3.2 v6 4v Engine Mechanical, Engine Code(s): Bkh Audi A6 С6

Safety Precautions

Note the following when working on the fuel system

1. Procedures before opening high pressure fuel injection system --> «Before Opening High Pressure Fuel Injection System»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__before-opening-high-pressure-fuel-injection) .

To prevent personal injury and damage to the injection and ignition system, observe the following

1. The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
2. Only clean engine with ignition switched off.
3. If electrical connectors were disconnected, faults are saved in ECM

1. Connect Vehicle Diagnosis, Testing and Information System VAS 5051B.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

1. Disconnect battery --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .

Note the following when working on the cooling system

If it is necessary to use testing and measuring devices on road tests, observe the following

Before Opening High Pressure Fuel Injection System

1. The fuel injection system is separated into a high-pressure section (max. approximately 120 bar) and a low-pressure section (approximately 6 bar).
2. Before opening high pressure area, fuel pressure must be reduced to a residual pressure of approximately 6 bar. The procedure for this is as follows.

Special tools, testers and auxiliary items required

1. Vehicle diagnostic, testing, and information system VAS 5051B

Procedure

Proceed as follows

Scheme 1

1. Connect vehicle diagnosis, testing and information system VAS 5051B while the ignition is switched off.

Scheme 2

Display on VAS 5051B

1. Press Vehicle Self-Diagnosis button - 1 - in selection.

Scheme 3

Display on VAS 5051B

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

Scheme 4

Display on VAS 5051B

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

Scheme 5

Display on VAS 5051B

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

Scheme 6

Display on VAS 5051B

Example

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

Scheme 7

1. Press button A to activate basic setting.

Display on VAS 5051B

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.

1. Lay clean cloths around connectors and catch escaping fuel.

Final procedures

1. Start "Guided Functions" operating mode.
2. Generate readiness code in ECM.

General Repair Information

> Clean Working Conditions

> Contact Corrosion

> Lines, Routing and Securing

Clean Working Conditions

Even a little contamination can lead to faults. When working on the fuel supply and on the fuel injection system, observe the following guidelines for a clean working environment

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. Use lint-free cloths.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (e.g. in tool boxes etc.).

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

Contact Corrosion

Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are 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.

If there are doubts about the suitability of parts, generally use new parts .

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.

Lines, Routing and Securing

To prevent mistakes and ensure the original installation location is kept, mark the hydraulic lines, vacuum lines or electrical lines before removing them. If necessary, draw sketches or take pictures.

Engine Data

Scheme 8

1. Remove front engine cover - arrows -.

Scheme 9

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

Engine, with Multitronic Transmission, Removing and Installing

> Engine, Removing

> Engine and Transmission, Separating

> Engine, Securing to Engine and Transmission Holder

> Engine, Installing

Scheme 10

Special tools, testers and auxiliary items required

1. Pry Lever - Rmv Outside Mirror 80-200
2. Hose Clamps Up to 25 mm dia. 3094
3. Hose clamp pliers V.A.G 1921
4. Step ladder VAS 5085

1. Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
2. Drip tray for workshop crane VAS 6208

Special tools, testers and auxiliary items required

Scheme 11

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

Scheme 12

1. Tension strap T10038

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

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.

Note. So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.

1. Remove luggage compartment floor trim.

Scheme 13

1. Release retaining clips - arrows - with a screwdriver - 2 - and remove cover - 1 -.

Scheme 14

1. Disconnect Ground (GND) cable - arrow - at battery.

Scheme 15

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrows -.

1. Open cap of coolant expansion tank.

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

Scheme 16

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

Note. Secure brake discs using a wheel bolts.

Scheme 17

1. Remove noise insulation and mountings - 1, 2 - - arrow - where present.

Scheme 18

1. Place drip tray for workshop crane VAS 6208 under engine.
2. Open drain plug - 1 - and allow coolant to drain.
3. Then disconnect coolant hose - 2 - from radiator.

Scheme 19

1. Disconnect coolant hose - arrow - from oil cooler and drain remaining coolant.
2. Then remove coolant hose.

Scheme 20

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

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

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

1. Hang up air conditioning compressor with attached lines on left side of vehicle.

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

Scheme 21

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

Vehicles with auxiliary heater

Scheme 22

1. Remove right front wheel housing liner in front area --> «66 - EXTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove bolt - arrow - for corrugated exhaust pipe.

Scheme 23

1. Loosen nut - A - on clamp for corrugated exhaust pipe.
2. Remove bolt - B - and remove muffler with corrugated exhaust pipe.

All

Scheme 24

1. Remove bolts - arrows - and remove torque support from engine.

Note. Observe the rules of cleanliness for working on automatic transmissions --> 00 TECHNICAL DATA .

1. Place old oil collecting and extracting device V.A.G 1782 under engine.

Scheme 25

1. Loosen union nuts - 2 - and - 3 - and disconnect ATF lines.

Note. Ignore - 1 -.

Scheme 26

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

Scheme 27

1. Remove vacuum hose - arrow - for brake booster at bulkhead.

Scheme 28

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

Scheme 29

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

Scheme 30

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

Scheme 31

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

Scheme 32

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

Scheme 33

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

Scheme 34

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

Scheme 35

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

Scheme 36

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

Scheme 37

1. Open clips - arrows - and remove upper part of air filter housing.

Scheme 38

1. Disconnect vacuum line - 1 -.
2. Remove pin from spreader clips - 3 -.
3. Remove lower part of air filter housing and, on the backside, disconnect electrical connection - 2 - at the intake air switch-over valve N335.

Scheme 39

1. Disconnect vacuum hose - arrow - to EVAP canister.

Scheme 40

1. Remove nuts - 2 - and - 3 - and remove right bracket for harness connectors from bulkhead.
2. Remove Ground (GND) wire - 1 - on right strut tower.

Scheme 41

1. Remove Ground (GND) wire - arrow - on left strut tower.

Scheme 42

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

Scheme 43

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

Scheme 44

1. Pry off caps on the wiper arms using a screwdriver.
2. Loosen nuts - arrows - by several turns.
3. Loosen wiper arms by gently rocking the wiper arm. Remove the nuts and remove the wiper arms.

Scheme 45

1. Remove bolts - arrows - for cowl grill - 1 -.

1. Pull cowl grill off from windshield.

Scheme 46

1. If equipped, remove bolts - 1 - and - 3 - and remove strut tower brace - 2 -.

Scheme 47

1. Remove bolts - arrows - and remove cover form E-box at left in engine compartment.

Scheme 48

1. Release retaining tabs and pull fuse holder - 1 - and 3-socket relay carrier - 4 - upward and off.
2. Remove electrical wire connection - 3 -.
3. Disconnect all electrical connections - 2 - at rear on the connector strip.
4. Disengage and free up engine wiring harness at E-Box.

Scheme 49

1. Remove bolts - arrows - and remove cover for E-box at right in engine compartment.

Scheme 50

1. Where present, open cover - 1 - using a screwdriver - arrow - and remove.

Scheme 51

1. Carefully pry off the retaining clip - 3 - with a screwdriver - arrows 1 and 2 - and remove the ECM from the E-box.

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

1. Unclip suppression capacitor - 5 - from bracket in E-box.
2. Disconnect electrical connection - 4 - at rear on connector strip.
3. Remove electrical wiring connections - 1 - and - 2 -.

Scheme 52

1. Free electrical wiring up to generator using Pry Lever - Rmv Outside Mirror 80-200.
2. Set both wiring harnesses on engine and secure Engine Control Module (ECM) against falling down.
3. Have a second technician press brake pedal.

Scheme 53

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

Scheme 54

1. Evenly remove left and right nuts - 1 -.
2. Remove left and right bolts - 2 - and remove stabilizer bar.

Scheme 55

1. Disconnect electrical harness connector - 2 - at Level Control System Sensor.

Scheme 56

1. Disconnect connecting link - 1 - at control arm.

1. Tie up wheel bearing housing with Tension Strap T10038 as shown in illustration.

Scheme 57

1. Remove suspension strut from control arm - arrow -.

Scheme 58

1. Remove guide control arm - 1 - and control arm - 2 - on subframe.

Scheme 59

1. Swing guide control arm - 1 - and control arm - 2 - outward.

1. Repeat work procedure on opposite side of the vehicle.

Scheme 60

1. Remove heat shield for drive axle - arrows -.
2. Remove drive axle from transmission flanged shaft.

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

Scheme 61

1. Loosen clamping sleeves - 1 - and - 2 -.

Scheme 62

1. Remove front transverse beam - arrows -.

Scheme 63

1. Remove subframe transverse beam - arrows -.

Scheme 64

Prepare scissor lift platform

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

1. Install support elements first tightly by hand on scissor lift platform.
2. Place scissor lift platform VAS 6131 A in horizontal position.

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

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

Scheme 65

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 screwed in.

Scheme 66

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

Scheme 67

1. Position support elements from VAS 6131/10 at rear 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 A.

Scheme 68

1. Remove bolts - arrows - on tunnel cross member.

Scheme 69

1. Remove bolts - 1 -.
2. Mark installation position of subframe and of both engine mount consoles to longmembers using a felt-tip marker.
3. Remove bolts - 2 - , - 3 - and - 4 - in diagonal sequence and in stages.

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. Slowly lower engine/transmission subassembly downward (approximately 10 cm).
2. Mark selector lever cable bracket installation location.

Scheme 70

1. Remove selector lever cable bracket bolt - 1 -.
2. Press ball socket - 2 - of selector lever cable from selector shaft lever.

Note. Do not bend or kink selector lever cable.

1. Completely lower Scissor Lift Table VAS 6131 A and remove it with engine/transmission assembly under vehicle.

Engine and Transmission, Separating

Special tools, testers and auxiliary items required

1. Support Set VAS 6131/10 and Supplementary Set Audi A6 (C6) VAS 6131/12

Procedure

1. Engine/transmission assembly removed and placed on Scissor Lift Table VAS 6131 A.

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 the subframe support elements on scissor lift table VAS 6131 A.

Scheme 71

1. Remove ATF line bracket - arrow -.

Note. Observe the rules of cleanliness for working on automatic transmissions --> 00 TECHNICAL DATA .

Scheme 72

1. Remove bolt - arrow - and disconnect ATF lines from transmission.

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

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

Scheme 73

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

Scheme 74

1. Position support elements from VAS 6131/10 and VAS 6131/12 at right on engine/transmission assembly 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 A.

Scheme 75

1. Release electrical connector - 1 - and remove from transmission.
2. Free up wiring harness to engine - arrows -.

Scheme 76

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

1. Disconnect electrical harness connector - 2 - 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 - 1 -.

Note. Do not bend the flex joint in front of the exhaust pipe more than 10 or it could be damaged.

Scheme 77

1. Remove bolts - 1 - at rear bracket for exhaust system.

Note. Ignore - 2 - and - 3 -.

Scheme 78

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

Note. Ignore - 2 -.

Scheme 79

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

Scheme 80

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 -.

Note. Do not bend the flex joint in front of the exhaust pipe more than 10 or it could be damaged.

1. Remove bolts - 2 - at rear bracket for exhaust system.

Note. Ignore - 1 - and - 3 -.

Scheme 81

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

Note. Ignore - 2 -.

Scheme 82

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

Scheme 83

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

Scheme 84

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

Scheme 85

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

Procedure

1. Engine separated from transmission --> «Engine and Transmission, Separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__engine-and-transmission-separating) .

Scheme 86

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. Remove engine supports from cylinder block.

Scheme 87

1. Secure engine using bracket VAS 6095/1-5 to 40 Nm Engine and Transmission Holder VAS 6095 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 with hose clamps appropriate for the model . During installation, all cable ties must be re-installed at the same location. Clean the transmission input shaft splines and the splines of the damper unit on the flywheel, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Remove all excess grease.

1. Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
2. Attach transmission to engine with new bolts.

Note. Tightening 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, noting the following.

1. Install front exhaust pipes with catalytic converter: Left --> «Left Front Exhaust Pipe with Catalytic Converter, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) , right --> «Right Exhaust Pipe with Catalytic Converter, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Fasten ATF lines --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

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 A.

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 A.

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

1. Equip scissor lift platform VAS 6131 A 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.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A.
4. Using Scissor Lift Platform VAS 6131 A , slowly guide engine/transmission unit with subframe into body from below.

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

1. 55 Nm
2. 115 Nm
3. 115 Nm
4. 75 Nm

1. Tighten bolts - arrows - at tunnel cross member.

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

1. Install selector lever cable, adjust if necessary --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install guide control arm, control arm, stabilizer bar and suspension strut --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Align exhaust system free of tension --> «Exhaust System, Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__exhaust-system-installing) .

1. Install front cross member --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install subframe front cross member --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install A/C compressor --> «87 - AIR CONDITIONING»(/audi/a6/6-2004-2008/remont/ac-compressor/#heating-air-conditioning) .
4. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-removing-and-installing) .

Scheme 88

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 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .

1. Mount wiper arms and adjust --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .
2. Check oil level --> «Oil Level, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Bleed fuel system --> «24 - FUEL INJECTION SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
4. Fill with coolant --> «Cooling System, Draining and Filling»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Check ATF level --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Align subframe and both engine bearing plates --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering)
4. Perform axle alignment --> «44 - WHEELS, TIRES, WHEEL ALIGNMENT»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening Specifications

Note. Tightening 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, with Automatic Transmission 09L, Removing and Installing

> Engine, Removing

> Engine and Automatic Transmission 09L, Separating

> Engine, Securing to Engine and Transmission Holder

> Engine, Installing

Engine, Removing

Special tools, testers and auxiliary items required

1. Pry Lever - Rmv Outside Mirror 80-200
2. Hose Clamps Up to 25 mm dia. 3094
3. Hose clamp pliers V.A.G 1921
4. Step ladder VAS 5085

1. Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
2. Drip tray for workshop crane VAS 6208

Special tools, testers and auxiliary items required

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

1. Tension strap T10038

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.

Note. So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted. On vehicles with all-wheel drive, the electrical parking brake must be released before disconnecting the battery, so that the driveshaft can be rotated for removal.

1. Remove luggage compartment floor trim.
2. Release retaining clips - arrows - with a screwdriver - 2 - and remove cover - 1 -.

1. Disconnect Ground (GND) cable - arrow - at battery.

1. Remove front engine cover - arrows -.

1. Remove rear engine cover - arrows -.

1. Open cap of coolant expansion tank.

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation 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.
3. Remove both front wheels.

Note. Secure brake discs using a wheel bolt.

1. Remove noise insulation and mountings - 1, 2 - - arrow - where present.

1. Place drip tray for workshop crane VAS 6208 under engine.
2. Open drain plug - 1 - and allow coolant to drain.
3. Then disconnect coolant hose - 2 - from radiator.

1. Disconnect coolant hose - arrow - from oil cooler and drain remaining coolant.
2. Then remove coolant hose.

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

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

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

1. Hang up the air conditioning compressor with attached lines on left side of vehicle.

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

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

Vehicles with auxiliary heater

1. Remove right front wheel housing liner in front area --> «66 - EXTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Remove bolt - arrow - for corrugated exhaust pipe.

1. Loosen nut - A - on clamp for corrugated exhaust pipe.
2. Remove bolt - B - and remove muffler with corrugated exhaust pipe.

All

1. Remove bolts - arrows - and remove torque support from engine.

Note. Observe the rules of cleanliness for working on automatic transmissions --> 00 TECHNICAL DATA .

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

Note. Ignore - 1 -.

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

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

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

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.

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

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

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

1. Open clips - arrows - and remove upper part of air filter housing.

1. Disconnect vacuum line - 1 -.
2. Remove pin from spreader clips - 3 -.
3. Remove lower part of air filter housing and, on the backside, disconnect electrical connection - 2 - at the intake air switch-over valve N335.

1. Disconnect vacuum hose - arrow - to EVAP canister.

1. Remove nuts - 2 - and - 3 - and remove right bracket for harness connectors from bulkhead.
2. Remove Ground (GND) wire - 1 - on right strut tower.

1. Remove Ground (GND) wire - arrow - on left strut tower.

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

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

1. Pry off caps on the wiper arms using a screwdriver.
2. Loosen nuts - arrows - by several turns.
3. Loosen wiper arms by gently rocking the wiper arm. Remove nuts and wiper arms.

1. Remove bolts - arrows - for cowl grill - 1 -.

1. Pull cowl grill off from windshield.

1. If equipped, remove bolts - 1 - and - 3 - and remove strut tower brace - 2 -.

1. Remove bolts - arrows - and remove cover form E-box at left in engine compartment.

1. Release retaining tabs and pull fuse holder - 1 - and 3-socket relay carrier - 4 - upward and off.
2. Remove electrical wire connection - 3 -.
3. Disconnect all electrical connections - 2 - at rear on the connector strip.
4. Disengage and free up engine wiring harness at E-Box.

1. Remove bolts - arrows - and remove cover for E-box at right in engine compartment.

1. Where present, open cover - 1 - using a screwdriver - arrow - and remove.

1. Carefully pry off retaining clip - 3 - with a screwdriver - arrows 1 and 2 - and remove ECM from the E-box.

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

1. Unclip suppression capacitor - 5 - from bracket in E-box.
2. Disconnect electrical connection - 4 - at rear on the connector strip.
3. Remove electrical wiring connections - 1 - and - 2 -.

1. Free electrical wiring up to generator using Pry Lever - Rmv Outside Mirror 80-200.
2. Set both wiring harnesses on engine and secure Engine Control Module (ECM) against falling down.

1. Have a second technician press brake pedal.

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

1. Evenly remove left and right nuts - 1 -.
2. Remove left and right bolts - 2 - and remove stabilizer bar.

1. Disconnect electrical harness connector - 2 - at Level Control System Sensor.
2. Disconnect connecting link - 1 - at control arm.

1. Tie up wheel bearing housing with Tension Strap T10038 as shown in illustration.

1. Remove suspension strut from control arm - arrow -.

1. Remove guide control arm - 1 - and control arm - 2 - on subframe.

1. Swing guide control arm - 1 - and control arm - 2 - outward.

1. Repeat work procedure on opposite side of the vehicle.
2. Remove drive axle from transmission flanged shaft.

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

1. Remove subframe transverse beam - arrows -.

Scheme 89

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

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.

1. Loosen clamping sleeves - 1 - and - 2 -.

1. Remove front transverse beam - arrows -.

Scheme 90

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

Scheme 91

1. Tie driveshaft up and to the side against heat shield - arrow -.

Prepare scissor lift platform

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

1. Install support elements first tightly by hand on scissor lift platform.
2. Place scissor lift platform VAS 6131 A in horizontal position.

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

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

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

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

Scheme 92

1. Position support elements from VAS 6131/10 and VAS 6131/12 at left on transmission and tunnel cross member as shown in illustration.

Scheme 93

1. Position support elements from VAS 6131/10 and VAS 6131/11 at right 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 A.

1. Remove bolts - arrows - on tunnel cross member.

1. Remove bolts - 1 -.
2. Mark installation position of subframe and of both engine mount consoles to longmembers using a felt-tip marker.
3. Remove bolts - 2 - , - 3 - and - 4 - in diagonal sequence and in stages.

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. Slowly lower engine/transmission subassembly downward.
2. Remove scissor lift table VAS 6131 A under vehicle.

Engine and Automatic Transmission 09L, Separating

Special tools, testers and auxiliary items required

Scheme 94

1. Adapter T40058

Procedure

1. Engine/transmission assembly removed and placed on Scissor Lift Table VAS 6131 A.

1. Twist spindles of support elements at left and right at subframe completely downward.
2. Remove support pins from spindles.
3. Remove subframe to the side.

Note. A second technician is required to remove subframe.

1. Remove both base plates of the subframe support elements on scissor lift table VAS 6131 A.

Note. Support points for front of engine, transmission and tunnel cross member remain unchanged.

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

Scheme 95

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

Scheme 96

1. Position support elements from VAS 6131/10 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 A.

1. Disconnect electrical harness connector - 2 - 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 - 1 -.

Note. Do not bend the flex joint in front of the exhaust pipe more than 10 or it could be damaged.

1. Remove bolts - 1 - at rear bracket for exhaust system.

Note. Ignore - 2 - and - 3 -.

Scheme 97

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

Note. Disregard the other items.

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 -.

Note. Do not bend the flex joint in front of the exhaust pipe more than 10 or it could be damaged.

1. Remove bolts - 2 - at rear bracket for exhaust system.

Note. Ignore - 1 - and - 3 -.

1. Remove bolt - 6 - at right bracket for front exhaust pipe.

Note. Disregard the other items.

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 TECHNICAL DATA .

Scheme 98

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

Scheme 99

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

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

Scheme 100

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

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

Scheme 101

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

Scheme 102

1. Disconnect electrical harness connector - 1 - at right engine mount.
2. Free up electrical wire on engine mount console.
3. Remove bolts - arrows - and remove right engine mount.

Note. Shown without engine mount console to provide a better illustration.

Scheme 103

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

Scheme 104

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

Scheme 105

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

Note. Disregard - arrow -.

Scheme 106

1. Remove 3 torque converter bolts - arrows - in opening on 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 A and pull rear platform top with transmission toward rear - arrow - , simultaneously push torque converter through opening of drive plate while doing this.
2. Secure torque converter in transmission to prevent it from falling out.

Engine, Securing to Engine and Transmission Holder

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

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.

Scheme 107

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

Note. Shown without engine mount console to provide a better illustration.

1. Secure engine using bracket VAS 6095/1-5 to 40 Nm Engine and Transmission Holder VAS 6095 as shown in illustration.

Special tools, testers and auxiliary items required

1. Depth gauge

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 with hose clamps appropriate for the model . During installation, all cable ties must be re-installed at the same location.

Installation dimension for torque converter, checking

Scheme 108

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 minimum 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 the removed starter - arrow -.
2. To secure torque converter to drive plate, use new original ribbed bolts .
3. Make sure alignment 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. Tightening 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, noting the following.

1. Fasten the ATF lines --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Install front exhaust pipes: Left --> «Left Front Exhaust Pipe with Catalytic Converter, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) , right --> «Right Exhaust Pipe with Catalytic Converter, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Always clean threaded bores in transmission flanged shaft for locking fluid residue using a tap before installation.

1. Turn spindle of left support element on engine downward.
2. Remove base plate for left support element on scissor lift platform VAS 6131 A.

1. Turn spindle of right support element on engine downward.
2. Remove base plate for right support element on scissor lift platform VAS 6131 A.

Note. Support points for front of engine, transmission and tunnel cross member remain unchanged.

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

Note. A second technician is required to position subframe onto support elements.

1. Position subframe on both support elements 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 A.
4. Using Scissor Lift Platform VAS 6131 A , slowly guide engine/transmission unit with subframe into body from below.

1. Align subframe and engine bearing consoles according to markings applied on longmembers during removal.
2. Tighten bolts for subframe and engine mount consoles only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

1. 55 Nm
2. 115 Nm
3. 115 Nm
4. 75 Nm

1. Fasten bolts - arrows - for tunnel cross member.

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

1. Install selector lever cable, adjust if necessary --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install guide control arm, control arm, stabilizer bar and suspension strut --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Install subframe cross member --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Install front cross member --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install driveshaft --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-01r) for REAR FINAL DRIVE 01R «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#rear-final-drive-0ar) for REAR FINAL DRIVE 0AR .
3. Align exhaust system --> «Exhaust System, Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__exhaust-system-installing) .
4. Install A/C compressor --> «87 - AIR CONDITIONING»(/audi/a6/6-2004-2008/remont/ac-compressor/#heating-air-conditioning) .

1. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-removing-and-installing) .

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 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .

1. Mount wiper arms and adjust --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .
2. Install dome brace --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Check oil level --> «Oil Level, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Bleed fuel system --> «24 - FUEL INJECTION SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-fuel-injection-ignition-engine-codes-bkh) .

1. Fill with coolant --> «Cooling System, Draining and Filling»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Check ATF level --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Align subframe and both engine bearing consoles --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering)
4. Perform axle alignment --> «44 - WHEELS, TIRES, WHEEL ALIGNMENT»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening Specifications

Note. Tightening 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%.

Belt Pulley Side, Servicing

> Ribbed Belt Drive, Component Overview

> Coolant Pump Ribbed Belt Pulley, Removing and Installing

> Power Steering Pump Ribbed Belt Pulley, Removing and Installing

> Ribbed Belt, Removing and Installing

> Vibration Damper, Removing and Installing

> Ribbed Belt Side Sealing Flange with Crankshaft Seal, Replacing

Scheme 109

1 - Ribbed belt

1. Check for wear
2. Before removing, mark direction of rotation using chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt
3. Removing and installing --> «Ribbed Belt, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-removing-and-installing)
4. When installing, make sure it is seated correctly on the pulleys

2 - 20 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

3 - 22 Nm

4 - Generator

1. Removing and installing --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/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

1. Removing and installing --> «Coolant Pump Ribbed Belt Pulley, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__coolant-pump-ribbed-belt-pulley-removing)

9 - 9 Nm

10 - Coolant pump

1. Removing and installing --> «Coolant Pump, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering)

18 - 20 Nm

19 - Belt pulley for power steering pump

1. Removing and installing --> «Power Steering Pump Ribbed Belt Pulley, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-steering-pump-ribbed-belt-pulley)

20 - 20 Nm

21 - 25 Nm

22 - Air conditioner compressor

1. Do not unfasten/separate refrigerant lines
2. Removing and installing --> «87 - AIR CONDITIONING»(/audi/a6/6-2004-2008/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. Various versions. Sequence
3. Removing and installing --> «Vibration Damper, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

Coolant Pump Ribbed Belt Pulley, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 110

1. Spanner Wrench 3212

Removing

1. Remove front engine cover - arrows -.

1. Pivot tensioning device in direction of - arrow - to relieve tension on ribbed belt.
2. Remove ribbed belt from coolant pump belt pulley.
3. Release tensioner unit

Scheme 111

1. Remove ribbed belt pulley from coolant pump.
2. When loosening bolts use spanner wrench 3212 to counter-hold.

Installing

Installation is in reverse order of removal, noting the following

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

1. Start engine and check belt running.

Tightening specifications

Power Steering Pump Ribbed Belt Pulley, Removing and Installing

Special tools, testers and auxiliary items required

1. Spanner Wrench 3212

Removing

1. Remove front engine cover - arrows -.

1. Pivot tensioning device in direction of - arrow - to relieve tension on ribbed belt.
2. Remove ribbed belt from power steering pump belt pulley.
3. Release tensioner unit

Scheme 112

1. Remove ribbed belt pulley from power steering pump.
2. When loosening bolts use spanner wrench 3212 to counter-hold.

Installing

Installation is in reverse order of removal, noting the following

1. Installation position: Designation "Front" points in direction of travel.

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

1. Start engine and check belt running.

Tightening specifications

Ribbed Belt, Removing and Installing

Removing

1. Remove front engine cover - arrows -.

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.

Installing

Installation is in reverse order of removal, noting the following

Scheme 113

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. Start engine and check belt running.

Vibration Damper, Removing and Installing

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

Removing

1. Remove front engine cover - arrows -.

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.

1. Remove noise insulation and the mountings - 1, 2 - - arrow - where present.

Scheme 114

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

Installing

Installation is in reverse order of removal, noting the following

1. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-removing-and-installing) .

Tightening specifications

Ribbed Belt Side Sealing Flange with Crankshaft Seal, Replacing

Special tools, testers and auxiliary items required

Scheme 115

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

Procedure

1. Remove ribbed belt from the coolant pump --> «Coolant Pump Ribbed Belt Pulley, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__coolant-pump-ribbed-belt-pulley-removing) .
2. Remove vibration damper --> «Vibration Damper, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Scheme 116

1. Remove bolts - arrows -.
2. Remove sealing flange on the belt pulley side.

Note. Replace the ribbed belt side sealing flange.

Scheme 117

1. Remove any sealant residue remaining on the cylinder block and the upper part of the oil pan; use a rotating plastic brush, for example.
2. Clean sealing surfaces so they are completely free of any oil or grease.

Scheme 118

1. Cut tube nozzle at front marking (diameter of nozzle approximately 1.5 mm).

Scheme 119

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

1. The groove - arrow - of sealing surface must be completely filled with sealant.
2. The sealant bead must be 1.5 to 2.0 mm above the 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 sealing flange on the belt pulley side must be installed within 5 minutes after applying the sealant.

Scheme 120

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

Scheme 121

1. Place sealing flange with inserted pull sleeve T40048/2 onto crankshaft.
2. Without tipping, push the sealing flange onto engine sealing surface and fasten.

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

1. Install vibration damper --> «Vibration Damper, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Install coolant pump ribbed belt --> «Coolant Pump Ribbed Belt Pulley, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__coolant-pump-ribbed-belt-pulley-removing) .
3. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-removing-and-installing) .

Tightening specifications

Timing Chain Side, Servicing

> Flywheel, Multitronic, Component Overview

> Damper Unit, Removing and Installing

> Flywheel, Multitronic Transmission, Removing and Installing

> Drive Plate, Automatic Transmission 09L, Component Overview

> Drive Plate, Automatic Transmission 09L, Removing and Installing

> Crank Shaft Seal, Timing Chain Side, Replacing

Scheme 122

1 - Damper unit

1. Removing and installing --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing)

2 - 22 Nm

3 - Flywheel

1. Removing and installing --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing)

4 - Crankshaft

5 - Shaft seal for crankshaft -timing chain side

1. Replacing --> «Crank Shaft Seal, Timing Chain Side, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

6 - 60 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

Damper Unit, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 123

1. Counter-holder tool 10 - 201

Removing

Scheme 124

1. Remove multitronic transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Insert counterhold tool 10 - 201 to loosen bolts - arrow -.

Scheme 125

1. Remove bolts - 1 - and disconnect damper unit - A - from the flywheel - B -.

Installing

Installation is in reverse order of removal, noting the following

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

1. Align damper unit - A - on the flywheel - B -.

1. Both tabs - 2 - must match up with each other.

1. Install bolts - 1 - hand-tight and then tighten diagonally.
2. Install multitronic transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Tightening specifications

Flywheel, Multitronic Transmission, Removing and Installing

Special tools, testers and auxiliary items required

1. Counter-holder tool 10 - 201

Removing

1. Remove multitronic transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Remove damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) .
3. Mark crankshaft flywheel

Scheme 126

1. Insert counterhold tool 10 - 201 to loosen bolts - arrow -.
2. Remove bolts and the flywheel.

Installing

Installation is in reverse order of removal, noting the following

Note. Replace the flywheel bolts.

1. Turn over counterhold tool 10 - 201 to tighten bolts.
2. Install damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) .
3. Install multitronic transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Tightening specifications

Scheme 127

1 - Drive plate

1. Removing and installing --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing)

2 - Backing plate

3 - 60 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

4 - Centering washer

1. Installed location --> «Centering washer for drive plate on automatic transmission 09L»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__centering-washer-for-drive-plate-on)

5 - Crankshaft

6 - Shaft seal for crankshaft -timing chain side

1. Replacing --> «Crank Shaft Seal, Timing Chain Side, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Drive Plate, Automatic Transmission 09L, Removing and Installing

Special tools, testers and auxiliary items required

1. Counter-holder tool 10-201

Removing

1. Remove automatic transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Scheme 128

1. Insert counter hold tool 10-201 to loosen the 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, noting the following

Scheme 129

1. Install drive plate with centering washer - arrow - and backing plate.
2. Use new bolts when securing.
3. Turn over counterhold tool 10-201 to tighten bolts.
4. Install automatic transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Tightening specifications

Crank Shaft Seal, Timing Chain Side, Replacing

Special tools, testers and auxiliary items required

Scheme 130

1. Pulling fixture T10122

Scheme 131

1. Extractor lever T20143/2

Procedure

1. Remove transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Vehicles with multitronic transmission: Remove damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) and flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) .
3. Vehicles with automatic transmission 09L: Remove drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .

Scheme 132

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

Scheme 133

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

Scheme 134

1. Install pull sleeve T10122/2 with shaft seal - 1 - onto crankshaft.

Scheme 135

1. Press shaft seal in, evenly and flush, using pressure sleeve T10122/3.

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

1. Vehicles with multitronic transmission: Install flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) and damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) .
2. Vehicles with automatic transmission 09L: Install drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
3. Install transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

Timing Chain Covers

> Timing Chain Covers, Component Overview

> Timing Chain Covers, Removing and Installing

> Lower Timing Chain Cover, Removing and Installing

Scheme 136

1 - M6 - 9 Nm; M8 - 20 Nm

1. Observe sequence for tightening: Vehicles through 04.2005 --> Set lower timing chain cover in place, guiding the cover at an angle from below onto the sealing surface of the cylinder block and cylinder head. under «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) , vehicles from 05.2005 --> Set lower timing chain cover in place, guiding the cover at an angle from below onto the sealing surface of the cylinder block and cylinder head. under «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

2 - Shaft seal for crankshaft timing chain side

1. Replacing --> «Crank Shaft Seal, Timing Chain Side, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

3 - Alignment bushing

1. 2 pieces

4 - Lower timing chain cover

1. Removing and installing --> «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

5 - Left cylinder head gasket

6 - 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 1 to 8. under «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

7 - Left timing chain cover

1. Removing and installing --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

8 - 16 Nm

1. For vehicles from 05.2005

9 - 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 1 to 8. under «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

10 - Right timing chain cover

1. Removing and installing --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

11 - Right cylinder head gasket

12 - Alignment bushing

1. 2 pieces

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

Removing

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 -.

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.

Scheme 137

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 138

1. Remove bolts - arrows - and separate electrical connections at the ignition coils.

Note. Ignore items - 1 to 4 -.

1. Free up electrical wiring.

Scheme 139

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 the clips - arrows -.

Scheme 140

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

Scheme 141

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

Installing

Note. During installation, all cable ties must be re-installed at the same location.

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 (diameter of nozzle approximately 1 mm).

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

Scheme 142

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.

Tightening 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

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

1. Remove transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

1. Vehicles with multitronic transmission: Remove damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) and flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) .
2. Vehicles with automatic transmission 09L: Remove drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .

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 -.

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

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

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

Scheme 143

1. Remove cap - arrow - for oil filter housing.
2. Remove oil filter element.
3. Extract engine oil using old oil collecting and extracting device V.A.G 1782 from oil filter housing.

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

Scheme 144

1. Disconnect electrical harness connector from Oil Pressure Switch F1 - arrow -.
2. Remove oil pressure switch.

Scheme 145

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.

Vehicles through 04.2005

Scheme 146

1. Remove bolts - arrows -.
2. Remove bolts - 1 to 9 - and remove lower timing chain cover.

Vehicles from 05.2005

Scheme 147

1. Remove bolts - 1 to 9 - and remove lower timing chain cover.

All

1. Press rear crankshaft seal out of lower timing chain cover.

Installing

Note. Replace gaskets, seals and O-rings. During installation, all cable ties must be re-installed at the same location.

1. Pull alignment bushing out of top right of cylinder block.

Scheme 148

1. 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 the 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 149

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

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

Scheme 150

1. Bend the ends of the cylinder head gaskets very slightly downward - arrows - until the upper sealing surface of the 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 (diameter of nozzle approximately 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 approximately 5 minutes.

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

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

Vehicles through 04.2005

Scheme 151

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 be 1.5 to 2.0 mm above the sealing surface.
3. The sealant bead - 3 - must be pulled through as shown in the illustration even though the 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 the cover at an angle from below onto the sealing surface of the 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: Insert bolts arrows with locking compound and tighten to 5 Nm. Tighten bolts 1 to 8 in a diagonal sequence to 9 Nm using a torque wrench. Tighten bolts arrows to 9 Nm. Tighten bolts 6 , 7 and 8 to 20 Nm.
4. Then immediately install the oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
5. Apply sealant beads - 1 to 5 - on clean sealing surfaces of lower timing chain cover, as shown in illustration. The groove of sealing surface must be completely filled with sealant. Sealant beads must be 1.5 to 2.0 mm above the sealing surface. The sealant bead - 2 - must be pulled through as shown in the illustration even though the groove is intermittent.
6. Insert seals - arrows - in lower timing chain cover grooves.
7. Set lower timing chain cover in place, guiding the cover at an angle from below onto the sealing surface of the cylinder block and cylinder head.
8. When installing, make sure that the cylinder head gaskets do not become damaged. A damaged gasket must be replaced.
9. Tighten bolts as follows: Insert bolts arrows with locking compound and tighten to 5 Nm. Tighten bolts 1 to 9 in a diagonal sequence to 9 Nm using a torque wrench. Tighten bolts arrows to 9 Nm. Tighten bolts 7 , 8 and 9 to 20 Nm. Tighten stud bolt 3 to 16 Nm. All: Further installation is in reverse order of removal, noting the following: Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) . Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) . Install crankshaft seal, timing chain side --> «Crank Shaft Seal, Timing Chain Side, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) . Vehicles with multitronic transmission: Install flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) and damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) .
10. Vehicles with automatic transmission 09L: Install drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
11. Install transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
12. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Tightening Specifications

Camshaft Drive

> Camshaft Timing Chain, Component Overview

> Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing

> Timing Mechanism Drive Chain, Component Overview

> Timing Mechanism Drive Chain, Removing and Installing

> Power Take-Off Drive Chain, through 03.06, Component Overview

> Power Take-Off Drive Chain, from 04.06, Removing and Installing

> Power Take-Off Drive Chain, from 04.06, Component Overview

> Power Take-Off Drive Chain, from 04.06, Removing and Installing

> Balancing Shaft, Component Overview

> Balancing Shaft, Removing and Installing

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.

Left camshaft timing chain

Scheme 152

1 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

2 - Camshaft bolt

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

3 - Camshaft bolt

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

4 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

5 - Left camshaft timing chain

1. Removing and installing --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

6 - 9 Nm

7 - Chain tensioner for left camshaft timing chain

1. Removing and installing --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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

Right camshaft timing chain

Scheme 153

1 - Drive sprocket for right camshaft timing chain

2 - Pivot pin for drive sprocket

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

4 - Right camshaft timing chain

1. Removing and installing --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

5 - Camshaft bolt

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

6 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

7 - Chain tensioner for right camshaft timing chain

1. Removing and installing --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

8 - Oil strainer

1. Set into chain tensioner
2. Installation position: 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 --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

12 - Camshaft bolt

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

13 - Thrust washer for drive sprocket

Scheme 154

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 155

1. Multi-point socket T10035

Removing

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.
2. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

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 156

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

Scheme 157

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

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

Scheme 158

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

Scheme 159

1. Install crankshaft holder T40069 into hole - 1 - to 10 Nm, if necessary rotate crankshaft very slightly back and forth to completely center the holder.

Scheme 160

1. Mark running direction of left camshaft timing chain with paint.
2. Remove bolts - 1 - and - 2 - for camshaft adjuster using multipoint socket T10035.
3. Remove both camshaft adjusters.

Scheme 161

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

Scheme 162

1. Mark running direction of right camshaft timing chain with paint.
2. Remove bolts - 1 - and - 2 - for camshaft adjuster using multipoint socket T10035.
3. Remove both camshaft adjusters.

Scheme 163

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

Installing

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 --> Timing Mechanism Drive Chain, 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 164

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

1. The piston of the tensioning element - 1 - must be driven out completely, thereby releasing the retainer - for this the 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 165

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

Scheme 166

1. Clean oil strainer - 3 - in both chain tensioners if necessary.
2. Place a new gasket - 2 - onto the rear of the chain tensioner - 1 -.

Scheme 167

1. Set chain tensioner in place on the left cylinder head and install the camshaft timing chain, as shown in the illustration.
2. Tighten bolts - 1 - and - 2 -.

1. Replace camshaft bolts.
2. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in the 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 168

1. Set chain tensioner in place on the right cylinder head and install the camshaft timing chain, as shown in the illustration.
2. Tighten bolts - 1 - and - 2 -.
3. Replace camshaft bolts.

1. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in the 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 169

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

1. Tightening Specifications 40 Nm.

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

1. Tightening Specifications 40 Nm.

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

1. Tightening Specifications 80 Nm plus an additional 90 ( 1 / 4 turn).

Scheme 170

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

1. Tightening Specifications 40 Nm.

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

1. Tightening Specifications 40 Nm.

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

1. Tightening Specifications 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 approximately 30 and set to TDC again.

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

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

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

1. Install crankshaft holder T40069 directly into the hole.

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

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

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

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

1. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Install cylinder head cover.

Tightening Specifications

Scheme 171

1 - Pivot pin for drive sprocket

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

1. Replace

3 - Bolt

1. Replace
2. Version and tightening specifications, depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

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

1. Replace

5 - Thrust washer for drive sprocket

6 - Bushing

1. Depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

7 - Drive sprocket for left camshaft timing chain

8 - Bolt

1. Replace
2. Version and tightening specifications, depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

9 - Timing Mechanism Drive Chain

1. Before removing, mark the direction of rotation with paint

10 - Guide rail

11 - Bolt

1. Replace
2. Version and tightening specifications, depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

12 - Bushing

1. Depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

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

1. Depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

16 - Thrust washer

17 - Drive sprocket for right camshaft timing chain

18 - Bushing

1. Depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

19 - Bolt

1. Replace
2. Version and tightening specifications, depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

20 - O-ring

1. Replace

21 - Chain tensioner

22 - 6 Nm plus an additional 45 ( 1 / 8 turn)

1. Replace

23 - Glide track for chain tensioner

24 - Crankshaft

25 - Bushing

1. Depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

26 - Guide rail

1. Note installation position

27 - Bolt

1. Replace
2. Version and tightening specifications, depending on the version --> «Different glide track mountings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

Scheme 172

Depending on the version, the timing chain glide tracks are mounted differently

Scheme 173

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 --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

1. Vehicles with multitronic transmission: Remove damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) and flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) .
2. Vehicles with automatic transmission 09L: Remove drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
3. Place old oil collecting and extracting device V.A.G 1782 under engine.
4. Drain engine oil.

1. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Remove camshaft timing chains from camshafts --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Remove power take-off drive chain: Vehicles up to 04.2006 --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406) , vehicle from 04.2006 --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406) .

Scheme 174

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, noting the following

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

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

1. Install power take-off drive chain: Vehicles up to 04.2006 --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406) , vehicle from 04.2006 --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406) .
2. Install camshaft timing chains --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

1. Vehicles with multitronic transmission: Install flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) and damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) .
2. Vehicles with automatic transmission 09L: Install drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
3. Install transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
4. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Tightening Specifications

Scheme 175

1 - Power take-off drive chain

1. Before removing, mark the direction of rotation with paint
2. Removing and installing --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406)

2 - Drive sprocket for oil pump

1. Installation position: 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. Installation position: 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. Depending on version
2. Replace

Scheme 176

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 8 mm diameter

Removing

1. Remove transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

1. Vehicles with multitronic transmission: Remove damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) and flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) .
2. Vehicles with automatic transmission 09L: Remove drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
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/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Scheme 177

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

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 the holder.
2. Mark running direction of power take-off chain with paint.

Scheme 178

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 179

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

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

1. Tighten chain tensioner bolts.
2. Loosely screw in 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 the chain tensioner.
2. Press against chain tensioner guide rail - arrow - with screwdriver and simultaneously fasten the bolts - 2 - for sprocket.
3. Pull drill - 1 - out of the balance shaft.

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

1. Install lower timing chain cover --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install crankshaft seal, timing chain side --> «Crank Shaft Seal, Timing Chain Side, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Vehicles with multitronic transmission: Install flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) and damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) .

1. Vehicles with automatic transmission 09L: Install drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
2. Install transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Tightening Specifications

Scheme 180

1 - Crankshaft

2 - Power take-off drive chain

1. Before removing, mark the direction of rotation with paint
2. Removing and installing --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

3 - Drive sprocket for oil pump

1. Installation position: Labeled side faces engine

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

1. Replace

5 - Spring

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

1. Replace

7 - Balance shaft chain sprocket

1. Installation position: Labeled side faces transmission

8 - Chain tensioner

1. With glide track

9 - 10 Nm plus an additional 45 ( 1 / 8 turn)

1. Replace

Power Take-Off Drive Chain, from 04.06, Removing and Installing

Special tools, testers and auxiliary items required

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

Scheme 181

1. Wrench T40049

Scheme 182

1. Securing pin T40071
2. Drill bit 8 mm dia.

Removing

1. Remove transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
2. Vehicles with multitronic transmission: Remove damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) and flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) .
3. Vehicles with automatic transmission 09L: Remove drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
4. Place Used Oil Collecting and Extracting Device V.A.G 1782 under engine and drain engine oil.

1. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Scheme 183

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

1. Remove locking bolt - arrow - for the "TDC" marking from the upper part of the oil pan.
2. Rotate crankshaft in direction of engine rotation to "TDC".

1. Install crankshaft holder T40069 into hole to 20 Nm, if necessary rotate crankshaft very slightly back and forth to completely center the holder.

Scheme 184

1. Mark running direction of power take-off chain with paint.
2. Press chain tensioner guide rail in direction of - arrow - and secure chain tensioner using a locking pin T40071.
3. Remove bolts - 3 - and balance shaft chain sprocket.
4. Remove bolts - 1 - and - 2 - and chain tensioner with the chain.

Installing

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

Scheme 185

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

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

1. Tighten chain tensioner bolts.
2. Loosely install chain sprocket bolts - 1 - and - 3 -.

1. It must still be possible to rotate the chain sprocket on the balance shaft and it must not tip.

1. Pull out securing pin T40071 to release the chain tensioner.
2. Press against the chain tensioner guide rail - arrow - using a screwdriver while tightening the chain sprocket bolts - 1 - and - 3 -.
3. Pull drill bit - 2 - out of the balance shaft.

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

1. Install timing chain lower cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install transmission-side crankshaft shaft seal --> «Crank Shaft Seal, Timing Chain Side, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Vehicles multitronic transmission: Install flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) and damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) .

1. Vehicles with automatic transmission 09L: Install drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
2. Install transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Tightening Specifications

Scheme 186

1 - Differential shaft

1. Removing and installing --> «Balancing Shaft, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__balancing-shaft-removing-and-installing)

2 - 60 Nm

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

3 - Balance weight (timing chain side)

1. Can only be positioned one way on balance shaft

4 - Bearing end bracket

5 - 13 Nm

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 drill 8 mm dia. as counter-holder

Balancing Shaft, Removing and Installing

Special tools, testers and auxiliary items required

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

Removing

1. Remove transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

1. Vehicles with multitronic transmission: Remove damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) and flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) .
2. Vehicles with automatic transmission 09L: Remove drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
3. Place old oil collecting and extracting device V.A.G 1782 under engine.
4. Drain engine oil.

1. Remove sealing flange, belt pulley side --> «Ribbed Belt Side Sealing Flange with Crankshaft Seal, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-side-sealing-flange-with) .
2. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Remove power take-off drive chain: Vehicles up to 04.2006 --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406) , vehicle from 04.2006 --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406) .

Scheme 187

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 drill bit 8 mm dia. - 1 -.
3. Remove bolt - 3 - and remove balance weight from balance shaft.

Scheme 188

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

Scheme 189

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, noting the following

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

1. Install power take-off drive chain: Vehicles up to 04.2006 --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406) , vehicle from 04.2006 --> «Power Take-Off Drive Chain, from 04.06, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__power-take-off-drive-chain-from-0406) .
2. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install sealing flange, belt pulley side --> «Ribbed Belt Side Sealing Flange with Crankshaft Seal, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-side-sealing-flange-with) .
4. Vehicles with multitronic transmission: Install flywheel --> «Flywheel, Multitronic Transmission, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__flywheel-multitronic-transmission-removing-and-installing) and damper unit --> «Damper Unit, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__damper-unit-removing-and-installing) .

1. Vehicles with automatic transmission 09L: Install drive plate --> «Drive Plate, Automatic Transmission 09L, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__drive-plate-automatic-transmission-09l-removing) .
2. Install transmission --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Tightening Specifications

Crankshaft, Removing and Installing

> Crankshaft, Component Overview

> Crankshaft Dimensions

> Axial Clearance, Measuring

> Radial Clearance, Measuring

Crankshaft, Component Overview

Note. Secure engine to Engine and Transmission Holder VAS 6095 when working on engine. Vehicles with multitronic transmission --> Engine, Securing to Engine and Transmission Holder , vehicles with automatic transmission 09L --> Engine, Securing to Engine and Transmission Holder .

Scheme 190

1 - 9 Nm

1. Fasten in diagonal sequence in steps

2 - Sealing flange (belt pulley side)

1. Removing and installing --> «Ribbed Belt Side Sealing Flange with Crankshaft Seal, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-side-sealing-flange-with)

3 - Seals

1. Different versions
2. Replace

4 - Crankshaft

1. Measuring axial play --> «Axial Clearance, Measuring»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__axial-clearance-measuring)
2. Radial clearance, measuring --> «Radial Clearance, Measuring»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

6 - Bearing bracket

1. Sealant application --> «Sealant application for guide frame, position of alignment bushings»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
2. Tightening sequence for manifold mounting bolts --> «Installing guide frame»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

15 - O-ring or sealing ring

1. Depending on version
2. Replace

16 - Cylinder block

Centering washer for drive plate on automatic transmission 09L

Note. On vehicles with automatic transmission 09L, the drive plate is bolted to the crankshaft with a centering washer - arrow -.

Scheme 191

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 be 1.5 to 2.0 mm above the sealing surface.

1. Install seals - 1 to 3 -.

Note. Depending on the version, the seals - 2 - and - 3 - are connected by a rib.

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

Scheme 192

1. Replace guide frame bolts - 1 through 16 -.
2. Insert long bolts in the inner row of the guide frame.
3. Tighten bolts - 1 through 31 - in 3 stages as follows
4. Tighten bolts to 50 Nm in sequence - 1 to 16 -.

1. Tighten bolts an additional 90 in the sequence - 1 to 16 -.
2. Tighten bolts for guide frame sealing surfaces on the cylinder block to 23 Nm in sequence - 17 to 31 -.

Scheme 193

1. Bearing shells with the correct thickness are allocated to the 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 the respective bearing on guide frame

Through engine no. AUK 028 000 or BKH 033 000

On engines through no. AUK 028 000 or BKH 033 000 another allocation of letters on guide frame to bearing shell color applies to bearing 1 (front).

From engine no. AUK 028 001 or BKH 033 001

Scheme 194

1. Bearing shells with the correct thickness are allocated to the 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. AUK 028 000 or BKH 033 000

On engines through no. AUK 028 000 or BKH 033 000 another allocation of letters on crankshaft to bearing shell color applies to bearing 1 (front).

From engine no. AUK 028 001 or BKH 033 001

Crankshaft Dimensions

Axial Clearance, Measuring

Special tools, testers and auxiliary items required

Scheme 195

1. Dial gauge holder VW 387

Scheme 196

1. Dial gauge VAS 6079

Procedure

Scheme 197

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: 0.15 to 0.25 mm.

Radial Clearance, Measuring

Special tools, testers and auxiliary items required

1. Plastigage

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: 0.015 to 0.055 mm.
2. Radial clearance wear limit: 0.08 mm.

Piston and Connecting Rod, Disassembling and Assembling

> Piston and Connecting Rod, Component Overview

> Piston and Cylinder Dimensions

> Connecting Rod, Checking Radial Clearance

Piston and Connecting Rod, Component Overview

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

Scheme 198

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/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

3 - Bearing shell

The version depends on the construction

1. Lower bearing shell (for bearing cap), identified by a dark-colored bearing. Upper bearing shell (for connecting rod) made of wear-resistant material, identified by a light-colored bearing

or

1. The same bearing, no allocation
2. Check that retaining tabs are secured
3. Do not interchange used bearing shells (mark)
4. Radial clearance, measuring --> «Connecting Rod, Checking Radial Clearance»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__connecting-rod-checking-radial-clearance)

4 - Connecting rod

1. Only replace as set
2. Mark allocation to cylinder with paint - B - --> «Mark connecting rod»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-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

1. Replace

7 - Piston

1. Installed position and allocation, piston/cylinder --> «Installed position of piston and piston/cylinder allocation»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
2. Arrow on piston face points toward belt pulley side
3. Checking --> «Checking piston»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
4. Install with piston ring compressor

1. Piston and cylinder dimensions --> «Piston and Cylinder Dimensions»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__piston-and-cylinder-dimensions)
2. Cylinder bore, checking --> «Checking cylinder bores»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

1. Check piston ring groove clearance --> «Checking ring to groove clearance»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

Scheme 199

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

Scheme 200

1. Clean ring groove of piston before checking.

Scheme 201

1. Measure approximately 10 mm from the 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 202

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 203

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. Installation position: Arrow on piston face points toward belt pulley side.

Scheme 204

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 205

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

Scheme 206

1. Install bolt - 9 Nm - using a locking compound
2. Oil spray jet with spray nozzle valve

Piston and Cylinder Dimensions

Connecting Rod, Checking Radial Clearance

Special tools, testers and auxiliary items required

1. Plastigage

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, Removing and Installing

> Cylinder Head, Component Overview

> Left Cylinder Head Cover, Removing and Installing

> Right Cylinder Head Cover, Removing and Installing

> Cylinder Head, Removing and Installing

> Brake Booster Vacuum Pump, Removing and Installing

> Compression, Checking

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 207

1 - High pressure pump

1. Removing and installing --> «24 - FUEL INJECTION SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-fuel-injection-ignition-engine-codes-bkh)

2 - 9 Nm

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

1. Replace

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

17 - Cylinder head cover

18 - Cylinder head cover gasket

1. Replace if damaged or leaking

19 - Cylinder head bolt

1. Replace
2. Observe sequence for loosening --> Follow sequence 1 to 8 when loosening cylinder head bolts. under «Cylinder Head, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
3. Observe sequence for tightening --> Tighten cylinder head in sequence indicated, in 3 stages as follows: under «Cylinder Head, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

20 - O-ring

1. Replace

21 - 8 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

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/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
2. Check for distortion --> «Checking cylinder head for distortion»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
3. Reworking dimension --> «Reworking dimension, cylinder head»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
4. Installing --> «Cylinder Head, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Installation position: Part Number, points to cylinder head
3. After replacing, change coolant and engine oil

Scheme 208

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

1. Max. distortion: 0.05 mm.

Scheme 209

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 210

1. Ignition Coil Puller T40039

Removing

1. Remove front engine cover - arrows -.

1. Remove rear 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 211

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 disconnect electrical connections at the ignition coils.
2. Set electrical wiring harness aside.

Scheme 212

1. Remove ignition coils using ignition coil puller T40039.

Scheme 213

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

Note. Disregard - arrow -.

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

Installing

Installation is in reverse order of removal, noting 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 -.

Tightening specifications

Right Cylinder Head Cover, Removing and Installing

Special tools, testers and auxiliary items required

1. Ignition Coil 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 the hose clamp - 2 - and opening the clips - arrows -.

1. Open clips - arrows - and remove upper part of air filter housing.

Scheme 214

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 215

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 the ignition coils.
2. Set electrical wiring harness aside.

1. Remove ignition coils using ignition coil puller T40039.

Scheme 216

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

Note. Disregard - arrow -.

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

Installing

Installation is in reverse order of removal, noting 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 -.

Tightening Specifications

Special tools, testers and auxiliary items required

Scheme 217

1. Locking pin T40069

Scheme 218

1. Camshaft locator T40070

Removing

1. Engine installed.

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

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Remove front exhaust pipe: Left --> «Left Front Exhaust Pipe with Catalytic Converter, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) , right --> «Right Exhaust Pipe with Catalytic Converter, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Remove ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-removing-and-installing)
4. Remove front coolant pipe --> «Front Coolant Line, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__front-coolant-line-removing-and-installing) .

1. Remove power steering pump --> «48 - STEERING»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Note. To remove the right cylinder head, the vacuum pump for brake booster must be removed --> Brake Booster Vacuum Pump, Removing and Installing .

1. Remove upper part of intake manifold --> «24 - FUEL INJECTION SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
2. Remove intake manifold lower part --> «24 - FUEL INJECTION SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
3. Disconnect electrical harness connectors at fuel injectors.
4. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

1. Disconnect fuel line - arrow -.

Scheme 219

1. Remove low pressure line, thereby removing bolts and union nuts - 1 through 6 -.

Scheme 220

1. If equipped, unbolt large lifting eye - arrows -.

Scheme 221

1. Disconnect electrical connectors - 1 - and - 2 -.
2. If necessary, remove high pressure pump from left cylinder head - arrows -.

Scheme 222

1. Remove bolt - arrow - and pull oil dipstick guide tube upward and out.
2. Remove cylinder head cover.
3. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Remove camshaft timing chains from camshafts --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Scheme 223

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

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

Scheme 224

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

Installing

Note. Replace cylinder head bolts. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. 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 freed up 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 with hose clamps appropriate for the model . 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 screwed into the crankshaft.

Scheme 225

1. Position cylinder head gasket.

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 226

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.
5. With Torx key, 90 ( 1 / 4 turn) additional turn. NOTE: There is no requirement to retighten the cylinder head bolts.
6. Tighten bolts - arrows - to 9 Nm. Left cylinder head: 3 bolts. Right cylinder head: 4 bolts.
7. Install camshaft timing chains --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
8. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
9. Install cylinder head cover.
10. Install high pressure pump --> «24 - FUEL INJECTION SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
11. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
12. Install intake manifold lower-part with high and low-pressure lines --> «24 - FUEL INJECTION SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
13. Install intake manifold upper-part --> «24 - FUEL INJECTION SYSTEM»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-fuel-injection-ignition-engine-codes-bkh) .
14. Install vacuum pump for brake booster --> «Brake Booster Vacuum Pump, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__brake-booster-vacuum-pump-removing-and) .
15. Install power steering pump --> «48 - STEERING»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
16. Install front coolant pipe --> «Front Coolant Line, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__front-coolant-line-removing-and-installing) .
17. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__ribbed-belt-removing-and-installing) .
18. Install front exhaust pipe with catalytic converter: Left --> «Left Front Exhaust Pipe with Catalytic Converter, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) ; right --> «Right Exhaust Pipe with Catalytic Converter, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
19. Align exhaust system --> «Exhaust System, Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__exhaust-system-installing) .
20. Replace engine oil --> «01 - MAINTENANCE»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
21. Replace coolant --> «Cooling System, Draining and Filling»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
22. Fill power-steering system oil and bleed steering system --> «48 - STEERING»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening Specifications

Brake Booster Vacuum Pump, Removing and Installing

Removing

1. Remove front engine cover - arrows -.

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

Scheme 227

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

Installing

Installation is in reverse order of removal, noting the following

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

Scheme 228

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

Tightening specifications

Scheme 229

Special tools, testers and auxiliary items required

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

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 the hose clamp - 2 - and opening clips - arrows -.

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

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

Note. Ignore - 1 to 4 -.

1. Remove bolts - arrows - and disconnect electrical connections at the 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 the reverse order of removal, noting the following

1. Install spark plugs --> «01 - MAINTENANCE»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
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".

Tightening specifications

Valvetrain, Servicing

> Valvetrain, Component Overview

> Camshafts, Checking Axial Clearance

> Camshafts, Removing and Installing

> Valve Stem Seals, Cylinder Head Installed, Replacing

> Valve Stem Seals, Cylinder Head Removed, Replacing

> Hydraulic Adjusting Elements, Checking

> Valve Dimensions

> Valves, Checking

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 approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on 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 (Scheme 235)

Scheme 230

1 - Exhaust valve

1. Different versions
2. Do not rework, only lapping is permitted
3. Mark installed position for re-installation
4. Valve dimensions --> «Valve Dimensions»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

1. Check valve guides --> «Valve Guides, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__valve-guides-checking)

2 - Sealing plug

1. Install with sealant; sealant

3 - Cylinder Head

1. Check valve guides --> «Valve Guides, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__valve-guides-checking)

4 - Hydraulic adjusting element

1. Checking --> «Hydraulic Adjusting Elements, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__hydraulic-adjusting-elements-checking)
2. Do not interchange
3. Lubricate contact surface

5 - Securing clip

1. Check for secure seat

6 - Intake camshaft

1. Checking axial play --> «Camshafts, Checking Axial Clearance»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-checking-axial-clearance)
2. Removing and installing --> «Camshafts, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-dia. 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-dia. 36 mm: 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/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)

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

1. Replace

9 - Exhaust camshaft

1. Checking axial play --> «Camshafts, Checking Axial Clearance»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__camshafts-checking-axial-clearance)
2. Removing and installing --> «Camshafts, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-dia. 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-dia. 36 mm: 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

11 - Valve keys

12 - Valve spring plate

13 - Valve spring

1. Installation position: The tight spring coils face toward cylinder head

14 - Valve stem seal

1. Replacing, Cylinder Head Installed --> «Valve Stem Seals, Cylinder Head Installed, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
2. Replacing, Cylinder Head Removed --> «Valve Stem Seals, Cylinder Head Removed, Replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__valve-stem-seals-cylinder-head-removed)

15 - Intake valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve Dimensions»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh)
4. Check valve guides --> «Valve Guides, Checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-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

Procedure

1. Perform measurement with roller rocker levers and hydraulic adjusting elements removed.

Scheme 231

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.

Scheme 232

Special tools, testers and auxiliary items required

1. Impact puller T10133/3 from the tool set T10133
2. Locking pin T40069
3. Camshaft locator T40070 (qty. 2)
4. Securing pins 1 set = qty. 2 T40116

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

Removing

1. Remove cylinder head cover.
2. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Remove camshaft timing chains from camshafts --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. To remove right camshafts, the vacuum pump for brake booster must be removed --> «Brake Booster Vacuum Pump, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__brake-booster-vacuum-pump-removing-and) .

Scheme 233

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.

Scheme 234

Note. Since the securing pins T40116 cannot be used during installation, the alignment pins - arrows - on an engine with alignment pins must be driven out with a cotter pin driver.

Installing

Note. Always replace gaskets and seals.

1. 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 the workbench.

Scheme 235

1. Set camshafts into guide frame.

1. The placement of the camshafts must be exactly within the axial bearings - arrows - of the 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 the guide frame with installed camshafts, thereby holding the camshafts tight within the 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 the bolts - arrows - to 20 Nm.

1. Cut tube nozzle at front marking (diameter of nozzle approximately 1 mm).
2. Turn around guide frame again.

Vehicles through approximately 08.2004

Scheme 236

1. Apply sealant beads - 1 through 6 - on clean sealing surfaces of guide frame as shown in illustration.

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

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

Vehicles from approximately 08:2004

Scheme 237

1. Apply a small quantity of sealant in the seal groove - 3 - in the area of the 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.

All

Note. Because the sealant begins hardening immediately, guide frame must be promptly positioned and tightened.

1. Place guide frame on cylinder head.

Scheme 238

1. Insert locating pins T40116 in guide frame and cylinder head.

1. Attach guide frame on cylinder head immediately.
2. 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. After installing guide frame, sealant must dry for approximately 30 minutes.

Scheme 239

1. Clean sealing plug hole in the cylinder head. It must be free of oil and grease.
2. Coat outer circumference of the sealing plug - arrow - with sealant; sealant
3. Drive in sealing plugs until they are flush.

Scheme 240

1. Remove locating pins T40116 with impact puller T10133/3.

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

Note. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on 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 --> «Brake Booster Vacuum Pump, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh__brake-booster-vacuum-pump-removing-and) .
2. Install camshaft timing chains --> «Timing Chains, Removing from Camshafts and Chain Tensioner, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
4. Install cylinder head cover.

Tightening specifications

Scheme 241

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

Procedure

1. Remove camshafts --> «Camshafts, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
2. Mark the positioning of the roller rocker lever and hydraulic adjusting elements for re-installation.
3. Remove roller rocker lever together with the hydraulic adjusting elements and place them on a clean surface.
4. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 242

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

Scheme 243

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 244

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 the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

1. Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the installation cartridge.
2. Release pressure fork.
3. Take out 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 245

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

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

Scheme 246

1. Using a drift, drive out the roll pin - arrow - at Valve Seal Removal Tool 3364 and remove the impact puller attachment.
2. Place lower part of the Valve Seal Removal Tool 3364 on the valve stem seal.

Scheme 247

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

Scheme 248

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 Valve Stem Seal Driver 3365.

1. Remove plastic sleeve again.

Scheme 249

If the valve keepers were removed from the installation cartridge, they must then be inserted into the valve keeper insertion device VAS 5161/18.

1. The large diameter of the valve keepers point upward.

Scheme 250

1. Install valve spring and valve spring plate.

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 the pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
4. Release pressure fork with the knurled bolt still pulled.

1. Make sure all the roller rocker levers seat properly on the valve stem ends and are clipped onto the respective hydraulic adjusting elements.
2. Install camshafts --> «Camshafts, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .
3. Install spark plugs --> «01 - MAINTENANCE»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Note. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on 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.

Valve Stem Seals, Cylinder Head Removed, Replacing

Special tools, testers and auxiliary items required

Scheme 251

1. Valve Seal Removal Tool 3364

Scheme 252

1. Valve stem seal driver 3365

Scheme 253

1. Valve cotter disassembly and assembly device VAS 5161

Scheme 254

1. Engine and transmission holder VAS 6095
2. Tensioning element VAS 6419

Procedure

1. Remove camshafts --> «Camshafts, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Scheme 255

1. Insert tensioning element VAS 6419 in the engine and transmission holder VAS 6095.
2. Tension the cylinder head on the tensioning element VAS 6419 as shown in the illustration.
3. Connect the tensioning element VAS 6419 to compressed air.
4. Slide the air cushion with the lever - arrow - under the cylinder onto the valve stem seal that will be removed.

1. Let enough compressed air flow into the air cushion until it contacts the valve plate.

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

Scheme 256

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.

Scheme 257

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 the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

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

1. Remove valve spring with valve spring plate.

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

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 Valve Stem Seal Driver 3365.

1. Remove plastic sleeve again.

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

1. The large diameter of the valve keepers point upward.

1. Install valve spring and valve spring plate.

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 pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
4. Release pressure fork with the knurled bolt still pulled.

1. Make sure all the roller rocker levers seat properly on the valve stem ends and are clipped onto the respective hydraulic adjusting elements.
2. Install camshafts --> «Camshafts, Removing and Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#32-v6-4v-engine-mechanical-engine-codes-bkh) .

Hydraulic Adjusting Elements, Checking

Special tools, testers and auxiliary items required