mounted on both cylinder heads and tightened to 20 Nm.

Scheme 520

1. Fully relieve tension of guide rail for left and right camshaft timing chain tensioner - arrow -.

1. The piston of tensioning element - 1 - must be driven out completely, thereby releasing retainer - for this chain tensioner must be removed.

Note. If the tensioning element is to be removed from the chain tensioner, observe the installed position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail.

Scheme 521

1. Press guide rail of left and right camshaft timing chain inward - arrow - up to stop and secure chain tensioner with securing pin T40071.

Scheme 522

1. Clean oil strainer - 3 - in both chain tensioners, if necessary.
2. Place a new gasket - 2 - onto rear of chain tensioner - 1 -.
3. Set chain tensioner in place on left cylinder head and install camshaft timing chain, as shown in the illustration.

Scheme 523

1. Tighten bolts - 1 - and - 2 -.
2. Replace camshaft bolts.

1. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 - and - 2 -.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

1. Remove Locking Pin T40071.
2. Set chain tensioner in place on right cylinder head and install camshaft timing chain, as shown in the illustration.

Scheme 524

1. Tighten bolts - 1 - and - 2 -.
2. Replace camshaft bolts.

1. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 - and - 2 -.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

1. Remove Locking Pin T40071.

Scheme 525

1. Set counter-holder T10172 with pin T10172/2 in place on camshaft adjuster of left intake camshaft.
2. Hold camshaft timing chain pre-tensioned by pressing on counter-holder in direction of - arrow -.
3. Simultaneously, pre-torque camshaft bolt using multipoint socket T10035 and torque wrench.

1. Torque specification: 40 Nm.

1. Continue holding pretension on intake camshaft and pre-torque bolt - 1 - on exhaust camshaft.

1. Torque specification: 40 Nm.

1. Tighten camshaft bolts - 1 - and - 2 - on left cylinder head to final torque specification.

1. Torque specification: 80 Nm plus an additional 90 ° ( 1 / 4 turn).

Scheme 526

1. Set counter-holder T10172 with pin T10172/2 in place on camshaft adjuster of right exhaust camshaft.
2. Hold camshaft timing chain pre-tensioned by pressing on counter-holder in direction of - arrow -.
3. Simultaneously, pre-torque camshaft bolt using multipoint socket T10035 and torque wrench.

1. Torque specification: 40 Nm.

1. Continue holding pretension on exhaust camshaft and pre-torque bolt - 1 - on intake camshaft.

1. Torque specification: 40 Nm.

1. Tighten camshaft bolts - 1 - and - 2 - on right cylinder head to final torque specification.

1. Torque specification: 80 Nm plus an additional 90 ° ( 1 / 4 turn).

1. Remove camshaft locators T40070 on both cylinder heads.

1. Remove crankshaft holder T40069.

1. Using key T40058 turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at TDC again.

Note. If rotated unintentionally beyond TDC, turn back crankshaft again approx. 30 ° and set to TDC again. The threaded holes - arrows - in camshafts must face upward.

1. Mount camshaft locating tools T40070 to both cylinder heads and tighten bolts - arrows - to 20 Nm.

1. The camshaft locating tool T40070 is correctly positioned when holes for cylinder head bolts remain free.

1. Install crankshaft holder T40069 directly into hole.

1. The crankshaft holder T40069 must engage in locating hole of crankshaft - 1 - , otherwise repeat adjustment.

1. Remove camshaft locating tools on both cylinder heads.
2. Remove crankshaft holder.

1. Install sealing plug - arrow - of TDC marking with new seal into cylinder block.

Further installation is in reverse order of removal, note the following

1. Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
3. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .

Scheme 527

1 - Pivot pin for drive sprocket

2 - 30 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace

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

1. Replace
2. Insert using locking compound; locking compound .

4 - 6 Nm plus an additional 60 ° ( 1 / 6 turn)

1. Replace

5 - Thrust washer for drive sprocket

6 - Bushing with shoulder

7 - Drive sprocket for left camshaft timing chain

8 - 10 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. Insert using locking compound; locking compound .

9 - Drive chain for timing mechanism

1. Before removing, mark direction of rotation with paint

10 - Guide rail

11 - 10 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. Insert using locking compound; locking compound .

12 - Bushing with shoulder

13 - 8 Nm plus an additional 45 ° ( 1 / 8 turn)

1. Replace
2. To be oiled for installation

14 - Mounting bracket for drive sprocket

15 - Bushing with shoulder

16 - Thrust washer

17 - Drive sprocket for right camshaft timing chain

18 - Bushing with shoulder

19 - 10 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. Insert using locking compound; locking compound .

20 - O-ring

1. Replace

21 - Chain tensioner

22 - 10 Nm

23 - Glide track for chain tensioner

24 - Crankshaft

25 - Bushing with shoulder

26 - Guide rail

1. Note installation position

27 - 10 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. Insert using locking compound; locking compound .

Scheme 528

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Locking pin T40069
3. Securing pin T40071

Removing

1. Remove transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
2. Vehicles with manual transmission: Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE and dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) .
3. Vehicles with automatic transmission: Remove drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .

Note. After removing transmission, the engine is supported by engine support bridge 10-222 A and the torque support stop is loosened.

1. To remove transmission, remove attached engine support bridge 10-222 A from engine.

1. Tighten torque support stop to 28 Nm - arrows -.
2. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .
3. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
4. Place old oil collecting and extracting device V.A.G 1782 under engine.

1. Drain engine oil.
2. Remove lower timing chain cover --> «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and) .
3. Remove camshaft timing chains from camshafts --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Remove drive chain for oil pump and balance shaft --> «Drive chain for oil pump and balance shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

Scheme 529

1. Push drive chain tensioner guide rail in direction of - arrow - and secure chain tensioner using securing pin T40071.
2. Mark running direction of timing chain with paint.
3. Remove bolts - 2 - and - 3 - and remove chain sprockets with drive chain and glide track - 1 -.

Installing

Installation is in reverse order of removal, note the following

1. Secure crankshaft - 1 - in TDC position using crankshaft holder T40069.

1. First, install left camshaft timing chain sprocket - 2 -.
2. Install guide rail - 1 - with installed drive chain.
3. Now install right camshaft timing chain sprocket - 3 -.
4. Press drive chain tensioner guide rail in direction of - arrow - and pull securing pin T40071 out of chain tensioner.

1. Install oil pump drive chain and balance shaft --> «Drive chain for oil pump and balance shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Install camshaft timing chains «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install lower timing chain cover --> «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and) .
4. Install crankshaft seal, timing chain side --> «Crankshaft seal, timing chain side, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__crankshaft-seal-timing-chain-side-replacing) .

1. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-filter-housing-removing-and-installing) .
2. Install left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
3. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .
4. Vehicles with manual transmission: Install dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) and clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .

1. Vehicles with automatic transmission: Install drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .
2. Install transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .

Torque specifications

Scheme 530

1 - Drive chain for oil pump and balance shaft

1. Before removing, mark direction of rotation with paint
2. Removing and installing --> «Drive chain for oil pump and balance shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

2 - Drive sprocket for oil pump

1. Installed location: Labeled side faces engine

3 - 30 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace

4 - Spring

5 - Crankshaft

6 - 15 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace

7 - Chain sprocket for balance shaft

1. Installed location: Labeled side faces transmission

8 - 6 Nm plus an additional 45 ° ( 1 / 8 turn)

1. Replace

9 - Chain tensioner

1. With glide track

10 - Gasket

1. Replace

Scheme 531

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Adapter T40049
3. Locking pin T40069
4. Securing pin T40071

1. Drill bit dia. 8 mm

Removing

1. Remove transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
2. Vehicles with manual transmission: Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE and dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) .
3. Vehicles with automatic transmission: Remove drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .

Note. After removing transmission, the engine is supported by engine support bridge 10-222 A and the torque support stop is loosened.

1. To remove transmission, remove attached engine support bridge 10-222 A from engine.

1. Tighten torque support stop to 28 Nm - arrows -.
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
3. Place old oil collecting and extracting device V.A.G 1782 under engine.
4. Drain engine oil.

1. Remove lower timing chain cover --> «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and) .

Scheme 532

1. Install key T40049 at rear on crankshaft using 2 old bolts - arrows - for dual-mass flywheel.

Vehicles with manual transmission

1. Unfasten left and right stabilizer bar mountings - 1 - and - 2 -.
2. Pivot stabilizer bar downward.

All

1. Remove sealing plug - arrow - from cylinder block.

1. Rotate crankshaft in direction of engine rotation to TDC of ignition timing.

1. Install crankshaft holder T40069 into hole to 20 Nm, if necessary rotate crankshaft very slightly back and forth to completely center holder.
2. Mark running direction of drive chain for oil pump and balance shaft with paint.

Scheme 533

1. Press chain tensioner guide rail in direction of - arrow - and secure chain tensioner with securing pin T40071.
2. Remove bolts - 1 through 3 - and remove chain tensioner, balance shaft sprocket and chain.

Installing

1. Secure crankshaft - 1 - in TDC position using crankshaft holder T40069.

Scheme 534

1. Mount chain tensioner with chain and balance shaft sprocket.
2. To protect against cuts, wrap point and cutting edges of with insulating tape.
3. Secure balance shaft with 8 mm dia. drill bit - 1 - in TDC position.

1. The slots in balance shaft sprocket must be at middle position in relation to threaded holes of balance shaft. If necessary, adjust chain by one tooth.

1. Tighten chain tensioner bolts.
2. Loosely install bolts - 2 - for sprocket.

1. Chain sprocket must still be able to be rotated on balance shaft and must not tip.

1. Pull out securing pin T40071 to release chain tensioner.
2. Press against chain tensioner guide rail - arrow - with screwdriver and simultaneously fasten bolts - 2 - for sprocket.
3. Pull drill - 1 - out of balance shaft.

Further installation is in reverse order of removal, note the following

1. Install lower timing chain cover --> «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and) .
2. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-filter-housing-removing-and-installing) .
3. Install left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
4. Install crankshaft seal, timing chain side --> «Crankshaft seal, timing chain side, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__crankshaft-seal-timing-chain-side-replacing) .

1. Vehicles with manual transmission: Install dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) and clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
2. Vehicles with automatic transmission: Install drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .
3. Install transmission --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 - CONTROLS, HOUSING»(ref-278905-S37295550152008020700000) for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(/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 «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE .
4. Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Add engine oil and check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .

Torque specifications

Scheme 535

1 - Friction bearing

2 - 60 Nm

1. To loosen and fasten, use a 8 mm dia. drill bit as counter-holder

3 - Balance weight (timing chain side)

1. Can only be positioned one way on balance shaft

4 - 9 Nm

5 - Bearing end bracket

6 - Balance weight (belt pulley side)

1. Can only be positioned one way on balance shaft

7 - 60 Nm

1. To loosen and fasten, use a 8 mm dia. drill bit as counter-holder

8 - Friction bearing

9 - Differential shaft

1. Removing and installing --> «Balance shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__balance-shaft-removing-and-installing)

Balance shaft, removing and installing

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. 8 mm dia. drill bit

Removing

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

1. Loosen quick-release fasteners - 1 through 3 - and remove front and rear noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine.
3. Drain engine oil.
4. Remove engine: Vehicles with manual transmission --> «Engine, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-removing) , vehicles with automatic transmission --> «Engine, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

1. Separate engine/transmission assembly: Vehicles with manual transmission --> «Engine and manual transmission, separating»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-and-manual-transmission-separating) , vehicles with automatic transmission --> «Engine and automatic transmission 09L, separating»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-and-automatic-transmission-09l-separating) .
2. Secure engine to assembly stand: Vehicles with manual transmission --> «Engine, securing to assembly stand»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-securing-to-assembly-stand) , Vehicles with automatic transmission --> «Engine, securing to assembly stand»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) or lower engine on scissor lift platform VAS 6131.
3. Vehicles with manual transmission: Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE and dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) .
4. Vehicles with automatic transmission: Remove drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .

1. Remove front sealing flange --> «Front sealing flange with crankshaft seal, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__front-sealing-flange-with-crankshaft-seal) .
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
3. Remove lower timing chain cover --> «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and) .
4. Remove drive chain for oil pump and balance shaft --> «Drive chain for oil pump and balance shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

Scheme 536

1. To protect against cuts, wrap point and cutting edges of 8 mm dia. drill bit with insulating tape.
2. Secure balance weight - 2 - at rear of engine with 8 mm dia. drill bit - 1 -.
3. Remove bolt - 3 - and remove balance weight from balance shaft.

Scheme 537

1. Remove bolt - 2 - , thereby counter-hold balance weight with drift and remove balance weight - 1 - from balance shaft at front of engine.

Scheme 538

1. Remove bolts - arrows - and remove bearing end bracket from balance shaft at rear of engine.
2. Pull balance shaft rearward and out from cylinder block.

Installing

1. Secure crankshaft - 1 - in TDC position using crankshaft holder T40069.

Installation is in reverse order of removal, note the following

Note. The balance weights can only be positioned one way on balance shaft.

1. Install oil pump drive chain and balance shaft --> «Drive chain for oil pump and balance shaft, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Install lower timing chain cover --> «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and) .
3. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-filter-housing-removing-and-installing) .
4. Install left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .

1. Install crankshaft seal, timing chain side --> «Crankshaft seal, timing chain side, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__crankshaft-seal-timing-chain-side-replacing) .
2. Install front sealing flange --> «Front sealing flange with crankshaft seal, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__front-sealing-flange-with-crankshaft-seal) .
3. Vehicles with manual transmission: Install dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) and clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE .
4. Vehicles with automatic transmission: Install drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .

1. Attach transmission to engine and install engine/transmission assembly: Vehicles with manual transmission --> «Engine, installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-installing) , vehicles with automatic transmission --> «Engine, installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Add engine oil and check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .

Torque specifications

Crankshaft, component overview

Note. Secure engine to engine and transmission holder VAS 6095 when working on engine. Vehicles with manual transmission --> Engine, securing to assembly stand or vehicles with automatic transmission --> Engine, securing to assembly stand .

Scheme 539

1 - 9 Nm

1. Fasten in diagonal sequence in steps

2 - Sealing flange, front

1. Removing and installing --> «Front sealing flange with crankshaft seal, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__front-sealing-flange-with-crankshaft-seal)

3 - Seals

1. Replace

4 - Crankshaft

1. Measuring axial play --> «Axial clearance, measuring»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__axial-clearance-measuring)
2. Radial clearance, measuring --> «Radial clearance, measuring»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__radial-clearance-measuring)
3. Do not turn crankshaft when measuring radial play
4. Crankshaft dimensions --> «Crankshaft dimensions»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__crankshaft-dimensions)

5 - Alignment bushing

1. 4 pieces
2. Insert into guide frame «Sealant application for guide frame, position of alignment bushings»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

6 - Bearing bracket

1. Sealant application «Sealant application for guide frame, position of alignment bushings»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
2. Tightening sequence for manifold mounting bolts «Installing guide frame»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

7 - Bolt

1. For sealing surfaces of cylinder block/guide frame
2. Varying bolt lengths and bolt heads
3. Tightening order «Installing guide frame»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

8 - Long bolt, large shoulder

1. For inner row of guide frame
2. Tightening order «Installing guide frame»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

9 - Short bolt, small shoulder

1. For outer row of guide frame
2. Tightening order «Installing guide frame»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

10 - Thrust washer

1. Only on 3rd crankshaft bearing
2. Lubricating grooves face outward
3. Note locating point in guide frame
4. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__axial-clearance-measuring)

11 - Bearing shell

1. For guide frame without lubricating groove
2. Do not interchange used bearing shells (mark)
3. Note installation position
4. Insert new bearing shells for guide frame with proper color marking «Allocation of crankshaft bearing shells for guide frame»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

12 - Centering washer

1. For vehicles with automatic transmission 09L «Centering washer for drive plate on automatic transmission 09L»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__centering-washer-for-drive-plate-on)

13 - Thrust washer

1. Only on 3rd crankshaft bearing
2. Lubricating grooves face outward
3. Note locating point in guide frame
4. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__axial-clearance-measuring)

14 - Bearing shell

1. For cylinder block with oil groove
2. Do not interchange used bearing shells (mark)
3. Note installation position
4. Insert new bearing shells for cylinder block with proper color marking «Allocation of crankshaft bearing shells for cylinder block»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

15 - Seal

1. Replace

16 - Cylinder block

Centering washer for drive plate on automatic transmission 09L

Note. On vehicles with automatic transmission, the drive plate is bolted to the crankshaft with a centering washer - arrow -.

Scheme 540

1. Clean sealing surfaces, they must be free of oil and grease on top and bottom.
2. Apply sealant beads - arrows - on clean sealing surfaces of guide frame as shown in illustration.

1. The groove of sealing surface must be completely filled with sealant.
2. Sealant beads must stand 1.5 to 2.0 mm above sealing surface.

1. Install seals - 1 through 3 -.
2. Check whether alignment bushings - 4 through 7 - are inserted at locations in guide frame as shown in the illustration.

Scheme 541

1. Replace bolts - 1 to 16 -.
2. Place long bolts into inner row of guide frame.
3. Tighten bolts for guide frame as follows
4. Tighten bolts - 1 to 16 - to 50 Nm with torque wrench.

1. Tighten bolts - 1 to 16 - 90 ° ( 1 / 4 additional turn) using a rigid wrench.
2. Tighten bolts for sealing surfaces of cylinder block/guide frame - dark hatching in the illustration - to 23 Nm in diagonal sequence.

Scheme 542

1. Bearing shells with correct thickness are allocated to cylinder block in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to cylinder block is marked by a letter on respective bearing on guide frame

Through engine no. BKH 033 000

On engines through no. BKH 033 000 another allocation of letters on guide frame to bearing shell color applies to bearing 1 (front).

From engine no. BKH 033 001

Scheme 543

1. Bearing shells with correct thickness are allocated to guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to guide frame is marked on flywheel flange of crankshaft by a row of letters. The first letter of the row of letters represents bearing "1" , the second letter is for bearing "2" , etc.

Through engine no. BKH 033 000

On engines through no. BKH 033 000 another allocation of letters on crankshaft to bearing shell color applies to bearing 1 (front).

From engine no. BKH 033 001

Crankshaft dimensions

Axial clearance, measuring

Special tools, testers and auxiliary items required

Scheme 544

1. Dial gauge holder VW 387

Scheme 545

1. Dial gauge VAS 6079

Work procedure

Scheme 546

1. Attach dial indicator VAS 6079 together with dial gauge holder VW 387 to cylinder block and set indicator against crankshaft counterweight.
2. Press crankshaft against dial indicator by hand, set indicator to - 0 -.
3. Press crankshaft off dial indicator and read off value

1. Axial clearance: 0.209 to 0.251 mm.

Radial clearance, measuring

Special tools, testers and auxiliary items required

1. Plastigage

Work procedure

Note. Do not interchange used bearings Bearing shells that are worn down to the nickel layer must be replaced.

1. Remove guide frame and clean 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 guide frame and tighten to 30 Nm. Do not turn crankshaft.
2. Remove guide frame again.
3. Compare width of Plastigage with measuring scale

1. Radial clearance, new: 0.010 to 0.039 mm.
2. Radial clearance wear limit: 0.08 mm.

Piston and connecting rod, component overview

Note. Oil injector jet for piston cooling Oil spray jet for piston cooling

Scheme 547

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

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

2 - Connecting rod bearing cap

1. Do not interchange
2. Mark allocation to cylinder using a color marker - B - «Mark connecting rod»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
3. When installing bearing cap, observe: The wide thrust flange - A - must point to the same side on connecting rod and connecting rod bearing cap
4. Installation position of connecting rod pairs «Connecting rod, installed location»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

3 - Bearing shell

1. Upper bearing shell (for connecting rod) made of wear-resistant material; identification: Bright color of bearing
2. Lower bearing shell (for bearing cap) identification: Dark color of bearing
3. Check that retaining tabs are secured
4. Do not interchange used bearing shells (mark)

1. Radial clearance, measuring --> «Radial clearance of connecting rod, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__radial-clearance-of-connecting-rod-checking)

4 - Connecting rod

1. Only replace as set
2. Mark allocation to cylinder with paint - B - «Mark connecting rod»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
3. When installing bearing cap, observe: The wide thrust flange - A - must point to the same side on connecting rod and connecting rod bearing cap
4. Installation position of connecting rod pairs «Connecting rod, installed location»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

5 - Piston pin

1. If tight, heat piston to 60 ° C
2. Removing and installing using a drift VW 222 A

6 - Circlip

7 - Piston

1. Installed position and allocation, piston/cylinder «Installed position of piston and piston/cylinder allocation»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
2. Arrow on piston face points toward belt pulley side
3. Checking «Checking piston»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
4. Install with piston ring compressor

1. Piston and cylinder dimensions --> «Piston and cylinder dimensions»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__piston-and-cylinder-dimensions)
2. Cylinder bore, checking «Checking cylinder bores»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

8 - Piston rings

1. Offset gaps by 120 °
2. Use piston ring pliers for removal and installation
3. "TOP" marking or inscribed side must point to piston head
4. Checking ring gap «Checking piston ring gap»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

1. Check piston ring groove clearance «Checking ring to groove clearance»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

Scheme 548

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

Scheme 549

1. Clean ring groove of piston before checking.

Scheme 550

1. Measure approx. 10 mm from lower edge, at a 90 ° angle to piston pin axis using an external micrometer 75 to 100 mm.

1. Maximum deviation from nominal dimension: 0.04 mm.

Nominal dimension --> Piston and cylinder dimensions .

Scheme 551

1. Using an internal dial gauge 50 to 100 mm, measure at 3 points in diagonal sequence horizontally - A - and vertically - B -.

1. Maximum deviation from nominal dimension: 0.08 mm.

Nominal dimension --> Piston and cylinder dimensions .

Scheme 552

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. Installed location: Arrow on piston face points toward belt pulley side.

Scheme 553

Note. Only replace connecting rod as a set. Do not interchange connecting rod bearings.

1. Before removing, mark allocation of connecting rod and connecting rod bearing caps to each other and to cylinder with paint - arrow -.

Scheme 554

1. The molded tabs - arrows - at beveled surfaces of connecting rod pairs 1 and 2, 3 and 4, and 5 and 6 must point toward each other.

Scheme 555

1. Insert bolt (9 Nm) using locking compound; locking compound
2. Oil spray jet with spray nozzle valve

Piston and cylinder dimensions

Radial clearance of connecting rod, checking

Special tools, testers and auxiliary items required

1. Plastigage

Work procedure

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

1. Compare width of Plastigage with measuring scale

1. Radial clearance, new: 0.010 to 0.052 mm.
2. Radial clearance wear limit: 0.12 mm.

1. Replace bolts for connecting rod bearings.

Cylinder head, component overview

Note. Illustration depicts left cylinder head. Both cylinder heads can be removed and installed when engine is installed in engine compartment.

Scheme 556

1 - High pressure pump

1. Removing and installing --> «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh)

2 - 9 Nm

1. Always apply Loctite 5910 on sealing surface when reinstalling.

3 - 20 Nm

4 - Lifting eye

5 - O-ring

1. Replace

6 - Camshaft position sensor, intake camshaft

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

7 - 9 Nm

8 - O-ring

1. Replace

9 - Solenoid valve for camshaft adjustment - intake side

1. Cylinder bank 1 (right) Camshaft Adjustment Valve 1 N205
2. Cylinder bank 2 (left) Camshaft Adjustment Valve 2 N208

10 - 2.5 Nm

11 - Gasket

1. Replace if damaged or leaking

12 - Cap

13 - O-ring

1. Replace

14 - Solenoid valve for camshaft adjustment - exhaust side

1. Cylinder bank 1 (right) Exhaust camshaft control valve 1 N318
2. Cylinder bank 2 (left) Camshaft Adjustment Valve 2 (exhaust) N319

15 - 2.5 Nm

16 - Special bolt, 9 Nm

1. Replace if damaged or leaking
2. Observe sequence for tightening Tighten cylinder head cover in sequence under «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and)

17 - Cylinder head cover

1. Removing and installing: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and)

18 - Cylinder head cover gasket

1. Replace if damaged or leaking

19 - Cylinder head bolt

1. Replace
2. Observe sequence for loosening --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and)
3. Observe sequence for tightening Tighten cylinder head in sequence indicated, in 3 stages as follows: under «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

20 - O-ring

1. Replace

21 - 9 Nm

22 - Camshaft position sensor, exhaust camshaft

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

23 - Cylinder head

1. Removing --> «Cylinder head, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
2. Check for distortion «Checking cylinder head for distortion»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
3. Reworking dimension «Reworking dimension, cylinder head»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
4. Installing «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

1. After replacing, change coolant and engine oil

24 - Cylinder head gasket

1. Replacing --> «Cylinder head, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Installed location: Part Number, points to cylinder head
3. After replacing, change coolant and engine oil

Scheme 557

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

1. Max. distortion: 0.05 mm.

Scheme 558

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

1. Minimum dimension - a - = 139.20 mm.

Left cylinder head cover, removing and installing

Special tools, testers and auxiliary items required

Scheme 559

1. Puller T40039

Removing

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

1. Remove coolant expansion tank - arrow -.
2. Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

Scheme 560

1. Disconnect electrical harness connectors.

1. Change-over valve for intake manifold flap N239
2. Intake Manifold Tuning (IMT) Valve Position Sensor G513

1. Disconnect electrical harness connectors.

1. Camshaft position (CMP) sensor 2 G163
2. Camshaft Adjustment Valve 2 N208
3. Camshaft Adjustment Valve 2 (exhaust) N319
4. Camshaft position (CMP) sensor 4 G301

1. Remove bolts - arrows - and separate electrical connections at ignition coils.
2. Set electrical wiring harness aside.

Scheme 561

1. Remove ignition coils using ignition coil puller T40039.

Scheme 562

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

Installing

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover gaskets if damaged. Replace bolts for cylinder head cover if gasket is damaged.

1. Clean sealing surfaces so they are completely free of any oil or grease.
2. Tighten cylinder head cover in sequence - 1 to 12 -.

Torque specifications

Left cylinder head cover, US./Can. vehicles, removing and installing

Special tools, testers and auxiliary items required

1. Puller T40039

Removing

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

1. Remove coolant expansion tank - arrow -.
2. Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

1. Disconnect electrical harness connectors.

1. Change-over valve for intake manifold flap N239
2. Intake Manifold Tuning (IMT) Valve Position Sensor G513

1. Disconnect electrical harness connectors.

1. Camshaft position (CMP) sensor 2 G163
2. Camshaft Adjustment Valve 2 N208
3. Camshaft Adjustment Valve 2 (exhaust) N319
4. Camshaft position (CMP) sensor 4 G301

1. Remove bolts - arrows - and separate electrical connections at ignition coils.
2. Set electrical wiring harness aside.

1. Remove ignition coils using ignition coil puller T40039.

1. Remove left cylinder head cover bolts in sequence - 12 to 1 -.

1. Lay aside removed cylinder head cover with connected crankcase ventilation hose.

Installing

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover gaskets if damaged. Replace bolts for cylinder head cover if gasket is damaged.

1. Clean sealing surfaces so they are completely free of any oil or grease.
2. Tighten cylinder head cover in sequence - 1 to 12 -.

Torque specifications

Right cylinder head cover, removing and installing

Special tools, testers and auxiliary items required

1. Puller T40039

Removing

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

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

1. Disconnect check valve - 1 - from air duct hose.
2. Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

1. Remove pin from spreader clips - arrow -.
2. Remove air filter housing.

Scheme 563

1. Disconnect electrical harness connectors.

1. Engine Coolant Temperature (ECT) Sensor G62
2. Change-over valve for intake manifold flap N239

Note. Ignore - 3 -.

Scheme 564

1. Disconnect electrical connector - arrow - at Low Fuel Pressure Sensor G410.

1. Disconnect electrical harness connectors.

1 - Camshaft Adjustment Valve 1 (exhaust) N318

3 - Camshaft Position (CMP) sensor G40

4 - Intake Manifold Runner Position Sensor G336

5 - Camshaft position (CMP) sensor 3 G300

Note. Ignore - 2 -.

1. Remove bolts - arrows - and separate electrical connections at ignition coils.
2. Set electrical wiring harness aside.

1. Remove ignition coils using ignition coil puller T40039.

Scheme 565

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

Installing

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover gaskets if damaged. Replace bolts for cylinder head cover if gasket is damaged.

1. Clean sealing surfaces so they are completely free of any oil or grease.
2. Tighten cylinder head cover in sequence - 1 to 12 -.

Torque specifications

Right cylinder head cover, US./Can. vehicles, removing and installing

Special tools, testers and auxiliary items required

1. Puller T40039

Removing

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

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

1. Disconnect check valve - 1 - from air duct hose.
2. Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

1. Remove pin from spreader clips - arrow -.
2. Remove air filter housing.

1. Disconnect electrical harness connectors.

1. Engine Coolant Temperature (ECT) Sensor G62
2. Change-over valve for intake manifold flap N239

Note. Ignore - 3 -.

1. Disconnect electrical connector - arrow - at Low Fuel Pressure Sensor G410.

1. Disconnect electrical harness connectors.

1 - Camshaft Adjustment Valve 1 (exhaust) N318

3 - Camshaft Position (CMP) sensor G40

4 - Intake Manifold Runner Position Sensor G336

5 - Camshaft position (CMP) sensor 3 G300

Note. Ignore - 2 -.

1. Remove bolts - arrows - and separate electrical connections at ignition coils.
2. Set electrical wiring harness aside.

1. Remove ignition coils using ignition coil puller T40039.

1. Remove right cylinder head cover bolts in sequence - 12 to 1 -.

1. Lay aside removed cylinder head cover with connected crankcase ventilation hose.

Installing

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover gaskets if damaged. Replace bolts for cylinder head cover if gasket is damaged.

1. Clean sealing surfaces so they are completely free of any oil or grease.
2. Tighten cylinder head cover in sequence - 1 to 12 -.

Torque specifications

Cylinder head, removing and installing

Special tools, testers and auxiliary items required

Scheme 566

1. Locking pin T40069

Scheme 567

1. Camshaft locator T40070

Note. The following removal and installation procedure is for the left cylinder head. The procedure for the other side is identical.

1. Remove front engine cover - arrows -.

1. Remove bolts - arrows -.
2. Remove air duct - 1 - and - 2 -.
3. Drain coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Remove both front wheels.

Note. Secure the brake disc with a wheel bolt.

1. Remove front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Bring lock carrier into service position --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Remove upper part of intake manifold --> «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) .

1. Disconnect fuel line - arrow -.

Scheme 568

1. Remove low pressure line, thereby removing bolts and union nuts - 1 through 6 -.
2. Remove intake manifold lower part --> «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
3. Disconnect electrical harness connectors at fuel injectors.
4. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)

1. Remove front coolant pipe --> «Front coolant line, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__front-coolant-line-removing-and-installing) .

Left cylinder head

1. Remove power steering pump --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove oil filter housing --> «Oil filter housing, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-filter-housing-removing-and-installing) .

Right cylinder head

1. Disconnect vacuum hose - 1 - at vacuum pump.

Note. Ignore - arrows -.

Continued for both sides

1. Remove nut - 2 - of relevant threaded fastener for front exhaust pipe/exhaust manifold, which is accessible from top.

Note. To improve clarity, the removed engine is shown from the rear.

Scheme 569

1. Remove heat shield - arrows - for left drive axle.

Right cylinder head and vehicles with automatic transmission

1. Remove right drive axle from transmission flange shaft.

Continued for both sides

1. Separate exhaust system at relevant clamping sleeve - arrows - and push clamping sleeve toward rear.

1. Remove nuts - 1 - and - 3 - of relevant threaded fastener for front exhaust pipe/exhaust manifold, which are accessible from bottom.

Note. To improve clarity, the removed engine is shown.

1. Disconnect front exhaust pipe from exhaust manifold.

1. Disconnect electrical harness connector - 1 - for oxygen sensor before catalytic converter on relevant side and free up wiring.

Note. Ignore - 2 -.

Left cylinder head

Scheme 570

1. Disconnect electrical connector - 2 -.

Note. Ignore - 1 - and - arrows -.

Scheme 571

1. Remove bolt - arrow - and pull oil dipstick guide tube upward and out.

All

1. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
3. Remove camshaft timing chains from camshafts --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

Scheme 572

1. Remove bolts - arrows - at rear of cylinder head.

1. Left cylinder head: 3 bolts.
2. Right cylinder head: 4 bolts.

Scheme 573

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

Note. Replace cylinder head bolts. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings. Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Carefully remove all grinding and sanding residue. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. Checking cylinder head for distortion Checking cylinder head for distortion Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage. Install cylinder head gasket onto guide sleeves. Marking "oben" (top) or part number must face toward cylinder head. After installing a replacement cylinder head with camshafts installed, oil contact surfaces between roller cam followers and cam lubricating surfaces after installing cylinder head. Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head. When replacing cylinder head or cylinder head seal, coolant and engine oil must be changed. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location. 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. Before installing cylinder head, set crankshaft and camshafts to TDC setting, mounting camshaft locating tool T40070 on both cylinder heads and tightening to 20 Nm.

1. The camshaft locating tool T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

1. Crankshaft holder T40069 must be installed into crankshaft - 1 -.

1. Position cylinder head gasket.

Scheme 574

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

1. Install cylinder head.

Scheme 575

1. Insert new cylinder head bolts and tighten by hand.
2. Tighten cylinder head in sequence indicated, in 3 stages as follows
3. Using torque wrench, tighten to 40 Nm.
4. With Torx key, 90 ° ( 1 / 4 turn) additional turn.

1. With Torx key, 90 ° ( 1 / 4 turn) additional turn.

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

1. Tighten bolts - arrows - to 9 Nm.

1. Left cylinder head: 3 bolts.
2. Right cylinder head: 4 bolts.

Further installation is in reverse order of removal, note the following

1. Install camshaft timing chains «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Install left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
3. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .
4. Install front exhaust pipe with catalytic converter: Left, Vehicles with manual transmission --> «Left front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-front-exhaust-pipe-with-catalytic) , Vehicles with automatic transmission --> «Left front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-front-exhaust-pipe-with-catalytic) ; Right, Vehicles with manual transmission --> «Right front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-front-exhaust-pipe-with-catalytic) , Vehicles with automatic transmission --> «Right front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-front-exhaust-pipe-with-catalytic) .

1. Align exhaust system free of tension --> «Exhaust system, installing free of tension»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__exhaust-system-installing-free-of-tension) .
2. Install right drive axle --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-filter-housing-removing-and-installing) .
4. Install power steering pump --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Install front coolant pipe --> «Front coolant line, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__front-coolant-line-removing-and-installing) .
2. Install ribbed belt «Installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__installing) .
3. Install intake manifold lower-part with high and low-pressure lines --> «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
4. Install intake manifold upper-part --> «24 - FUEL INJECTION SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-fuel-injection-ignition-engine-codes-bkh) .

1. Install lock carrier with attachments --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
2. Install front bumper cover --> «63 BUMPER»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «63 - BUMPERS»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET .
3. Change engine oil --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .
4. Replace coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

1. Fill power-steering system oil and bleed steering system --> «48 - STEERING»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Torque specifications

Vacuum pump for brake booster, removing and installing

Removing

1. Remove front engine cover - arrows -.

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

1. Disconnect vacuum hose - 1 - at vacuum pump.
2. Remove bolts - arrows - and remove vacuum pump.

Installing

Installation is in reverse order of removal, note the following

Note. Replace O-rings. Secure all hose connections using hose clamps appropriate for the model type .

Scheme 576

1. Position vacuum pump coupling - 1 - so that it engages symmetrical groove of camshaft - arrows - when installing vacuum pump.

Torque specifications

Scheme 577

Special tools, testers and auxiliary items required

1. Spark plug removal tool 3122 B
2. Compression tester V.A.G 1763
3. Puller T40039

Work procedure

1. Engine oil temperature min. 30 ° C.
2. Battery voltage at least 12.5 V.

1. Switch off ignition.

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

1. Remove coolant expansion tank - arrow -.
2. Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.

1. Disconnect check valve - 1 - from connection at air duct hose.
2. Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

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

1. Remove bolts - arrows - and separate electrical connections at ignition coils of left cylinder head.

Note. Ignore items - 1 to 4 -.

1. Remove bolts - arrows - and separate electrical connections at ignition coils of right cylinder head.

Note. Ignore items - 1 to 5 -.

1. Remove ignition coils using ignition coil puller T40039.

1. On rear of left cylinder head, disconnect electrical harness connector - 3 - for fuel injectors.

Note. Ignore - 1 - , - 2 - and - arrow -.

1. On rear of right cylinder head, disconnect electrical harness connector - 1 - for fuel injectors.

Note. Disregard - arrow -.

1. Using spark plug removal tool 3122 B , remove spark plugs.
2. Check compression using compression tester V.A.G 1763.

Note. Using tester operating instructions.

1. Have a second technician press accelerator pedal completely and at the same time operate starter long enough until pressure increase no longer appears on tester.

Assembly is in reverse order of removal, note the following

1. Install spark plugs --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .
2. Finally, check DTC memory and, if necessary, erase it. After DTC memory is erased, a readiness code must be generated for the engine control module using operating mode "Guided Fault Finding".

Torque specifications

Valvetrain, servicing

Note. Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked. After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting. Left cylinder head is shown in following illustration.

Scheme 578

1 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve dimensions»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
4. Check valve guides --> «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__valve-guides-checking)

2 - Sealing plug

3 - Cylinder head

1. Check valve guides --> «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__valve-guides-checking)

4 - Support element

1. With hydraulic valve clearance compensation
2. Checking --> «Support elements with hydraulic adjustment, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__support-elements-with-hydraulic-adjustment-checking)
3. Do not interchange
4. Lubricate contact surface

5 - Securing clip

1. Check for secure seat

6 - Intake camshaft

1. Removing and installing --> «Camshafts, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-removing-and-installing)
2. Checking axial play --> «Camshafts, checking axial clearance»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-checking-axial-clearance)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing- 24 mm dia.: 0.024 to 0.066 mm

1. Radial clearance at bearing- 36 mm dia.: 0.032 to 0.078 mm
2. Run-out: max. 0.04 mm

7 - Bearing bracket

1. With integrated camshaft bearings
2. Removing and installing --> «Camshafts, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-removing-and-installing)

8 - 9 Nm

9 - Exhaust camshaft

1. Removing and installing --> «Camshafts, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-removing-and-installing)
2. Checking axial play --> «Camshafts, checking axial clearance»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-checking-axial-clearance)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing- 24 mm dia.: 0.024 to 0.066 mm

1. Radial clearance at bearing- 36 mm dia.: 0.032 to 0.078 mm
2. Run-out: max. 0.04 mm

10 - Roller rocker lever

1. Do not interchange
2. Check roller for easy movement
3. Lubricate contact surface
4. To assemble, clip onto support element - 4 - with securing clip - 5

11 - Valve keys

12 - Valve spring plate

13 - Valve spring

1. Installed location: The tight spring coils face toward cylinder head

14 - Valve stem seal

1. Replacing --> «Valve stem seals, replacing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

15 - Intake valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve dimensions»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
4. Check valve guides --> «Valve guides, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__valve-guides-checking)

Camshafts, checking axial clearance

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387
2. Dial gauge VAS 6080

Work procedure

1. Perform measurement with roller rocker levers and support elements removed.

Scheme 579

1. Secure dial gauge holder VW 387 to dial gauge VAS 6080 on cylinder head.
2. Determine axial clearance.

1. Axial clearance: 0.100 to 0.191 mm.

Camshafts, removing and installing

Special tools, testers and auxiliary items required

1. Locking pin T40069

1. Camshaft locator T40070 (2x)
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

1. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
3. Remove camshaft timing chains from camshafts --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
4. To remove right camshafts, the vacuum pump for brake booster must be removed --> «Vacuum pump for brake booster, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__vacuum-pump-for-brake-booster-removing) .

Scheme 580

1. Loosen guide frame bolts in sequence - 22 to 1 -.

Note. Bearing bracket of left cylinder head is displayed in illustration.

1. Carefully remove guide frame.
2. Mark camshafts and remove.

Installing

Note. Always replace gaskets and seals. Secure crankshaft - 1 - using crankshaft holder T40069.

1. Using rotating plastic brush, remove any remaining sealant from cylinder head and guide frame.

1. Clean sealing surfaces, they must be free of oil and grease.
2. Oil journal surfaces of camshafts.
3. Place guide frame onto a soft surface on workbench.

Scheme 581

1. Set camshafts into guide frame.

1. The placement of camshafts must be exactly within axial bearings - arrows - of guide frame.
2. The ends of the piston rings - 1 - and - 2 - must face upward or downward, and must never face sideways.

1. Turn over guide frame with installed camshafts, thereby holding camshafts tight within guide frame.

1. Rotate camshafts until threaded holes - arrows - point upward.
2. Check whether camshafts still lie exactly in axial bearings of guide frame.

1. Mount camshaft locating tool T40070 as shown in the illustration and tighten bolts - arrows - to 20 Nm.

1. Cut tube nozzle at front marking (jet dia. approx. 1 mm).
2. Turn guide frame around again.

Scheme 582

1. Apply a small quantity of sealant in seal groove - 3 - in area of camshaft adjuster solenoid valve opening - arrows -.
2. Press seal into guide frame and wipe off escaping sealant on seal and guide frame.
3. Apply sealant beads - 1 - , - 2 - and - 4 - on clean sealing surfaces of guide frame as shown in illustration.

1. Thickness of sealant bead: 1.0 mm.

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

1. Attach guide frame on cylinder head immediately.

Note. Placing guide frame in place and tightening it should occur without interruption, since the sealant begins to harden immediately. After installing guide frame, sealant must dry for approx. 30 minutes.

1. Hand-tighten guide frame bolts equally, in sequence - 1 to 22 -.

1. The guide frame must be in contact with the entire contact surface of the cylinder head.

1. Fasten guide frame bolts in sequence - 22 to 1 - until they stop.

Note. Bearing bracket of left cylinder head is displayed in illustration.

1. Drive in sealing plugs flush.

Further installation is in reverse order of removal, note the following

Note. After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

1. Install vacuum pump for brake booster --> «Vacuum pump for brake booster, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__vacuum-pump-for-brake-booster-removing) .
2. Install camshaft timing chains onto camshafts --> «Detaching timing chains from camshaft, removing and installing chain tensioner»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
4. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .

Torque specifications

Scheme 583

Special tools, testers and auxiliary items required

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Valve cotter disassembly and assembly device VAS 5161 with guide plate VAS 5161/19 A

1. Adapter T40012

Work procedure

1. Remove camshafts --> «Camshafts, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-removing-and-installing) .
2. Mark positioning of roller rocker lever and support elements for re-installation.
3. Remove roller rocker lever together with support elements and place on a clean surface.
4. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 584

1. Place drift VAS 5161/3 on valve spring plate and loosen stuck valve keepers using a plastic hammer.

Scheme 585

1. Place guide plate VAS 5161/19 A from valve cotter disassembly and assembly device VAS 5161 on cylinder head.
2. Secure guide plate with knurled screws VAS 5161/12.
3. Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar positive pressure.

Scheme 586

1. Install engaging device VAS 5161/6 with installation fork VAS 5161/5 into guide plate.
2. Push installation cartridge VAS 5161/8 into guide plate.
3. Hook in pressure fork VAS 5161/2 at engaging device and press down installation cartridge.
4. At same time, turn knurled bolt of installation cartridge to the right, until points engage in valve keepers.

1. Lightly move knurled bolt back and forth, causing valve keepers to be pressed apart and be captured in the installation cartridge.
2. Release pressure fork.
3. Remove installation cartridge.
4. Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

1. Remove valve spring with valve spring plate.

Scheme 587

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

Scheme 588

If Valve Seal Removal Tool 3364 cannot be used, on several valve stem seals due to restricted clearance, proceed as follows

1. Using a drift, drive out roll pin - arrow - at Valve Seal Removal Tool 3364 and remove impact puller attachment.

Scheme 589

1. Place lower part of Valve Seal Removal Tool 3364 on valve stem seal.
2. Secure Valve Seal Removal Tool 3364 with a drift or cotter pin driver - 1 - , as shown in the illustration.
3. Place valve lever on Valve Seal Removal Tool 3364 and pull off valve stem seal - arrow -.

Scheme 590

Note. A plastic sleeve - A - is supplied with the new valve shaft seals.

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

1. Remove plastic sleeve again.

Scheme 591

If valve keys were removed from installation cartridge, they must be inserted into insertion device VAS 5161/18 next.

1. The large diameter of valve keepers point upward.

1. Install valve spring and valve spring plate.

Scheme 592

1. The tight spring coils - arrow - face toward cylinder head.

1. Install guide plate onto cylinder head again.
2. Insert installation cartridge into guide plate.
3. Press down pressure fork and pull knurled bolt upward turning to left and right - the valve keepers are inserted in this manner.
4. Release pressure fork with knurled bolt still pulled.

1. Ensure that all roller rocker levers seat properly on valve stem ends and are clipped onto respective support elements.
2. Install camshafts --> «Camshafts, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-removing-and-installing) .
3. Install spark plugs --> «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures) «01 - MAINTENANCE»(/audi/a4/b7-2004-2009/remont/procedures/#maintenance-procedures-cabriolet) for MAINTENANCE PROCEDURES - CABRIOLET .

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

Support elements with hydraulic adjustment, checking

Special tools, testers and auxiliary items required

1. Feeler gauge

Note. The support elements with hydraulic adjustment cannot be serviced. Irregular valve noises are normal while starting the engine.

Work procedure

1. Start engine and let it run until radiator fan has switched on once.
2. Increase engine speed for about 2 minutes to approx. 2500 RPM, perform road test if necessary.

If support elements with hydraulic adjustment are still loud, locate faulty support element as follows

1. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__right-cylinder-head-cover-removing-and) .
2. Rotate crankshaft until lobes on support element to be checked face upward

1. Vehicles with manual transmission: With 4th gear engaged an ignition switched off, slide forward.
2. Vehicles with multitronic: turn crankshaft clockwise at ribbed belt pulley center bolt.

Scheme 593

1. Check play between cam lobes and roller rocker lever.
2. Press roller rocker lever down with screwdriver - arrow -.

If a 0.20 mm feeler gauge can be inserted between camshaft and roller rocker lever

1. Replace support element --> «Camshafts, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-removing-and-installing) .

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

Scheme 594

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

Valve guides, checking

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387

1. Dial gauge VAS 6079

Work procedure

Scheme 595

1. Insert valve into valve guide. Due to slight difference in stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust guide.

1. Valve stem tip must seal with valve guide.

1. Determine tilt clearance.

1. Wear limit: 0.8 mm.

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

Valves, checking

1. Perform a visual check for signs of wear at stem and at seating surface.

If significant wear is discovered

1. Replace respective valve.

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. The oil level must not be above the max. mark - danger of damage to catalytic converter! Viscosity classes, oil specifications, oil capacities Maintenance tables.

Oil pan (lower part), oil pan (upper part), oil pump, oil cooler, component overview

Note. Oil injector jet for piston cooling Oil spray jet for piston cooling

Scheme 596

1 - 9 Nm

1. Insert using locking compound; locking compound .

2 - Oil Level Thermal Sensor G266

3 - Oil drain plug, 30 Nm

4 - 9 Nm

5 - Lower oil baffle

6 - 16 Nm

1. Fasten in diagonal sequence in steps

7 - Oil pan (upper section)

1. Removing and installing --> «Upper part of oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__upper-part-of-oil-pan-removing)

8 - O-ring

1. Replace

9 - 9 Nm

1. Insert using locking compound; locking compound .

10 - Upper oil baffle

11 - O-ring

1. Replace

12 - Gasket

1. Replace

13 - 9 Nm

14 - Oil cooler

1. See note
2. Removing and installing --> «Oil cooler, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh)
3. With oil cooler by-pass valve

15 - 9 Nm

16 - Drive shaft for oil pump

17 - Spring

18 - Bracket

19 - 9 Nm

20 - Chain sprocket for oil pump

1. Can only be placed onto drive shaft in one position

21 - 30 Nm plus an additional 90 ° ( 1 / 4 turn)

1. Replace
2. To loosen, counter hold on sprocket with pin wrench 3212

22 - O-ring

1. Replace

23 - O-rings

1. Replace

24 - 20 Nm

25 - Oil pump

1. Do not disassemble
2. With cold pressure relief valve 11 bar and pressure regulator valve 4.3 bar
3. Removing and installing --> «Oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-pump-removing-and-installing)

26 - 9 Nm

1. Fasten in diagonal sequence in steps

27 - Oil pan (lower section)

1. Removing and installing --> «Lower part of oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-part-of-oil-pan-removing)

28 - Seal

1. Replace

Oil spray jet for piston cooling

1. Insert bolt (9 Nm) using locking compound; locking compound
2. Oil spray jet with spray nozzle valve (opening pressure 2 to 2.4 bar positive pressure)

Scheme 597

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Drip tray for workshop crane VAS 6208
3. Hose Clamps Up to 25 mm dia. 3094

Removing

1. Open cap of coolant expansion tank.

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

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation. Rear section of noise insulation remains installed.

Scheme 598

1. Place drip tray for workshop crane VAS 6208 under engine.
2. Connection coolant hoses - 1 - and - 2 - with Hose Clamps Up to 25 mm dia. 3094.
3. Remove coolant hoses on oil cooler and drain coolant.
4. Place old oil collecting and extracting device V.A.G 1782 under engine.

1. Remove bolts - arrows - and remove oil cooler.

Installing

Installation is in reverse order of removal, note the following

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

1. Check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .
2. Fill with coolant --> «Cooling system, draining and filling»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

Torque specifications

Lower part of oil pan, removing and installing

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

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

1. Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation. Rear section of noise insulation remains installed.
2. Place old oil collecting and extracting device V.A.G 1782 under engine.
3. Drain engine oil.

1. Remove bolts - arrows - and remove oil cooler with coolant hoses - 1 - and - 2 - connected.

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

1. Remove bracket for refrigerant lines at right on oil pan - arrow -.

1. Remove left and right stabilizer bar mountings - 1 - and - 2 -.
2. Pivot stabilizer bar downward.

Scheme 599

1. Disconnect electrical connector - 1 - to Oil Level Thermal Sensor G266 and free up lines.
2. Remove lower part of oil pan - 2 - and carefully remove it.

Installing

Note. Always replace gaskets and seal.

Scheme 600

1. Using rotating plastic brush, remove any remaining sealant from lower part of oil pan and upper part.
2. Clean sealing surfaces so they are completely free of any oil or grease.

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

Scheme 601

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

1. Thickness of sealant bead: approx. 1.5 mm.

Note. Sealant bead must not be thicker than specified, otherwise excess sealant may get into lower section of oil pan and clog strainer in intake tube. The oil pan (lower part) must be installed within 5 minutes after application of sealant.

1. Set lower part of oil pan in place and fasten all bolts in diagonal sequence to 5 Nm.
2. Fasten bolts for lower part of oil pan in a diagonal sequence.
3. Install oil cooler --> «Oil cooler, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Add engine oil and check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .

Torque specifications

Oil pump, removing and installing

Removing

1. Remove lower section of oil pan --> «Lower part of oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-part-of-oil-pan-removing) .

Scheme 602

1. Remove bolts - arrows -.
2. Pull oil pump forward and off from drive shaft.

Installing

Installation is in reverse order of removal, note the following

Note. Replace O-rings.

1. Install oil pump onto drive shaft and fasten.
2. Install lower section of oil pan --> «Lower part of oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-part-of-oil-pan-removing) .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-level-checking) .

Torque specifications

Upper part of oil pan, removing and installing

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782
2. Protective glasses
3. Hand drill with plastic brush attachment
4. Sealant

Removing

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

1. Loosen quick-release fasteners - 1 through 3 - and remove front and rear noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine.
3. Drain engine oil.
4. Remove engine: Vehicles with manual transmission --> «Engine, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-removing) , vehicles with automatic transmission --> «Engine, removing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .

1. Separate engine/transmission assembly: Vehicles with manual transmission --> «Engine and manual transmission, separating»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-and-manual-transmission-separating) , vehicles with automatic transmission --> «Engine and automatic transmission 09L, separating»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-and-automatic-transmission-09l-separating) .
2. Secure engine to assembly stand: Vehicles with manual transmission --> «Engine, securing to assembly stand»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__engine-securing-to-assembly-stand) , vehicles with automatic transmission --> «Engine, securing to assembly stand»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Vehicles with manual transmission: Remove clutch pressure plate --> 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «30 CLUTCH»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «30 CLUTCH»(ref-278904-S05381615532008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE and dual mass flywheel --> «Dual mass flywheel (vehicles with manual transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__dual-mass-flywheel-vehicles-with-manual) .
4. Vehicles with automatic transmission: Remove drive plate --> «Drive plate (vehicles with automatic transmission), removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-vehicles-with-automatic-transmission) .

1. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__left-and-right-timing-chain-covers) .
2. Remove lower timing chain cover --> «Lower timing chain cover, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-timing-chain-cover-removing-and) .
3. Remove front sealing flange --> «Front sealing flange with crankshaft seal, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__front-sealing-flange-with-crankshaft-seal) .
4. Remove lower section of oil pan --> «Lower part of oil pan, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__lower-part-of-oil-pan-removing) .

1. Remove oil pump --> «Oil pump, removing and installing»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh__oil-pump-removing-and-installing) .

Scheme 603

1. Remove bolts - arrows - and remove lower oil baffle.

Scheme 604

1. Remove bolts - 1 to 6 - for upper section of oil pan.
2. Press upper part of oil pan from alignment pins of cylinder block.

Installing