4.2l v8 5v Fuel Injection and Ignition, Engine Code(s): Bat, Bnk Audi A6 С6

Engine number

Note. A sticker with "engine code" and "serial number" is affixed to cylinder head cover at right. The engine code is also located on the vehicle data plate. The engine number is only visible after a work step.

Scheme 832

1. Remove front engine cover - arrow 1 - and - arrows 2 -.

Scheme 833

Engine number ("engine code" and "serial number") is located at front on cylinder block at top - arrow -.

Engine data

* Super unleaded RON 95 is permissible, but with reduced power.

Rules of cleanliness for performing work on fuel injection system

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

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Plug open lines and connections immediately with appropriate protective caps.
3. Place parts that have been removed on a clean surface and cover them. 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 unpackaged (e.g. in tool boxes etc.).

1. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Fuel supply system, checking for leaks

1. Let engine run a few minutes at average RPM.
2. Switch off ignition.
3. Check entire fuel supply system for leaks.
4. If there are leaks in spite of correct tightening torque, the corresponding component must be replaced.

1. Afterwards, perform test drive, fully depressing accelerator pedal at least once.
2. Then, check high pressure areas for leaks again.

Engine, removing

Note. The 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.

Scheme 834

Special tools, testers and auxiliary items required

1. Ball Joint Puller T40043
2. Hose Clamps Up to 25 mm dia. 3094
3. Drip tray for workshop crane VAS 6208 or V.A.G 1306
4. Hose clamp pliers V.A.G 1921

1. Ball Joint Puller T40042
2. Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10

Special tools, testers and auxiliary items required

Scheme 835

1. Hose Clamps, Up to 40 mm 3093

Work procedure

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 836

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

1. Remove front engine cover - arrow 1 - and - arrows 2 -.

Scheme 837

1. Remove rear engine cover - arrows -.

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

Note. Secure brake discs using a wheel bolts.

Scheme 838

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

Scheme 839

1. Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.

Scheme 840

1. Disconnect lower coolant hose from radiator - arrow - and drain residual coolant.
2. Remove bumper --> «63 - BUMPERS»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove front end --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 841

1. Disconnect connector - arrow - from secondary air injection pump and free up wiring.

Scheme 842

1. Disconnect coolant hose - 1 - for permanent ventilation.
2. Disconnect hose - 2 - for variable intake manifold.
3. Disconnect hose - 3 - to Secondary Air Injection (AIR) pump.
4. Disconnect A/C line - 1 -.

1. Disconnect coolant hose - 2 - from thermostat housing.

Scheme 843

1. Disconnect coolant hose - 1 - for permanent ventilation from expansion tank.
2. Disconnect hose - 2 - from coolant line.
3. Remove coolant expansion tank - 3 -.
4. Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.

Scheme 844

1. Clamp off oil line of power steering fluid reservoir with Hose Clamps, Up to 40 mm 3093
2. Disconnect hose for power steering - arrow -.

Scheme 845

1. Unclip fuel hose - 1 -.
2. Disconnect electrical connector - 2 - from mass air flow (MAF) sensor.
3. Disconnect mass air flow sensor from intake air duct - 3 -.
4. Remove upper part of air filter housing with mass air flow (MAF) sensor - arrows -.

Scheme 846

1. Separate hose - 1 - for secondary air injection (AIR) system.
2. Disconnect electrical connector - 2 - from Air Flap Positioner V63.
3. Remove pin from spreader clip - 3 - and remove lower part of air filter housing.

Scheme 847

1. Pull resonator - 1 - in direction of - arrow - upward and unclip it.

Scheme 848

1. Disconnect fuel line - arrow -.

Scheme 849

1. Disconnect vacuum hose - 1 - for brake booster at bulkhead.
2. Remove intake hose - 2 - , thereby loosening clamp - 3 -.

Scheme 850

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

Scheme 851

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

Scheme 852

1. Remove rubber seal - 1 - for plenum chamber cover.
2. Remove plenum chamber cover - 2 -.
3. Pry off caps on wiper arms with a screwdriver and remove nuts.
4. Pull off and remove wiper arms from wiper axles.

Scheme 853

1. Remove bolts - arrows - for cowl grill - 1 -.
2. Remove cowl grill from windshield.

Scheme 854

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

Scheme 855

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 connector strip.
4. Disengage and free up engine wiring harness at E-Box.

Scheme 856

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

Scheme 857

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

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

1. Remove electrical wiring connections - 2 - and - 3 -.
2. Disconnect electrical connection - 4 - at rear on connector strip.
3. Unclip smoothing capacitor - 5 - from bracket in E-box.
4. Disconnect electrical connector - 6 -.

1. Unclip relay carrier from E-box.
2. Free electrical wiring up to Generator.
3. Set both wiring harnesses on engine and secure Engine Control Module (ECM) against falling down.

Scheme 858

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

Scheme 859

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

Scheme 860

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

Scheme 861

1. Remove front transverse beam - arrows -.

Scheme 862

1. Remove heat shield - A - for drive axle - 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 863

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

Scheme 864

1. Remove heat shield for left drive axle - arrows -.
2. Remove left and right drive axles from transmission.
3. Have a second technician press brake pedal.

Scheme 865

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

Scheme 866

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

Scheme 867

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

Scheme 868

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

Scheme 869

1. Loosen nut of guide link ball joint so far until it is flush with end of thread.

Note. Make sure that the ball joint protective boot does not become damaged when pressing off. Make sure that both lever arms of ball joint puller are positioned parallel to one another while increasing force. Secure ball joint puller from falling down.

1. Using ball joint puller T40043 press guide link ball joint off from tapered seat.
2. If necessary, counter hold ball joint with a 6 mm Allen key.
3. Remove nut and remove ball joint from guide.

Scheme 870

1. Loosen nut of ball joint at control arm so far until it is flush with end of thread.

Note. Make sure that the ball joint protective boot does not become damaged when pressing off. Make sure that both lever arms of ball joint puller are positioned parallel to one another while increasing force. Secure ball joint puller from falling down.

1. Using ball joint puller T40042 press control arm ball joint off from tapered seat.
2. If necessary, counter hold ball joint with a 6 mm Allen key.
3. Remove nut and remove ball joint from control arm.

Scheme 871

1. Remove guide link - 1 - and control arm - 2 - at subframe and remove them.
2. Repeat work procedure on opposite side of vehicle.

Scheme 872

1. Remove bolts - 1 - for support bracket from transmission.
2. Disengage selector lever cable - arrow -.

Scheme 873

Prepare scissor lift platform

1. Equip Scissor Lift Platform VAS 6131 A with Support Set For Audi VAS 6131/10 and VAS 6131/11 as follows

1. Install attachments on scissor lift table by hand first.
2. Place scissor lift platform VAS 6131 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 874

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

Scheme 875

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

Scheme 876

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

Scheme 877

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 878

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

Scheme 879

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

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 transmission, separating

Special tools, testers and auxiliary items required

1. Supplementary Set VAS 6131/11 and VAS 6131/12

Scheme 880

1. Adapter T40058

Work procedure

1. Engine/transmission unit removed and attached to scissor lift platform VAS 6131 A.

1. Twist spindles of support elements from VAS 6131/10 at left and right at subframe completely downward.
2. Remove support pins from spindles.
3. Remove subframe to side.

Note. A second technician is required to remove subframe.

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

Note. Support points for front of engine, rear of 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

*Support elements remain unchanged.

Scheme 881

1. Position support elements from VAS 6131/11 and VAS 6131/10 at left on engine/transmission as shown in illustration.

Scheme 882

1. Position support elements from VAS 6131/11 at right on engine/transmission 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 883

1. Disconnect electrical harness connectors - 1 - , - 2 - and - 4 -.
2. Free up cables.

Note. Harness connectors are depicted in the installation position in the illustration.

Scheme 884

1. Remove front exhaust pipe from left exhaust manifold nuts - 1 to 3 -.

Scheme 885

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

Note. Ignore - 2 -.

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

Scheme 886

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

Note. Ignore - 2 - and - 3 -.

1. Remove left front exhaust pipe with catalytic converter.

Scheme 887

1. Remove nuts - 1 to 3 -.

Scheme 888

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

Note. Ignore - 2 -.

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

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

Note. Ignore - 1 - and - 3 -.

Scheme 889

1. Remove oil lines - 2 - at transmission.
2. Remove transmission oil lines from engine and remove.

Scheme 890

1. Separate electrical connector - 1 - and turn in direction of - arrow -.

Scheme 891

1. Disconnect electrical connector - 1 -.
2. Remove nut - arrow - and remove right engine mount.

Scheme 892

1. Remove nuts - arrows - and remove engine support.

Scheme 893

1. Remove Ground (GND) wire - 1 -.
2. Disconnect electrical wires - 3 - and - 4 -.
3. Remove bolts - 2 and 5 - and remove starter.

Scheme 894

1. Turn engine in rotation direction - arrow - with Adapter T40058 until...

Scheme 895

1. ... 3 Torx bolts - arrow - of torque converter can be removed through opening of removed starter. (Turn crankshaft 1 / 3 rotation in each case using Adapter T40058).

Note. To loosen, counter hold torque converter bolts with Adapter T40058.

1. First remove lower and then upper engine/transmission bolts.
2. Press off torque converter from drive plate through starter hole in converter housing and at the same time remove engine from transmission.
3. Secure torque converter in transmission so that it cannot fall out.

Scheme 896

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

Scheme 897

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

Scheme 898

Special tools, testers and auxiliary items required

1. Shackle 10-222 A/12
2. Lifting tackle 3033
3. Engine and Transmission Holder VAS 6095 with Bracket For V8 Engine VAS 6095/1-6 or VAS 6095/1-6A
4. Shop crane VAS 6100

1. Lift arm extension for workshop crane VAS 6101

Special tools, testers and auxiliary items required

Scheme 899

1. Additional hooks 10-222 A/2

Work procedure

Scheme 900

1. Disconnect vacuum hose - 1 -.
2. Disconnect air guide hose - 2 - from throttle valve control module.

Scheme 901

1. Secure shackle 10-222 A/12 to right rear engine lifting eyelet.
2. Hook additional hook 10-222 A/2 on shackle 10-222 A/12.

Scheme 902

1. Engage engine sling 3033 on additional hook 10-222 A/2 and on workshop crane VAS 6100 with lift arm extension for workshop crane VAS 6101 as shown in the illustration.
2. Lift engine from support elements of scissor lift platform VAS 6131.
3. Remove engine mount with left engine support.

Scheme 903

1. Secure engine with Bracket For V8 Engine VAS 6095/1-6 or VAS 6095/1-6A on 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 using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location.

Scheme 904

Installation dimension for torque converter, checking

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

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

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

Engine/transmission, fastening

*Bolt class 10.9.

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

1. Install front exhaust pipes: Left --> «Left front exhaust pipe with catalytic converter, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__left-front-exhaust-pipe-with-catalytic) , right --> «Right exhaust pipe with catalytic converter, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__right-exhaust-pipe-with-catalytic-converter) .
2. Always clean threaded bores in transmission flanged shaft for crankshaft of locking fluid residue using a tap before installation.

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

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

Note. Support points for front of engine, rear of 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

*Support elements remain unchanged.

*Only install support elements after installing subframe.

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

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 long members during removal.
2. Tighten bolts for subframe and engine mount plates only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

1. 50 Nm
2. 150 Nm
3. 150 Nm
4. 75 Nm

1. Fasten bolts - arrows - for tunnel cross member.
2. 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) .
3. 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 .
4. Fasten ATF lines --> «37 CONTROLS, HOUSING»(/audi/a6/6-2004-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-awd) .

1. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Install guide control arm, control arm and stabilizer --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install power steering oil lines --> «48 - STEERING»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Install refrigerant lines --> «87 - AIR CONDITIONING»(/audi/a6/6-2004-2008/remont/ac-compressor/#heating-air-conditioning) .

1. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install front bumper --> «63 - BUMPERS»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Adjust headlights --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .
4. Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.

Note. Be sure to activate vehicle features (radio, radio/navigation system, clock, electric window regulator) according to owners manual when the battery is re-connected. Deactivate service mode of Telematics Control Module --> 90 - INSTRUMENTS . Further measures after reconnecting voltage supply --> 24 MULTIPORT FUEL INJECTION (MFI) .

1. Fill refrigerant circuit --> «87 - AIR CONDITIONING»(/audi/a6/6-2004-2008/remont/automatic-hvac-system/#refrigerant-r134a-servicing) .
2. Before starting, check engine oil level.
3. Before first engine start, fill hydraulic oil into power steering system reservoir; power steering pump must not run dry.
4. Fill with coolant.

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) .

Torque specifications

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

Scheme 905

1 - 22 Nm

2 - 22 Nm

3 - Tensioning device for ribbed belt

4 - 22 Nm

5 - Generator

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

6 - M8, 22 Nm; M10, 46 Nm

7 - Alignment bushing

1. For generator bracket
2. 2 pieces

8 - Bracket

1. For Generator

9 - 10 Nm

10 - Bracket

1. For idler pulley

11 - Vibration damper

1. Removing and installing --> «Vibration damper, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__vibration-damper-removing-and-installing)

12 - 22 Nm plus an additional 45° ( 1 / 8 turn)

1. Replace

13 - Idler roller

1. For ribbed belt

14 - 22 Nm

15 - Cover cap

16 - Ribbed belt

1. Check for wear
2. Do not kink
3. Before removing, mark direction of rotation using chalk or felt-tip marker. Reversing direction of rotation of a run-in belt can destroy belt
4. Removing and installing --> «Ribbed belt, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__ribbed-belt-removing-and-installing)

17 - Threaded bushing

Ribbed belt, removing and installing

Special tools, testers and auxiliary items required

Scheme 906

1. Torque wrench V.A.G 1332

Removing

1. Bring lock carrier into service position --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

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 907

1. Loosen tensioning bolt - arrow - and remove ribbed belt.

Installing

Scheme 908

1. Place ribbed belt over belt pulley in specified sequence.

1. Generator
2. Ribbed belt
3. Idler roller
4. Vibration damper
5. Tensioning roller

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

Scheme 909

1. Position torque wrench on belt tensioner hex bolt and pre-tighten ribbed belt to 70 Nm.
2. At the same time, tighten tensioning bolt - arrow - to 22 Nm.

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

1. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Start engine and check belt running.

Scheme 910

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper --> «63 - BUMPERS»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Adjust headlights --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Torque specifications

Vibration damper, removing and installing

Removing

1. Bring lock carrier into service position --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

Note. To loosen and tighten harmonic balancer, counter hold on center nut of generator belt pulley using open end wrench.

Scheme 911

1. Loosen 8 mounting bolts - arrow - on vibration damper a few turns.

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. Loosen tensioning bolt - arrow - and remove ribbed belt.
2. Remove vibration damper.

Installing

Installation is in reverse order of removal, note the following

1. Install vibration damper using only original equipment bolts .

1. Installation of harmonic balancer is only possible in one position - note alignment bushing.

1. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__ribbed-belt-removing-and-installing) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper --> - «63 - BUMPERS»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Adjust headlights --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Torque specifications

* 45° corresponds to a 1/8 turn

*Replace bolts.

Seal for crankshaft (ribbed belt side), replacing

Special tools, testers and auxiliary items required

Scheme 912

1. Seal remover T40019

Scheme 913

1. Assembly tool T40048
2. Bolt M8x55

Removing

1. Bring lock carrier into service position --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove vibration damper --> «Vibration damper, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__vibration-damper-removing-and-installing) .
3. Place inner part of seal extractor T40019 flush with outer part and secure using knurled-head screw.

Scheme 914

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

Installing

1. Clean running and sealing surface.

Scheme 915

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

Scheme 916

1. Place pull sleeve T40048/2 on crankshaft and slide seal - 1 - into sealing surface on engine.

Note. Pull sleeve T40048/2 remains on crankshaft for pressing on.

Scheme 917

1. Position pressure sleeve T40048/3 with bolts M8x55 mm - arrows - on crankshaft.
2. Then install bolts by hand.
3. Tighten bolts each 1 / 2 turn by alternating sides to press in seal until it reaches stop.

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

1. Install vibration damper --> «Vibration damper, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__vibration-damper-removing-and-installing) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper --> «63 - BUMPERS»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Adjust headlights --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Torque specifications

Scheme 918

1 - Drive plate

1. Removing and installing --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

2 - Washer

1. Mark for re-installation

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

1. Replace

4 - Shim

1. Mark for re-installation

5 - Seal

1. For crankshaft -timing chain side
2. Removing and installing --> «Crankshaft seal, timing chain side, replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__crankshaft-seal-timing-chain-side-replacing)

6 - Crankshaft

Drive plate, removing and installing

Special tools, testers and auxiliary items required

Scheme 919

1. Counter-holder tool 10-201

Removing

1. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Separate engine/transmission --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .
3. Mark drive plate and washer to engine.
4. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .

Scheme 920

1. Insert counter hold tool 10-201 to loosen bolts.
2. Remove drive plate.

Installing

Installation is in reverse order of removal, note the following

1. Install drive plate with washer.
2. Use new bolts when securing.
3. Reposition counter hold tool 10-201 to tighten bolts.
4. Bolt transmission to engine and install engine/transmission --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .

Torque specifications

* 90° corresponds to a 1/4 turn

*Replace bolts.

Crankshaft seal, timing chain side, replacing

Special tools, testers and auxiliary items required

Scheme 921

1. Pulling fixture T10122

Scheme 922

1. Extractor lever T20143/2

Removing

1. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Separate engine/transmission --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .
3. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .

Scheme 923

1. Remove shim - arrow - from crankshaft.

Scheme 924

1. Pry out sealing ring using extractor lever T20143/2.

Installing

1. Clean running and sealing surface.

Scheme 925

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

Scheme 926

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

Scheme 927

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

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

1. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .
2. Bolt transmission to engine and install engine/transmission unit --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .

Scheme 928

1 - M6, 10 Nm; M8, 22 Nm

1. Observe sequence for tightening --> see scheme 148

2 - Seal

1. For crankshaft timing chain side
2. Removing and installing --> «Crankshaft seal, timing chain side, replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__crankshaft-seal-timing-chain-side-replacing)

3 - Shim

4 - Alignment bushing

1. 2 pieces

5 - Heat shield

6 - 10 Nm

7 - Seal

1. Replace

8 - 10 Nm

9 - Sealing flange

10 - 10 Nm

11 - Camshaft Position (CMP) Sensor 2 G163

12 - O-ring

1. Replace

13 - 10 Nm

1. Observe sequence for tightening --> see scheme 151

14 - 10 Nm

1. Observe sequence for tightening --> see scheme 151

15 - Left cover

1. For timing chain

16 - Gasket

1. Replace

17 - 4 Nm

1. Insert with locking fluid
2. Locking fluid

18 - 10 Nm

19 - Camshaft Position (CMP) sensor G40

20 - O-ring

1. Replace

21 - 10 Nm

1. Observe sequence for tightening --> see scheme 153

22 - Right cover

1. For timing chain

23 - Gasket

1. Replace

24 - 4 Nm

1. Insert with locking fluid
2. Locking fluid

25 - 10 Nm

1. Observe sequence for tightening --> see scheme 153

26 - Heat shield

27 - 10 Nm

28 - Seal

1. Replace

29 - Sealing flange

30 - 10 Nm

31 - Alignment bushing

1. 2 pieces

32 - Lower cover

1. For timing chain

All covers for timing chain, removing and installing

Special tools, testers and auxiliary items required

Scheme 929

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

Removing

1. Drain engine oil --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
2. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
3. Separate engine/transmission --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .
4. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .

Scheme 930

1. Disconnect electrical connection - 1 - at throttle valve control module J338.
2. Disconnect crankcase ventilation hose - 3 - at intake pipe.

Note. Ignore - 2 -.

Scheme 931

1. Remove electrical harness connectors - 1 - , - 2 - , - 5 - and - 6 - toward front from brackets on intake pipe.
2. Disconnect electrical connectors - 3 - and - 4 -.

Scheme 932

1. Disconnect vacuum hose - arrow - at T-piece.

1. Pull resonator - 1 - in direction of - arrow - upward and unclip it.

Scheme 933

1. Remove connector strips - 2 - and - 3 - at 8 fuel injectors.
2. Remove bolts - arrows - from fuel rail.
3. Pull fuel rail with injectors upward uniformly from intake manifold and set aside in engine compartment on a clean cloth.

Note. Carefully protect removed fuel injectors from contamination.

Scheme 934

1. Remove left rear engine lifting eye - arrows -.

Scheme 935

1. Remove intake manifold bolts - arrows - and remove it.

Note. Plug intake ports of cylinder head with clean rags.

Scheme 936

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.

Scheme 937

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

1. Remove bolts - arrows -.
2. Remove oil filter housing.

Scheme 938

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

Scheme 939

1. Remove bolts - 1 - and - 2 -.
2. Remove return line from power steering pump - arrow -.

Scheme 940

1. Remove guide pipe for oil dipstick at cylinder head - arrow - , pull up and remove.

Scheme 941

1. Remove bolts - 1 - and - 2 -.
2. Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.

Scheme 942

1. Remove bolts - 1 - and - 2 -.
2. Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.

Scheme 943

1. Disconnect electrical connector - 2 - on Engine Coolant Temperature (ECT) Sensor G62.
2. Remove nut - 1 - and remove electrical wiring harness at rear coolant pipe.

Scheme 944

1. Remove bolts - 2 to 5 -.
2. Remove rear coolant pipe.

Note. Ignore - 1 - and - 6 -.

Scheme 945

1. Remove Secondary Air Injection (AIR) system combi-valve mounting bolts - 1 through 4 -.

Scheme 946

1. Remove nuts - 1 to 12 - and remove left exhaust manifold.

Scheme 947

1. Remove left heat shield - arrows -.

Scheme 948

1. Remove nuts - 1 to 12 - and remove right exhaust manifold.

Scheme 949

1. Remove right heat shield - arrows -.

Scheme 950

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

Note. Puller For Ignition Coil T10094 can be used for removal.

Scheme 951

1. Disconnect hose - arrow - of crankshaft housing ventilation.
2. Remove left cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

Scheme 952

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

Note. Puller For Ignition Coil T10094 can be used for removal.

Scheme 953

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove right cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

Scheme 954

1. Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 G163 on left cylinder head.

Scheme 955

1. Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor G40 on right cylinder head.

Scheme 956

1. Remove Ground (GND) cable on right cylinder head - arrow -.
2. Set wiring harness aside.

Scheme 957

1. Remove bolts - 1 to 6 - and remove left timing chain cover.

Scheme 958

1. Remove bolts - 1 to 6 - and remove right timing chain cover.

1. Pull off shim - arrow - from crankshaft.

Scheme 959

1. Remove bolts - 1 to 13 - and remove lower timing chain cover.
2. Press sealing ring for crankshaft at rear out of cover.

Installing

Note. Replace gaskets, seals and O-rings.

Scheme 960

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, must be free of oil and grease.

Scheme 961

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

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

Scheme 962

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

1. Thickness of sealant bead: 1.5 to 2.0 mm.

1. Check whether 2 alignment bushings are present in cylinder block, install if necessary.

1. Position lower cover for timing chain and tighten bolts as follows.

Scheme 963

1. Remove sealing flanges for camshaft adjuster on left and right covers for timing chain - arrows -.

Scheme 964

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

1. Groove on lower sealing surface - arrow 1 - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
2. Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.

1. Install new seal - 3 - on left cover for timing chain.

1. Position left cover for timing chain and tighten bolts as follows.

Scheme 965

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

1. Groove on lower sealing surface - arrow 1 - must be completely filled with sealant. Sealant bead must stand 1.5 to 2.0 mm above sealing surface.
2. Sealant bead on front sealing surface - arrows 2 - must be 1.5 to 2.0 mm thick.

1. Install new seal - 3 - on right cover for timing chain.

1. Position right cover for timing chain and tighten bolts as follows.

1. Install sealing flanges for camshaft adjuster with new sealing rings - arrows - on left and right covers for timing chain.

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

1. Install crankshaft seal, timing chain side --> «Crankshaft seal, timing chain side, replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__crankshaft-seal-timing-chain-side-replacing) .
2. Install cylinder head cover: left «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) , right «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
3. Install exhaust manifold: left --> «Left exhaust manifold, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__left-exhaust-manifold-removing-and-installing) , right --> «Right exhaust manifold, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__right-exhaust-manifold-removing-and-installing) .
4. Install combination valve for Secondary Air Injection (AIR) system: left --> «Left combination valve for Secondary Air Injection (AIR), removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__left-combination-valve-for-secondary-air) , right --> «Right combination valve for Secondary Air Injection (AIR), removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__right-combination-valve-for-secondary-air) .

1. Install rear coolant pipe --> «Rear coolant line, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__rear-coolant-line-removing-and-installing) .
2. Install left coolant pipe --> «Left coolant pipe, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__left-coolant-pipe-removing-and-installing) .
3. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__oil-filter-housing-removing-and-installing) .
4. Install intake manifold --> «Intake manifold, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

1. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .
2. Bolt transmission to engine and install engine/transmission unit --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .
3. Add engine oil and check oil level --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Torque specifications

* Insert using locking compound .

Camshaft drive

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

Left camshaft timing chain

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

Scheme 966

1 - Pivot pin, 10 Nm

2 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

3 - Washer

1. Note installation position

4 - Camshaft bolt

1. Replace
2. Initial tightening torque

1. 40 Nm

1. Final tightening torque

1. 100 Nm plus an additional 90° ( 1 / 4 turn)

5 - Chain sprocket

1. For exhaust camshaft

6 - Camshaft bolt

1. Replace
2. Initial tightening torque

1. 40 Nm

1. Final tightening torque

1. 100 Nm plus an additional 90° ( 1 / 4 turn)

7 - Hall sensor wheel

1. When installing timing chain, adjust using setting gauge T40047 --> (Scheme 984)

8 - Camshaft adjuster

1. For intake camshaft

9 - Chain tensioner

1. For left timing chain

10 - Left timing chain

11 - Guide rail

1. Can be replaced separately

12 - Control housing

1. For camshaft adjuster

13 - Gasket

1. Replace

14 - Alignment bushing

1. 2 pieces

15 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

16 - Bracket

1. For drive sprocket

17 - 10 Nm

18 - Drive sprocket

1. For left timing chain

19 - Thrust washer

1. For drive sprocket

20 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

21 - Guide rail

Right camshaft timing chain

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

Scheme 967

1 - Chain tensioner

1. For right timing chain

2 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

3 - Mounting pin

1. For drive sprocket

4 - Washer

5 - 42 Nm

6 - Camshaft bolt

1. Replace
2. Initial tightening torque

1. 40 Nm

1. Final tightening torque

1. 100 Nm plus an additional 90° ( 1 / 4 turn)

7 - Hall sensor wheel

1. When installing timing chain, adjust using setting gauge T40047 --> (Scheme 985)

8 - Camshaft adjuster

1. For intake camshaft

9 - Pivot pin, 10 Nm

10 - Guide rail

11 - Thrust washer

1. For drive sprocket

12 - Right timing chain

13 - Control housing

1. For camshaft adjuster

14 - Gasket

1. Replace

15 - Alignment bushing

1. 2 pieces

16 - Guide rail

1. Can be replaced separately

17 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

18 - Chain sprocket

1. For exhaust camshaft

19 - Washer

1. Note installation position

20 - Camshaft bolt

1. Replace
2. Initial tightening torque

1. 40 Nm

1. Final tightening torque

1. 100 Nm plus an additional 90° ( 1 / 4 turn)

21 - Drive sprocket

1. For right timing chain

22 - Guide rail

1. For timing chain

23 - Pivot pin, 10 Nm

Scheme 968

Special tools, testers and auxiliary items required

1. Locking pin 3242
2. Trim removal wedge 3409 (2x)
3. Old oil collecting and extracting device V.A.G 1782
4. Multi-point socket T10035

1. Camshaft locator T40046 (qty. 2)
2. Setting gauge T40047

Special tools, testers and auxiliary items required

Scheme 969

1. Wrench T40049
2. Drill bit 3.3 mm dia. (2x)

Removing

1. Drain engine oil --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
2. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
3. Separate engine/transmission --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .
4. Remove covers for timing chains --> «All covers for timing chain, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__all-covers-for-timing-chain-removing) .

Scheme 970

1. Install Key T40049 at rear on crankshaft using 2 old drive plate bolts.
2. Rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.

Scheme 971

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

Scheme 972

1. Rotate camshafts at hex head slightly back and forth if necessary so that camshaft locator T40046 can be inserted.
2. If camshaft locator T40046 cannot be inserted, rotate crankshaft 1 rotation (360°) further.
3. Remove camshaft locator again.
4. Remove drain plug from upper section of oil pan.

Scheme 973

1. Install crankshaft holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

Scheme 974

1. Push glide track of chain tensioner for left timing chain in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm dia. - 1 -.
2. Mark running direction of left timing chain with paint.

Scheme 975

1. Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
2. Remove camshaft chain sprocket, camshaft adjuster and timing chain.

Scheme 976

1. Push glide track of chain tensioner for right timing chain in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm dia. - 1 -.
2. Mark running direction of right timing chain with paint.

Scheme 977

1. Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
2. Remove camshaft chain sprocket, camshaft adjuster and timing chain.

Installing

1. Secure crankshaft in TDC position using crankshaft holder 3242.
2. Drive chain for timing mechanism installed --> «Drive chain for timing mechanism, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-chain-for-timing-mechanism-removing) .

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.

Scheme 978

1. Rotate inner part and outer part of both camshaft adjusters - arrows - against each other up to lock position.

1. Inner part and outer part must not be able to be against each other in lock position (slight play can still be felt)

1. Check whether camshafts of both cylinder heads stand in TDC position.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Insert camshaft locator T40046 into camshafts of left cylinder head, to do so rotate camshafts back or forth at hex head if necessary.

Scheme 979

1. Insert camshaft locator T40046 into camshafts of right cylinder head, to do so rotate camshafts back or forth at hex head if necessary.
2. Replace all four camshaft bolts.

1. Assemble left timing chain with chain sprocket and camshaft adjuster.
2. Loosely install bolts - 1 - and - 2 -.

1. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

1. Assemble right timing chain with chain sprocket and camshaft adjuster.
2. Loosely install bolts - 1 - and - 2 -.

1. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

1. Remove crankshaft holder 3242.

Scheme 980

1. Using Key T40049 , rotate crankshaft approx. 30° in opposite direction of engine rotation - arrow -.
2. Pull drill out of alignment hole, which loosens left chain tensioner.

Scheme 981

1. Insert Trim Removal Wedge 3409 as depicted in illustration and bring chain tensioner into contact with wedge.

Note. Lightly pressing in an extra 0.5 mm is permitted.

1. Pull drill out of alignment hole, which loosens right chain tensioner.

Scheme 982

1. Insert trim removal wedge 3409 as depicted in illustration and bring chain tensioner into contact with trim removal wedge 3409.

Note. Lightly pressing in an extra 0.5 mm is permitted.

1. Using Key T40049 , rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.

Note. If rotated unintentionally beyond TDC, turn back crankshaft again approx. 30° and set to TDC again.

1. Install crankshaft holder 3242 into hole, if necessary rotate crankshaft very slightly back and forth to completely center holder. Torque specification: 20 Nm.

Scheme 983

1. Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to initial tightening torque. Torque specification: 40 Nm.

Scheme 984

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 1 -.
3. Tighten camshaft bolt - 2 - on intake camshaft to initial tightening torque. Torque specification: 40 Nm

Scheme 985

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 2 -.
3. Tighten camshaft bolt - 1 - on intake camshaft to initial tightening torque. Torque specification: 40 Nm.
4. Remove setting gauge.

Scheme 986

1. Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to initial tightening torque. Torque specification: 40 Nm.

Note. Camshaft locators T40046 must not be used as counter holder for final tightening of camshaft bolts.

1. Remove camshaft locators T40046 on both cylinder heads.

1. Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to final tightening torque. Torque specification: 100 Nm plus an additional 90° ( 1 / 4 turn).

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 1 -.
3. Tighten camshaft bolt - 2 - on intake camshaft to final tightening torque. Torque specification: 100 Nm plus an additional 90° ( 1 / 4 turn).

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 2 -.
3. Tighten camshaft bolt - 1 - on intake camshaft to final tightening torque. Torque specification: 100 Nm plus an additional 90° ( 1 / 4 turn).
4. Remove setting gauge.

1. Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to final tightening torque. Torque specification: 100 Nm plus an additional 90° ( 1 / 4 turn).

1. Remove crankshaft holder 3242.

1. Using Key T40049 turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at TDC again.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Install crankshaft holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

1. Insert camshaft locator T40046 into camshafts of left cylinder head.

1. Insert camshaft locator T40046 into camshafts of right cylinder head.

Note. If camshaft locators cannot be inserted, repeat adjustment.

1. Pull out trim removal wedge 3409.
2. Remove camshaft locators T40046 on both cylinder heads.
3. Remove crankshaft holder 3242.
4. Install sealing plug of TDC-marking with new sealing ring into upper section of oil pan.

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

1. Install covers for timing chains «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__installing) .
2. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .
3. Bolt transmission to engine and install engine/transmission unit --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .

Torque specifications

* 90° corresponds to a 1/4 turn

*Replace bolts.

Camshaft timing chains, removing from camshafts

Note. For the removal of the cylinder head or camshafts, it is sufficient to remove camshaft timing chains only from the camshafts. The chains remain on the engine, the transmission is not disconnected. Even if work is performed only on one of the cylinder heads, the procedure described must be followed, since then the valve timing at both cylinder heads must be adjusted.

Special tools, testers and auxiliary items required

1. Locking pin 3242
2. Trim removal wedge 3409 (2x)
3. Old oil collecting and extracting device V.A.G 1782
4. Multi-point socket T10035

1. Camshaft locator T40046 (qty. 2)
2. Setting gauge T40047
3. Drill bit 3.3 mm (2x)

Special tools, testers and auxiliary items required

1. Adapter T40058

Work procedure

1. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Separate engine/transmission --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .

1. Disconnect electrical connection - 1 - at throttle valve control module J338.
2. Disconnect crankcase ventilation hose - 3 - at intake pipe.

Note. Ignore - 2 -.

1. Remove electrical harness connectors - 1 - , - 2 - , - 5 - and - 6 - toward front from brackets on intake pipe.
2. Disconnect electrical connectors - 3 - and - 4 -.

1. Disconnect vacuum hose - arrow - at T-piece.

1. Pull off connector strips - 2 - and - 3 - at 8 fuel injectors.
2. Remove bolts - arrows - from fuel rail.
3. Pull fuel rail with injectors upward uniformly from intake manifold and set aside in engine compartment on a clean cloth.

Note. Carefully protect removed fuel injectors from contamination.

1. Remove left rear engine lifting eye - arrows -.

1. Remove intake manifold - arrows - and remove it.

Note. Plug the intake ports of the cylinder head with clean rags.

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 around oil filter housing to catch escaping engine oil.

1. Remove bolts - arrows -.
2. Remove oil filter housing.

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

1. Remove bolts - 1 - and - 2 -.
2. Remove return line from power steering pump - arrow -.

1. Remove guide tube for oil dipstick at cylinder head - arrow - , pull up and remove.

1. Remove bolts - 1 - and - 2 -.
2. Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.

1. Remove bolts - 1 - and - 2 -.
2. Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.

1. Disconnect electrical connector - 2 - on Engine Coolant Temperature (ECT) Sensor G62.
2. Remove nut - 1 - and remove electrical wiring harness at rear coolant pipe.

1. Remove bolts - 2 to 5 -.
2. Remove rear coolant pipe.

Note. Ignore - 1 - and - 6 -.

1. Remove Secondary Air Injection (AIR) system combi-valve mounting bolts - 1 through 4 -.

1. Remove nuts - 1 to 12 - and remove left exhaust manifold.

1. Remove left heat shield - arrows -.

1. Remove nuts - 1 to 12 - and remove right exhaust manifold.

1. Remove right heat shield - arrows -.

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

Note. Puller For Ignition Coil T10094 can be used for removal.

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove left cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

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

Note. Puller For Ignition Coil T10094 can be used for removal.

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove right cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

1. Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 G163 on left cylinder head.

1. Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor G40 on right cylinder head.

1. Remove Ground (GND) cable on right cylinder head - arrow -.
2. Set wiring harness aside.

1. Remove bolts - 1 to 6 - and remove left timing chain cover.

1. Remove bolts - 1 to 6 - and remove right timing chain cover.

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

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Rotate camshafts at hex head slightly back or forth if necessary so that camshaft locator T40046 can be inserted.
2. If camshaft locator T40046 cannot be inserted, rotate crankshaft 1 rotation (360°) further.
3. Remove camshaft locator again.
4. Remove drain plug from upper section of oil pan.

1. Install crankshaft holder 3242 into hole, if necessary rotate crankshaft very slightly back and forth to completely center the holder. Torque specification: 20 Nm.

1. Push glide track of chain tensioner for left timing chain in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm dia. - 1 -.

Note. In the following illustration, the timing mechanism is depicted with covers completely removed.

1. Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
2. Remove camshaft chain sprocket and camshaft adjuster.

Note. Camshaft timing chain remains on engine. Also, if only one of the two cylinder heads is removed, bolts for camshaft gears must be loosened at both cylinder heads.

1. Push glide track of chain tensioner for right timing chain in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm dia. - 1 -.

1. Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
2. Remove camshaft chain sprocket and camshaft adjuster.

Note. Camshaft timing chain remains on engine. Also, if only one of the two cylinder heads is removed, bolts for camshaft gears must be loosened at both cylinder heads.

1. Secure crankshaft in TDC position using crankshaft holder 3242.

Note. During assembly, replace self-locking nuts and bolts. 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.

1. Rotate inner part and outer part of both camshaft adjusters against each other up to lock position - arrows -.

1. Inner part and outer part must not be able to be against each other in lock position (slight play can still be felt).

1. Check whether camshafts of both cylinder heads stand in TDC position.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Insert camshaft locator T40046 into camshafts of left cylinder head, to do so rotate camshafts back or forth at hex head if necessary.

1. Insert camshaft locator T40046 into camshafts of right cylinder head, to do so rotate camshafts back and forth at hex head if necessary.
2. Replace all four camshaft bolts.

1. Assemble left timing chain with chain sprocket and camshaft adjuster.
2. Loosely install bolts - 1 - and - 2 -.

1. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

1. Assemble right timing chain with chain sprocket and camshaft adjuster.
2. Loosely install bolts - 1 - and - 2 -.

1. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

1. Remove crankshaft holder 3242.

Scheme 987

1. Using Key T40058 , rotate crankshaft approx. 30° in opposite direction of engine rotation - arrow -.
2. Pull drill out of alignment hole, which loosens left chain tensioner.

1. Insert trim removal wedge 3409 as depicted in illustration and bring chain tensioner into contact with trim removal wedge 3409.

Note. Lightly pressing in an extra 0.5 mm is permitted.

1. Pull drill out of alignment hole, which loosens right chain tensioner.

1. Insert trim removal wedge 3409 as depicted in illustration and bring chain tensioner into contact with trim removal wedge 3409.

Note. Lightly pressing in an extra 0.5 mm is permitted.

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

Note. If rotated unintentionally beyond TDC, turn back crankshaft again approx. 30° and set to TDC again.

1. Install crankshaft holder 3242 into hole, if necessary rotate crankshaft very slightly back and forth to completely center holder. Torque specification: 20 Nm.

1. Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to initial tightening torque. Torque specification: 40 Nm.

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 1 -.
3. Tighten camshaft bolt - 2 - on intake camshaft to initial tightening torque. Torque specification: 40 Nm.

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 2 -.
3. Tighten camshaft bolt - 1 - on intake camshaft to initial tightening torque. Torque specification: 40 Nm.
4. Remove setting gauge.

1. Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to initial tightening torque. Torque specification: 40 Nm.

Note. Camshaft locators T40046 must not be used as counter holder for final tightening of camshaft bolts.

1. Remove camshaft locators T40046 on both cylinder heads.

1. Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to final tightening torque. Torque specification: 100 Nm plus an additional 90° ( 1 / 4 turn).

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 1 -.
3. Tighten camshaft bolt - 2 - on intake camshaft to final tightening torque. Torque specification: 100 Nm plus an additional 90° ( 1 / 4 turn).

1. Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
2. Place setting gauge T40047 on bolt - 2 -.
3. Tighten camshaft bolt - 1 - on intake camshaft to final tightening torque. Torque specification: 100 Nm plus an additional 90° ( 1 / 4 turn).
4. Remove setting gauge.

1. Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to final tightening torque. Torque specification: 100 Nm plus an additional 90° ( 1 / 4 turn).

1. Remove crankshaft holder 3242.

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

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Install crankshaft holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

1. Insert camshaft locator T40046 into camshafts of left cylinder head.

1. Insert camshaft locator T40046 into camshafts of right cylinder head.

Note. If camshaft locators T40046 cannot be inserted, repeat adjustment.

1. Pull out trim removal wedge 3409.
2. Remove camshaft locators T40046 on both cylinder heads.
3. Remove crankshaft holder 3242.
4. Install sealing plug of TDC-marking with new sealing ring into upper section of oil pan.

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

1. Install covers for timing chains «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__installing) .
2. Bolt transmission to engine and install engine/transmission unit --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .

Torque specifications

* 90° corresponds to a 1/4 turn

*Replace bolts.

Drive chain for timing mechanism, component overview

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

Scheme 988

1 - Mounting pin

1. For drive sprocket

2 - Washer

3 - 42 Nm

4 - Pivot pin, 10 Nm

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

1. Replace

6 - Thrust washer

1. For drive sprocket

7 - Drive sprocket

1. For left timing chain

8 - Pivot pin, 10 Nm

9 - Drive chain

1. For timing mechanism

10 - Guide rail

11 - Pivot pin, 10 Nm

12 - 10 Nm

13 - Bracket

1. For drive sprocket

14 - O-ring

1. Replace

15 - Thrust washer

16 - Drive sprocket

1. For right timing chain

17 - Pivot pin, 10 Nm

18 - O-ring

1. Replace

19 - Chain tensioner

20 - 10 Nm

21 - Guide rail

1. For timing chain

22 - Crankshaft

23 - Guide rail

24 - Pivot pin, 10 Nm

Drive chain for timing mechanism, removing and installing

Removing

1. Remove camshaft timing chains --> «Camshaft timing chain, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Remove chain for power take-off --> «Chain for power take-off, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__chain-for-power-take-off-removing-and) .

Scheme 989

1. Remove glide track - 1 - at left cylinder head.
2. Remove chain tensioner - 2 -.

Scheme 990

1. Remove glide track - 1 - at right cylinder head.
2. Remove chain tensioner - 2 -.

Scheme 991

1. Push glide track of chain tensioner for chain drive in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm dia. - 4 -.
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 the reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

1. Install chain for power take-off --> «Chain for power take-off, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__chain-for-power-take-off-removing-and) .
2. Install camshaft timing chains «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

Torque specifications

* 90° corresponds to a 1/4 turn

*Replace bolts.

Scheme 992

1 - 10 Nm

2 - Chain tensioner

1. With glide track

3 - 42 Nm

4 - Washer

5 - Mounting pin

1. For idler sprocket

6 - Idler sprocket

1. For chain for power take-off

7 - 10 Nm

8 - Bracket

1. For idler sprocket

9 - Chain

1. For power take-off
2. Removing and installing --> «Chain for power take-off, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__chain-for-power-take-off-removing-and)

10 - Crankshaft

11 - Drive sprocket

1. For power take-off

12 - 62 Nm

Chain for power take-off, removing and installing

Removing

1. Drain engine oil --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
2. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
3. Separate engine/transmission unit --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .
4. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshaft-timing-chains-removing-from-camshafts) .

1. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .
2. Remove covers for timing chains --> «All covers for timing chain, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__all-covers-for-timing-chain-removing) .

Scheme 993

1. Push glide track of chain tensioner in direction of - arrow - and pull off chain tensioner using a drill bit 3.3 mm dia. - 1 -.

Note. If chain sprocket for power take-off is to be removed, mounting bolt must be loosened before removing chain.

1. Mark running direction of chain for power take-off with paint.
2. Remove bolts - 2 to 5 - and remove chain tensioner.
3. Remove chain for power take-off.

Installing

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

1. First install chain for power take-off.
2. Install chain tensioner starting at top on engine.
3. Install covers for timing chains «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__installing) .
4. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .

1. Bolt transmission to engine and install engine/transmission unit --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .

Torque specifications

Scheme 994

1 - 62 Nm

2 - O-ring

1. Replace

3 - Spur gear

1. For power steering pump drive

4 - 10 Nm

5 - 22 Nm

6 - Rear bearing cap

1. For spur gear unit

7 - Alignment bushing

1. 2 pieces

8 - Spur gear

1. For A/C compressor drive

9 - Front bearing cap

1. For spur gear unit

10 - O-ring

1. Replace

11 - Seal

1. For A/C compressor drive
2. Replacing --> «Seals for power take-off, replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

12 - Protective dust cap

1. For A/C compressor drive

13 - Input shaft

1. For air conditioning compressor
2. Tighten to 60 Nm

14 - Seal

1. For power steering pump drive
2. Replacing --> «Seals for power take-off, replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

15 - Power steering pump

1. For power steering

16 - Input shaft

1. For oil pump

17 - Circlip

18 - Thrust washer

19 - O-ring

1. Replace

20 - Shaft for drive spur gear

21 - 22 Nm

22 - Drive spur gear

1. For power take-off

23 - Drive sprocket

1. For power take-off

24 - Spring

Scheme 995

Special tools, testers and auxiliary items required

1. Extractor hook T20143/1
2. Pressure piece T40051
3. Pressure piece T40052

Work procedure

1. Remove air conditioning compressor --> «87 - AIR CONDITIONING»(/audi/a6/6-2004-2008/remont/ac-compressor/#heating-air-conditioning) .
2. Remove power steering vane pump --> «48 - STEERING»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 996

1. Pry out sealing ring for A/C compressor drive using extractor lever T20143/1.

Scheme 997

1. Pry out seal for power steering pump drive using extractor lever T20143/1.

Scheme 998

1. Drive in seal for A/C compressor drive using thrust piece T40051.

Scheme 999

1. Drive in seal for power steering pump drive using thrust piece T40052.

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

1. Install power steering vane pump --> «48 - STEERING»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Install A/C compressor --> «87 - AIR CONDITIONING»(/audi/a6/6-2004-2008/remont/ac-compressor/#heating-air-conditioning) .

Spur gear unit, removing and installing

Special tools, testers and auxiliary items required

1. Sealant

Removing

1. Drain engine oil --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
2. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
3. Separate engine/transmission --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .
4. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .

1. Remove covers for timing chains --> «All covers for timing chain, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__all-covers-for-timing-chain-removing) .
2. Remove power steering pump from cylinder block.

Scheme 1000

1. Loosen bolt - 1 - on drive sprocket - 2 - a few turns.
2. Remove chain for power take-off --> «Chain for power take-off, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__chain-for-power-take-off-removing-and) .
3. Remove drive sprocket for power take-off.

Scheme 1001

1. Remove bolts - 1 to 8 -.
2. Remove spur gear unit rear bearing cap.

Scheme 1002

1. Remove spur gears in sequence - 1 to 3 -.

Scheme 1003

1. Remove compression spring - 1 - from shaft for drive spur gear.
2. Remove O-rings - 2 -.
3. Remove bolt - arrow -.
4. Remove front bearing cap from cylinder block.

Scheme 1004

1. Remove drive shaft - arrow - for oil pump.

Installing

Note. Replace seals and O-rings.

Scheme 1005

1. Drive out seals - 2 - (for A/C compressor drive) and - 3 - (for power steering pump drive) from front using a drift.
2. Remove O-ring - 1 -.
3. Remove remaining sealant on front bearing cap and on cylinder block.
4. Clean sealing surfaces, must be free of oil and grease.

1. Drive in seal for power steering pump drive and A/C compressor drive --> «Seals for power take-off, replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

1. Insert drive shaft - arrow - for oil pump into guide on oil pump.

Note. To guarantee that the drive shaft engages correctly in oil pump, insert drive shaft only into oil pump, do not install together with front bearing cap.

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

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

Scheme 1006

1. Apply sealant beads - arrows - to clean sealing surfaces of front bearing cap as depicted in illustration.

1. Thickness of sealant bead: 1.5 to 2.0 mm.

1. Install O-ring - 1 - and secure using some grease.

1. Install front bearing cap and tighten bolt - arrow - hand-tight.
2. Insert compression spring - 1 -.
3. Install O-rings - 2 - and secure using some grease.

1. Insert spur gears - 1 to 3 -.

Scheme 1007

1. Slide dust seal cap - arrow - onto shaft end of A/C compressor drive spur gear.
2. Check whether 2 alignment bushings are present in rear bearing cap, install if necessary.

Scheme 1008

1. Install rear bearing cap and tighten bolts as follows.

1. Fasten drive sprocket for power take-off hand-tight.
2. Install chain for power take-off --> «Chain for power take-off, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__chain-for-power-take-off-removing-and) .

1. Tighten drive sprocket - 2 - for power take-off to 62 Nm.
2. Push power steering pump with new O-ring onto spur gear for power steering pump drive.

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

1. Install covers for timing chains «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__installing) .
2. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__drive-plate-removing-and-installing) .
3. Bolt transmission to engine and install engine/transmission --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .
4. Add engine oil and check oil level --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Torque specifications

Crankshaft, component overview

Note. To perform assembly work, secure engine with Bracket For V8 Engine VAS 6095/1-6 or VAS 6095/1-6A to Engine and Transmission Holder VAS 6095 --> Engine, securing to assembly stand .

Scheme 1009

1 - Seals

1. Replace

2 - Seal for crankshaft - ribbed belt side

1. Replacing --> «Seal for crankshaft (ribbed belt side), replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__seal-for-crankshaft-ribbed-belt-side) .

3 - Alignment bushing

1. 3 pieces
2. Insert into guide frame
3. Installed location «Sealant applied on cylinder block (for guide frame)»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

4 - bolts

1. For guide frame
2. Replace
3. Different bolt sizes
4. Tightening order «Installing guide frame»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

5 - Bolt

1. For sealing surfaces of cylinder block/guide frame
2. Different bolt lengths
3. Tightening order «Installing guide frame»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

6 - Bearing bracket

1. Sealant applied on cylinder block (for guide frame) «Sealant applied on cylinder block (for guide frame)»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
2. Tightening sequence for manifold mounting bolts «Installing guide frame»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

7 - Thrust washer

1. Only at 4th 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/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__axial-clearance-measuring)

8 - Bearing shell

1. For guide frame without lubricating groove
2. Do not interchange used bearing shells (mark)
3. Insert new bearing shells for guide frame with proper color marking --> «Allocation of main bearing shells for new crankshafts»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) or --> «Allocation of main bearing shells for used and reworked crankshafts»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__allocation-of-main-bearing-shells-for)

9 - Crankshaft

1. Measuring axial play --> «Axial clearance, measuring»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__axial-clearance-measuring)
2. Radial clearance, measuring --> «Radial clearance, measuring»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__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/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__crankshaft-dimensions)

10 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__axial-clearance-measuring)

11 - Bearing shell

1. For cylinder block with oil groove
2. Do not interchange used bearing shells (mark)
3. Insert new bearing shells for cylinder block with proper color marking --> «Allocation of main bearing shells for new crankshafts»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) or --> «Allocation of main bearing shells for used and reworked crankshafts»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__allocation-of-main-bearing-shells-for)

12 - Gasket

1. Replace

13 - Cylinder block

1. Sealant applied on cylinder block (for guide frame) «Sealant applied on cylinder block (for guide frame)»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

Scheme 1010

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

1. Thickness of sealant beads: 1.5 to 2.0 mm.

1. Install seals - 1 to 3 -.

Scheme 1011

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

Scheme 1012

1. Replace bolts - 1 to 20 -.
2. Tighten bolts for guide frame as follows
3. Tighten bolts - 1 to 10 - to 30 Nm with torque wrench.
4. Tighten bolts - 11 to 20 - to 20 Nm with torque wrench.

1. Tighten bolts - 1 to 10 - to 50 Nm with torque wrench.
2. Tighten bolts - 11 to 20 - to 30 Nm with torque wrench.
3. Tighten bolts - 1 to 10 - 90° ( 1 / 4 turn) using a rigid wrench.
4. Tighten bolts - 11 to 20 - 90° ( 1 / 4 turn) using a rigid wrench.

1. Tighten bolts for sealing surfaces of cylinder block/guide frame - dark hatching in the illustration - to 9 Nm in diagonal sequence.

Scheme 1013

Allocation of crankshaft bearing shells for cylinder block

1. Bearing shells with correct thickness are allocated to cylinder block in 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 one letter each at left front on cylinder block (can be read from outside) as shown in the illustration.

Note. In addition, the letters are also stamped on the guide frame.

Scheme 1014

Allocation of crankshaft bearing shells for guide frame - crankshaft manufactured by Alfing

1. Bearing shells with 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 by one colored dot each on crankshaft counterweight as shown in the illustration.
3. Crankshafts manufactured by Alfing have no manufacturers identification.

Scheme 1015

Allocation of crankshaft bearing shells for guide frame - crankshaft manufactured by Weber

1. Bearing shells with correct thickness are allocated to guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to guide frame is marked by one colored dot each on front crankshaft counterweight as shown in the illustration. The "X" marks the end of the letter series and stand next to color identification for bearing 1 belt pulley side.
3. Crankshafts manufactured by Weber have a manufacturers identification - A - on front crankshaft counterweight.

Note. The letter series begins at left with bearing 5 flywheel side.

Allocation of main bearing shells for used and reworked crankshafts

Allocation of crankshaft bearing shells for cylinder block

1. Bearing shells are allocated to cylinder block corresponding to color markings stamped into cylinder block.
2. For used and reworked crankshafts, the main crankshaft journals must be measured in order to allocate the matching bearing shells.
3. Basic dimension of main crankshaft journals = dia. 65 mm.
4. Repair stage of main crankshaft journals = dia. 64.75 mm.

1. Thicker over-sized bearing shells are available for reworked crankshafts. These have the same color markings as the original-size bearing shells.

Allocation of crankshaft bearing shells for guide frame

1. For used and reworked crankshafts, the main crankshaft journals must be measured in order to allocate the matching bearing shells.
2. Any other markings on the crankshaft are invalid when reworking crankshafts.
3. Allocate bearing shells to determined diameter of main crankshaft journals according to the following table.

*Colored markings on bearing shells do not indicate if they are for new or used crankshafts.

Crankshaft dimensions

Axial clearance, measuring

Special tools, testers and auxiliary items required

Scheme 1016

1. Dial gauge holder VW 387

Scheme 1017

1. Dial gauge VAS 6079

Work procedure

Scheme 1018

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: 0.090 to 0.251 mm.

Radial clearance, measuring

Special tools, testers and auxiliary items required

1. Plastigage

Work procedure

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

1. Remove guide frame and clean journals.
2. Place Plastigage over entire width of bearing journal or into bearing shells.

1. Plastigage must rest in center of bearing shell.

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

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

Piston and connecting rod, component overview

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

Scheme 1019

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/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
3. When installing bearing cap, observe: The wide thrust flange - A - must point to 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/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

3 - Bearing shells

1. Check that retaining tabs are secured
2. Do not interchange used bearing shells (mark, but not on the running surface)
3. Radial clearance, measuring --> «Radial clearance of connecting rod, measuring»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__radial-clearance-of-connecting-rod-measuring)
4. Over-sized bearings are available for reworked crankshaft connecting rod journals

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/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
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/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

1. Axial play for each new connecting rod pair: 0.20 to 0.38 mm
2. Axial play wear limit: 0.60 mm
3. Radial clearance, measuring --> «Radial clearance of connecting rod, measuring»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__radial-clearance-of-connecting-rod-measuring)

5 - Piston pin

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

6 - Circlip

7 - Piston

1. Installation position of pistons «Piston installation position»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
2. Piston and cylinder dimension, piston allocation to cylinder bore --> «Piston and cylinder dimensions»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__piston-and-cylinder-dimensions)
3. Checking «Checking piston»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
4. Install with piston ring compressor

1. Measuring cylinder bore «Measuring cylinder bore»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

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. Gap, measuring «Piston ring end gap, measuring»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

1. Measuring side clearance «Measuring piston ring side clearance»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

Scheme 1020

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

Scheme 1021

1. Clean the ring groove of piston before checking.

Scheme 1022

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

1. Maximum deviation from nominal dimension: 0.04 mm.

Nominal dimension --> Piston and cylinder dimensions .

Scheme 1023

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 1024

1. Mark allocation to cylinder on piston head using chalk or water-proof felt pen.

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

Installed location

1. Arrows on piston heads point to belt pulley side.
2. Valve recesses - 1 - point toward center of engine.

Scheme 1025

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 1026

1. Molded tabs - arrows - at beveled surfaces of connecting rod pairs 1 and 2, 3 and 4, 5 and 6 as well as 7 and 8 must point toward each other.

Scheme 1027

1. Oil injector jet (opening pressure 2 to 2.4 bar positive pressure)
2. Bolts - 9 Nm. Insert using locking compound; locking compound

Piston and cylinder dimensions

Matching pistons are allocated to different manufacturing stages of cylinder block.

*Dimensions with coating (thickness 0.01 mm). The coating wears off.

Radial clearance of connecting rod, measuring

Special tools, testers and auxiliary items required

1. Plastigage

Test sequence

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

1. Remove connecting rod bearing caps again.
2. Compare width of Plastigage with measuring scale

Radial clearance

1. New: 0.028 to 0.077 mm.
2. Wear limit: 0.12 mm.

1. Replace bolts for connecting rod bearings.

Cylinder head, removing and 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. When installing a replacement cylinder head with camshafts installed, oil contact surfaces between roller rocker levers and cam running surfaces after installing cylinder head. Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head. When replacing the cylinder head or cylinder head gasket, coolant must be completely replaced. 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.

Cylinder head, component overview

Note. Right cylinder head is depicted in illustration.

Scheme 1028

1 - Cylinder head gasket

1. Replacing --> «Cylinder head, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Installed location: Part Number, points to cylinder head
3. After replacing, change engine oil and coolant

2 - Lifting eye

3 - 22 Nm

4 - Gasket

1. Replace if damaged or leaking

5 - Cylinder head cover gasket

1. Replace if damaged or leaking

6 - Cylinder head cover

1. Removing and installing left cylinder head cover --> «Left cylinder head cover, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__left-cylinder-head-cover-removing-and)
2. Removing and installing right cylinder head cover --> «Right cylinder head cover, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

7 - Ignition coil

8 - Special bolt, 10 Nm

1. Replace if damaged or leaking
2. Observe sequence for tightening --> see scheme 318

9 - Cylinder head cover gaskets

1. Replace if damaged or leaking

10 - Cylinder head cover gasket

1. Replace if damaged or leaking

11 - Semicircular seal

1. Replace if damaged or leaking

12 - Cylinder head bolt

1. Replace
2. Observe sequence for loosening --> (Scheme 1035)
3. Observe sequence for tightening --> (Scheme 1037)

13 - Cylinder head

1. Removing and installing --> «Cylinder head, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
2. Check for distortion «Checking cylinder head for distortion»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
3. Reworking dimension «Reworking dimension, cylinder head»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
4. After replacing, change engine oil and coolant

Scheme 1029

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

1. Permissible distortion: max. 0.1 mm.

Scheme 1030

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

1. Minimum dimension: - a - = 139.25 mm.

Left cylinder head cover, removing and installing

Special tools, testers and auxiliary items required

Scheme 1031

1. Hose Clamps Up to 25 mm dia. 3094

1. Remove front engine cover - arrow 1 - and - arrows 2 -.

1. Remove rear engine cover - arrows -.

Scheme 1032

1. Clamp off coolant hose - 2 - using Hose Clamps Up to 25 mm dia. 3094 and disconnect from coolant expansion tank.
2. Remove coolant expansion tank - arrow -.
3. Disconnect electrical wire to Engine Coolant Level (ECL) Warning Switch F66 on bottom of expansion tank and set aside coolant expansion tank with coolant hoses - 1 and 3 - connected.
4. If necessary, seal connection using an appropriate plug.

Scheme 1033

1. Disconnect vacuum hose at position indicated by - arrow -.

1. Remove bolt - arrow - at oil dipstick guide tube.

Note. Guide tube remains inserted in upper part of oil pan.

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

Note. Puller For Ignition Coil T10094 can be used for removal.

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove left cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

Installation is in reverse order of removal, note the following

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

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

Scheme 1034

1. Coat semicircular seals - arrows - lightly with oil and insert.

1. Tighten cylinder head cover in sequence - 1 to 15 -.

Torque specifications

* Insert using locking compound; locking compound .

1. Remove rear engine cover - arrows -.

1. Unclip fuel hose - 1 -.
2. Disconnect electrical connector - 2 - from mass air flow (MAF) sensor.
3. Disconnect mass air flow sensor from intake air duct - 3 -.
4. Remove upper part of air filter housing with mass air flow (MAF) sensor - arrows -.

1. Pull resonator - 1 - in direction of - arrow - upward and unclip it.

1. Disconnect fuel line - arrow -.

1. Disconnect vacuum hose - 1 - for brake booster at bulkhead.
2. Remove intake hose - 2 - , thereby loosening clamp - 3 -.

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

Note. Puller For Ignition Coil T10094 can be used for removal.

1. Disconnect hose of crankshaft housing ventilation - arrow -.
2. Remove right cylinder head cover bolts in sequence - 15 to 1 -.
3. Remove cylinder head cover.

Installation is in reverse order of removal, note the following

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

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

1. Coat semicircular seals - arrows - lightly with oil and insert.

1. Tighten cylinder head cover in sequence - 1 to 15 -.

Torque specifications

* Insert using locking compound; locking compound .

Removing

1. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshaft-timing-chains-removing-from-camshafts) .

1. Remove glide track - 1 - at left cylinder head.
2. Remove chain tensioner - 2 -.

1. Remove glide track - 1 - at right cylinder head.
2. Remove chain tensioner - 2 -.

Scheme 1035

1. Follow sequence - 1 to 10 - when loosening cylinder head bolts.
2. Remove cylinder head and place it on a soft surface (foam).

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. When installing a replacement cylinder head with camshafts installed, oil contact surfaces between roller rocker levers and cam running surfaces after installing cylinder head. Do not remove plastic bases protecting exposed valves until immediately before installing cylinder head. When replacing cylinder head or cylinder head seal, engine oil and coolant must be changed. 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. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks. Install cylinder head gasket onto guide sleeves. Marking "oben" (top) or part number must face toward cylinder head. Secure all hose connections using hose clamps appropriate for the model type . 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. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

1. Check whether camshafts of both cylinder heads stand in TDC position.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Crankshaft holder 3242 must be installed.

Scheme 1036

1. Set cylinder head gasket in place.

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

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

Scheme 1037

1. Tighten cylinder head in sequence indicated, in four stages as follows

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

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

1. Install camshaft timing chains «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Install engine --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .
3. Change engine oil --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
4. Replace coolant.

Torque specifications

* 90° corresponds to a 1/4 turn

*Replace bolts.

Compression pressures, checking

Special tools, testers and auxiliary items required

Scheme 1038

1. Spark plug removal tool 3122 B

Scheme 1039

1. Compression tester V.A.G 1763

1. Hose Clamps Up to 25 mm dia. 3094

Test conditions

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

Test sequence

1. Switch off ignition.

Scheme 1040

1. Remove fuse for Fuel Pump (FP) from socket "28".

1. Remove rear engine cover - arrows -.

1. Remove front engine cover - arrow 1 - and - arrows 2 -.

1. Clamp off coolant hose - 2 - using Hose Clamps Up to 25 mm dia. 3094 and disconnect from coolant expansion tank.
2. Remove coolant expansion tank - arrow -.
3. Disconnect electrical wire to Engine Coolant Level (ECL) Warning Switch F66 on bottom of expansion tank and set aside coolant expansion tank with coolant hoses - 1 and 3 - connected.
4. If necessary, seal connection using an appropriate plug.

1. Remove bolt - arrow - at oil dipstick guide tube.

Note. Guide tube remains inserted in upper part of oil pan.

Scheme 1041

1. Remove air filter cover - 2 -.
2. Remove air duct - 1 -.

Note. To pull out clips - arrows - , use Pry Lever - Rmv Outside Mirror 80-200. If necessary, use silicon-free spray lubricant to facilitate removal.

1. Unclip fuel hose - 1 -.
2. Disconnect electrical connector - 2 - from mass air flow (MAF) sensor.
3. Disconnect mass air flow sensor from intake air duct - 3 -.
4. Remove upper part of air filter housing with mass air flow (MAF) sensor - arrows -.

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

Note. Puller For Ignition Coil T10094 can be used for removal.

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

Note. Puller For Ignition Coil T10094 can be used for removal.

1. Using spark plug removal tool 3122 B , remove spark plugs.
2. Open throttle valve completely.
3. Check compression pressure using compression tester V.A.G 1763.

Note. Using tester operating instructions.

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

Compression pressure

Assembly is in reverse order of removal, note the following

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

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

1. As a final step, check DTC memory of Engine Control Module (ECM) and erase it , since malfunctions were stored by removing the fuse.

Torque specifications

* Insert using locking compound; locking compound .

Scheme 1042

1 - Intake manifold

1. Removing and installing --> «Intake manifold, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

2 - O-rings

1. For fuel injectors
2. Replace

3 - 10 Nm

4 - Fuel supply line

1. Tighten union nut to 25 Nm

5 - Fuel rail

6 - Pressure regulator valve

1. For crankcase ventilation

7 - 10 Nm

1. Fasten diagonally in steps

8 - Lifting eye

9 - 23 Nm

10 - Gasket

1. For intake manifold
2. Replace

11 - Locking pin, 0.6 Nm

Intake manifold, removing and installing

Removing

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

1. Remove engine compartment cover.
2. Disconnect vacuum hose - 3 - to brake booster at bulkhead.

Scheme 1043

1. Disconnect vacuum hose - 1 -.
2. Disconnect electrical connection - 6 - at throttle valve control module J338.
3. Release hose clamp - 2 - and pull out air duct hose.
4. Pull off vacuum hose - 4 - from crankcase breather at intake manifold.

1. Disconnect vacuum hose - 5 - from intake manifold.

1. Disconnect vacuum hose - arrow - at T-piece.

1. Remove electrical harness connectors - 1 to 4 - toward front from brackets on intake pipe.

Note. The electrical connections must not be separated.

1. Remove connector strips - 2 - and - 3 - at 8 fuel injectors.

1. Pull resonator - 1 - in direction of - arrow - upward and unclip it.

1. Remove bolts - arrows - from fuel rail.
2. Pull fuel rail with injectors upward uniformly from intake manifold and set aside in engine compartment on a clean cloth.

Note. Carefully protect the removed fuel injectors from contamination.

1. Unbolt left rear engine lifting eye - arrows -.

1. Unbolt intake manifold - arrows - and remove it.

Note. Plug the intake ports of the cylinder head with clean rags.

Installing

Installation is in reverse order of removal, note the following

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

Scheme 1044

1. Replace intake manifold gaskets, thereby removing locking bolt - 1 -.
2. Be aware of alignment pins - 2 - when setting intake manifold in place.

Scheme 1045

1. Tighten intake manifold bolts - arrows - in stages and in sequence as shown.
2. Reconnect all vacuum lines.
3. Make sure electrical connections are securely seated.
4. Bleed fuel system --> «Fuel system, bleeding»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__fuel-system-bleeding)

Torque specifications

Valvetrain, servicing

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

Scheme 1046

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

1. Replace

2 - Housing for camshaft adjustment solenoid valve

3 - Gasket

1. Replace

4 - Valve stem seal

1. Replacing --> «Valve stem seals, replacing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

5 - Valve spring

6 - Valve spring plate

7 - Valve keepers

8 - Hydraulic valve lifter

1. Pressed into roller rocker lever
2. Not removable without being damaged

9 - Roller rocker lever

1. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

10 - Alignment bushing

1. 2 pieces

11 - Double bearing cap

12 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

13 - Oil deflector

1. On cylinder head at right between bearing cap E4 and A4
2. On cylinder head at left between bearing cap E2 and A2

14 - 5 Nm plus an additional 90° ( 1 / 4 turn)

1. Replace

15 - Bearing cap

1. Note installation position and allocation --> see scheme 361

16 - Intake camshaft

1. Removing and installing --> «Camshafts, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-removing-and-installing)
2. Checking axial play --> «Camshafts, checking axial clearance»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-checking-axial-clearance)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance wear limit: 0.1 mm

1. Radial clearance run-out: max. 0.01 mm

17 - Exhaust camshaft

1. Removing and installing --> «Camshafts, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-removing-and-installing)
2. Checking axial play --> «Camshafts, checking axial clearance»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-checking-axial-clearance)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance wear limit: 0.1 mm

1. Radial clearance run-out: max. 0.01 mm

18 - Shaft for roller rocker lever, intake side

1. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

19 - 10 Nm

20 - Shaft for roller rocker lever, exhaust side

1. Removing and installing --> «Roller rocker lever, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

21 - O-ring

1. For roller rocker lever shaft
2. Replace

22 - Cylinder head

1. See note --> «Valvetrain, servicing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__valvetrain-servicing)
2. Check valve guides, grind valve seats --> «Valve guides, checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__valve-guides-checking)
3. Rework valve seats --> «Valve seats, reworking»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__valve-seats-reworking)

23 - Intake valve

1. Do not rework, only lapping is permitted
2. Valve dimensions --> «Valve dimensions»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
3. Checking valve guides, hand-lapping valve seats --> «Valve guides, checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__valve-guides-checking)

24 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Valve dimensions --> «Valve dimensions»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)
3. Checking valve guides, hand-lapping valve seats --> «Valve guides, checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__valve-guides-checking)

25 - Alignment bushing

1. 2 pieces

Camshafts, removing and installing

Removing

Note. Here, removal and installation at right cylinder head is depicted in the following description.

1. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Separate engine/transmission --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .
3. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshaft-timing-chains-removing-from-camshafts) .

Scheme 1047

1. Remove housing for camshaft adjuster - arrows -.

Scheme 1048

1. Remove bearing caps - 1 - , - E3 - , - E5 - , - A3 - and - A5 -.
2. Remove oil deflector - arrow -.
3. Loosen and remove bearing caps - E2 - , - E4 - , - A2 - and - A4 - for intake and exhaust camshafts, alternating and in diagonal sequence.
4. Remove intake and exhaust camshaft.

Installing

1. Secure crankshaft in TDC position using crankshaft holder 3242

Note. Always replace bolts that are tightened to torque as well as O-rings and gaskets.

1. Install camshafts at TDC position into cylinder head.

1. Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

1. Install bearing caps - E2 - , - E4 - , - A2 - and - A4 -.
2. Install oil deflector - arrow

1. On cylinder head at right between bearing cap - E4 - and - A4 -.
2. On cylinder head at left between bearing cap - E2 - and - A2 -.

1. Tighten bearing caps - E2 - , - E4 - , - A2 - and - A4 - for intake and exhaust camshafts, alternating and in diagonal sequence.
2. Tighten remaining bearing caps in diagonal sequence.

Note. Note alignment bushing on bearing cap - 1 -.

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

1. Install camshaft timing chains «Installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Install engine --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .

Torque specifications

* 90° corresponds to a 1/4 turn

* Replace bolts

Camshafts, checking axial clearance

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387
2. Dial gauge

Scheme 1049

Test sequence

1. Camshafts removed --> «Camshafts, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-removing-and-installing) .
2. Roller rocker lever removed --> «Roller rocker lever, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

1. Insert camshafts in cylinder head and tighten with outer bearing caps - arrows -.
2. Secure dial gauge holder VW 387 to dial gauge on cylinder head

1. Wear limit for intake and exhaust camshaft: max. 0.20 mm.

Scheme 1050

Removing

1. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Remove camshafts --> «Camshafts, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-removing-and-installing) .
3. Mark allocation of roller rocker lever and shafts for roller cam follower for re-installation.
4. Remove bolts - arrows -.

1. Thread a M6-bolt into hole in shaft for roller rocker lever.
2. Remove shaft from cylinder head and remove roller rocker lever.

Installing

Installation is in reverse order of removal, note the following

Note. Replace O-rings.

1. Before installing, oil bearing areas for roller rocker lever.
2. Install camshafts --> «Camshafts, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-removing-and-installing) .
3. Install engine --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .

Torque specifications

Scheme 1051

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

1. Adapter T40012

Work procedure

1. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Remove camshafts --> «Camshafts, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-removing-and-installing) .

Scheme 1052

1. Using spark plug removal tool 3122 B , remove spark plugs.
2. Turn roller rocker lever upward and secure it with a rubber band.

Scheme 1053

1. Place guide plate VAS 5161/7 from VAS 5161 onto cylinder head.
2. Secure guide plate VAS 5161/7 with knurled screws VAS 5161/12.

Note. If guide plate cannot be installed, drill mounting bores to approx. 0.5 mm.

1. Insert drift VAS 5161/3 into guide plate and loosen stuck valve keepers using a plastic hammer.

Scheme 1054

1. Install engaging device VAS 5161/6 with VAS 5161/5 into guide plate VAS 5161/7.
2. Guide installation cartridge VAS 5161/8 into guide plate VAS 5161/7.
3. Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar positive pressure.

1. Engage pressure fork VAS 5161/2 at engaging device VAS 5161/6 and press down installation cartridge.
2. At the same time, turn knurled bolt of installation cartridge to right, until points engage in valve keepers.
3. Lightly move knurled bolt back and forth, causing valve keepers to be pressed apart and be captured in the installation cartridge.
4. Release pressure fork.

1. Take out installation cartridge.
2. Remove guide plate.

1. Pressurized air hose remains connected.

Scheme 1055

1. Remove valve stem seals with valve seal removal tool 3364.

Scheme 1056

Note. For pressing on valve stem seals from delivery program, the valve stem seal driver 3365 must be drilled to dia. 10.5 mm. 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 oil seals - B -.
2. Lightly oil valve stem seal.
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 1057

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

Note. The large diameter of valve keepers points upward.

1. Insert valve spring and valve spring plate.
2. Install Guide Plate VAS 5161/7 onto cylinder head again.

1. Insert installation cartridge VAS 5161/8 into guide plate.
2. Press down pressure fork and pull knurled-head screw upward - thereby valve keepers are inserted.
3. Release pressure fork with knurled bolt still pulled.
4. Install camshafts --> «Camshafts, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__camshafts-removing-and-installing) .

1. Install engine --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .

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

Valve guides, checking

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387
2. Dial gauge

Scheme 1058

Test sequence

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

1. Wear limit of intake and exhaust valve guide: 0.80 mm.

Note. If wear limit is exceeded, re-measure using new valves. If wear limit is still exceeded, replace cylinder head. The valve guides cannot be replaced. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

Valves, checking

1. Visually check for signs of wear on stem and on seating surface. Replace valve if it shows significant signs of wear.

Scheme 1059

Note. Valves must not be reworked. Only lapping is permitted.

Valve seats, reworking

Note. If a perfect contact pattern is not achieved by lapping the valve seats, rework the valve seats.

Special tools, testers and auxiliary items required

1. Depth gauge
2. Valve seat refacing tool

Note. When repairing engines with leaking valves, it is not sufficient to rework or replace valve seats and valves. It is particularly important to check valve guides for wear on engines with higher mileage performance --> Valve guides, checking . Only reface valve seats enough until a perfect contact pattern is obtained. The maximum permissible reworking dimension must be calculated before work is carried out. If the reworking dimension is exceeded, the function of the hydraulic lifters can no longer be guaranteed and therefore the cylinder head should be replaced.

Calculating maximum allowable reworking dimension

1. Insert valve and press it firmly against valve seat.

Note. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

Scheme 1060

1. Measure distance - a - between end of valve stem and camshaft center axle (camshaft center axle is located at the level of cylinder head upper edge).
2. Calculate max. permissible reworking dimension from measured distance and minimum dimension.

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

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

Scheme 1061

Valve seats, reworking

Lubrication system components, removing and installing

Note. If large quantities of metal shavings or abraded material are found in the engine oil while servicing the engine, the oil passages must be carefully cleaned to prevent resulting damage and the oil cooler must be replaced. The oil level must not be above the max. mark - danger of damage to catalytic converter! Oil quantities, oil specifications and viscosity classes Maintenance tables.

Scheme 1062

1 - 10 Nm

2 - Oil pan (lower section)

1. Removing and installing --> «Lower part of oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__lower-part-of-oil-pan-removing)
2. With Oil Level Thermal Sensor G266
3. Oil Level Thermal Sensor G266 , removing and installing --> «Oil Level Thermal Sensor G266 , removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

3 - 10 Nm

4 - Intake tube

1. With oil strainer

5 - Seal

1. Replace

6 - O-ring

1. Replace

7 - 10 Nm

8 - Oil pipe

9 - Seal

1. Replace

10 - 10 Nm

11 - Oil pipe

12 - O-rings

1. Replace

13 - Input shaft

1. For coolant pump

14 - Fitting sleeves

1. 2 pieces

15 - Seal

1. Replace

16 - Oil pump

1. Do not disassemble
2. With relief valve approx. 4 bar
3. Removing and installing --> «Oil pump, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__oil-pump-removing-and-installing)

17 - Input shaft

1. For oil pump

18 - 10 Nm

19 - Housing for intake tube

20 - O-ring

1. Replace

21 - Seal

1. Replace

22 - 10 Nm

23 - Seal

1. Replace

24 - Oil drain plug, 50 Nm

Scheme 1063

1. Bolt, 10 Nm; Self-locking, replace
2. Sealing ring; replace
3. Electrical harness connector
4. Oil Level Thermal Sensor G266

Lower part of oil pan, removing and installing

Special tools, testers and auxiliary items required

Scheme 1064

1. Drip tray for workshop crane VAS 6208

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

Removing

1. Drain coolant --> «Cooling system, draining and filling»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Drain engine oil --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
3. Bring lock carrier into service position --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 1065

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

Scheme 1066

1. Place drip tray VAS 6208 under engine.
2. Remove front coolant pipe on engine - arrows -.

Scheme 1067

1. Remove nuts - 1 to 4 - for left and right stabilizer mounts.

Scheme 1068

1. Remove guide - arrow - on lower section of oil pan.

Scheme 1069

1. Disconnect electrical connector on Oil Level Thermal Sensor G266 - arrow - and free up wire.

Scheme 1070

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Remove oil pan (lower part) - 1 - and pry out carefully.

Note. There is still a residual amount of oil in lower section of oil pan.

Installing

Note. Replace seals.

Scheme 1071

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

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

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

Scheme 1072

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

1. Thickness of sealant bead: 1.5 to 2.0 mm

Note. Observe the position of the sealant bead at areas indicated with - arrows -. The oil pan (lower part) must be installed within 5 minutes after application of sealant. Sealant bead must not be thicker than specified, otherwise excess sealant may get into lower section of oil pan and clog strainer in intake tube.

1. Set lower part of oil pan in place and fasten all bolts in diagonal sequence to 5 Nm.
2. Fasten bolts for lower part of oil pan in a diagonal sequence to 10 Nm.

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

1. Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/a6/6-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Install front coolant pipe --> «Front coolant line, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__front-coolant-line-removing-and-installing) .
3. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
2. Install front bumper --> «63 - BUMPERS»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Add engine oil and check oil level --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
4. Fill with coolant.

1. Adjust headlights --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Torque specifications

Oil pump, removing and installing

Special tools, testers and auxiliary items required

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

Scheme 1073

1. Long-nose gripping pliers VAS 6226

Removing

1. Remove lower section of oil pan --> «Lower part of oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__lower-part-of-oil-pan-removing) .

Scheme 1074

1. Disconnect coolant hose - 1 -.
2. Remove coolant pump - arrows -.

Scheme 1075

1. Remove drive shaft - arrow - for coolant pump from oil pump.
2. Place Old oil collecting and extracting device V.A.G 1782 underneath.

Scheme 1076

1. Remove bolts and remove oil pipes - 1 - and - 2 -.

Note. Oil escapes when removing oil pipes.

Scheme 1077

1. Remove bolts - 1 to 3 - and remove intake tube with housing.

Scheme 1078

1. Press back drive shaft - 1 - for oil pump against spring force and clamp tightly using Long-nose gripping pliers VAS 6226 - 2 -.

Scheme 1079

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

Installing

Note. Replace seals and O-rings.

1. Check whether 2 alignment bushings are present in cylinder block, install if necessary.
2. Tighten oil pump - arrows -.

1. Unlock gripping pliers - 2 - and let drive shaft - 1 - glide into oil pump.

Scheme 1080

1. Check whether drive shaft is friction locked to oil pump. To do so, reach into intake opening - arrow - of oil pump and try to rotate oil pump gears.

1. Toothed gears must not be able to be rotated

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

1. Install coolant pump --> «Coolant pump, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__coolant-pump-removing-and-installing) .
2. Install oil pan (lower part) --> «Lower part of oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__lower-part-of-oil-pan-removing) .

Torque specifications

Scheme 1081

1 - Oil pan (lower section)

1. Removing and installing --> «Lower part of oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__lower-part-of-oil-pan-removing)
2. With Oil Level Thermal Sensor G266
3. Oil Level Thermal Sensor G266 , removing and installing --> «Oil Level Thermal Sensor G266 , removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

2 - 10 Nm

3 - 10 Nm

4 - Oil pipe

5 - Gasket

1. Replace

6 - 10 Nm

7 - Oil pipe

8 - O-rings

1. Replace

9 - Oil pan (upper section)

1. Removing and installing --> «Upper part of oil pan, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__upper-part-of-oil-pan-removing)

10 - Seal

1. Replace

11 - Gasket

1. Replace

12 - O-ring

1. Replace

13 - 15 Nm

14 - 10 Nm

15 - Guide tube for oil dipstick

16 - O-ring

1. Replace

17 - Seal

1. Replace

18 - Locking bolt, 35 Nm

19 - O-ring

1. Replace

20 - Seal

1. Replace

21 - Oil drain plug, 50 Nm

Upper part of oil pan, removing and installing

Special tools, testers and auxiliary items required

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

Removing

1. Drain engine oil --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .
2. Remove engine --> «Engine, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
3. Separate engine/transmission --> «Engine and transmission, separating»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-and-transmission-separating) .
4. Remove covers for timing chains --> «All covers for timing chain, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__all-covers-for-timing-chain-removing) .

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. Loosen tensioning bolt - arrow - and remove ribbed belt.

Scheme 1082

1. Remove tensioning roller - arrows -.

Scheme 1083

1. Remove hose clamps - 1 - and disconnect coolant hose.

Note. Ignore - 2 -.

Scheme 1084

1. Disconnect coolant hose - 3 - on generator.
2. Disconnect electrical connector - 1 -.
3. Remove electrical wire - 2 - on generator.

Scheme 1085

1. Remove bolts - arrows -.

Note. If generator is stuck in its bracket, install mounting bolt again up to 2 rotations. Carefully strike on bolt heads using flat side of hammer - doing this loosens threaded sleeves of generator mount.

1. Remove generator.

Scheme 1086

1. Remove bolts - arrows -.
2. Remove bracket for generator.

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

1. Remove front coolant pipe on engine - arrows -.

1. Disconnect coolant hose - 1 -.
2. Remove coolant pump - arrows -.

1. Remove drive shaft - arrow - for coolant pump from oil pump.

1. Remove guide tube for oil dipstick at cylinder head - arrow - , pull up and remove.

1. Remove guide - arrow - on lower section of oil pan.

1. Disconnect electrical connector on Oil Level Thermal Sensor G266 - arrow - and free up wire.

Scheme 1087

1. Remove wiring harness bracket - arrow - on lower section of oil pan.

1. Remove oil pan (lower part) - 1 - and pry out carefully.

1. Remove bolts and remove oil pipes - 1 - and - 2 -.

Scheme 1088

1. Remove bolts - 1 to 7 - for upper section of oil pan.
2. Press upper part of oil pan from alignment pins of cylinder block.

Installing

Note. Replace seals and O-rings.

Scheme 1089

1. Using rotating plastic brush, remove any remaining sealant from upper part of oil pan and cylinder block.

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

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

Scheme 1090

1. Insert new seals - 1 to 4 - into grooves on cylinder block.
2. Apply sealant beads - arrows - to clean sealing surface of cylinder block as depicted in illustration.

1. Thickness of sealant bead: 1.5 to 2.0 mm.

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

1. With a second technician, position upper section of oil pan and pre-tighten bolts - 1 to 7 - to 5 Nm in diagonal sequence.
2. Tighten bolts - 1 to 7 - diagonally to 15 Nm.

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

1. Install oil pan (lower part).
2. Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).
3. Bolt transmission to engine and install engine/transmission unit --> «Engine, installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__engine-installing) .
4. When installing generator bracket, note the two alignment bushings.

1. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__ribbed-belt-removing-and-installing) .
2. Add engine oil and check oil level --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Torque specifications

Oil check valves and spray nozzle valve, component overview

Note. If irregular valve noise occurs repeatedly during short journeys and disappears after extended driving, the oil check valves must be replaced.

Scheme 1091

1 - O-ring

1. Replace

2 - Oil check valve

1. Removing and installing --> «Oil check valves and spray nozzle valve, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__oil-check-valves-and-spray-nozzle)

3 - Ventilation pipe

4 - 10 Nm

1. Insert with locking fluid
2. Locking fluid

5 - 10 Nm

6 - Hose

1. To pressure regulating valve for crankshaft housing ventilation

7 - Cover

8 - Gasket

1. Replace

9 - Spray nozzle valve

1. Removing and installing --> «Oil check valves and spray nozzle valve, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__oil-check-valves-and-spray-nozzle)

10 - Oil check valve

1. Removing and installing --> «Oil check valves and spray nozzle valve, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__oil-check-valves-and-spray-nozzle)

11 - O-rings

1. Replace

Oil check valves and spray nozzle valve, removing and installing

Note. If irregular valve noise occurs repeatedly during short journeys and disappears after extended driving, the oil check valves must be replaced.

Removing

1. Remove intake manifold --> «Intake manifold, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Remove oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__oil-filter-housing-removing-and-installing) .

Scheme 1092

1. Remove right rear knock sensor, to do so remove bolt - 1 -.
2. Remove hose of crankshaft housing ventilation - arrow -.
3. Remove cover - 2 - for oil check valves.
4. Remove seal.

Scheme 1093

1. Remove oil check valves - 1 - and - 3 -.
2. Remove spray nozzle valve - 2 -.

Installing

Installation is in reverse order of removal, note the following

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

1. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__oil-filter-housing-removing-and-installing) .
2. Install intake manifold --> «Intake manifold, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

Torque specifications

*Do not oil bolt

Scheme 1094

1 - Gasket

1. Replace

2 - 10 Nm

3 - 22 Nm

4 - Oil filter housing

5 - Oil filter element

1. Note change intervals Fluid Capacity Chart

6 - O-ring

1. Replace

7 - Cap, 25 Nm

1. Loosen and tighten using socket wrench 36 mm.

8 - Seal

1. Replace

9 - Locking bolt, 50 Nm

10 - Seal

1. Replace

11 - Oil Pressure Switch F1 , 1.4 bar, 25 Nm

1. Black insulation
2. Checking --> «Oil pressure and oil pressure switch, checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

12 - O-ring

1. Replace

Oil filter housing, removing and installing

Special tools, testers and auxiliary items required

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

Removing

1. Remove intake manifold --> «Intake manifold, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .

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 around oil filter housing to catch escaping engine oil.

1. Remove bolts - arrows -.
2. Remove oil filter housing.

Installing

Installation is in reverse order of removal, note the following

Note. Replace seals and O-rings.

1. Install intake manifold --> «Intake manifold, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk) .
2. Add engine oil and check oil level --> «MAINTENANCE PROCEDURES»(/audi/a6/6-2004-2008/remont/procedures/#maintenance-procedures) .

Torque specifications

Oil cooler, removing and installing

Special tools, testers and auxiliary items required

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

Removing

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

1. Remove bolts - arrows -.
2. Remove bracket for generator.

Scheme 1095

1. Place Old oil collecting and extracting device V.A.G 1782 underneath.
2. Disconnect coolant hose - 1 - from oil cooler.
3. Remove bolts - arrows - and remove oil cooler.

Installing

Installation is in reverse order of removal, note the following

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

1. When installing generator bracket, note two alignment bushings.
2. Install generator --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/6-2004-2008/remont/cruise-control-systems/#electrical-equipment) .

Torque specifications

Scheme 1096

Special tools, testers and auxiliary items required

1. Oil pressure gauge V.A.G 1342 with adapter V.A.G 1342/14
2. Voltage tester V.A.G 1527 B
3. Connector test set V.A.G 1594 C

Test conditions

1. Oil level OK
2. Engine oil temperature approximately 90° C.

Test sequence

1. Remove rear engine cover - arrows -.

Scheme 1097

1. Disconnect electrical harness connector from oil pressure switch - arrow -.
2. Remove oil pressure switch.

Scheme 1098

1. Connect oil pressure gauge V.A.G 1342 with adapter V.A.G 1342/14 to hole for oil pressure switch.
2. Thread oil pressure switch - 2 - into oil pressure tester V.A.G 1342.

Oil pressure switch, checking

1. Connect brown wire - 1 - of tester to Ground ("").
2. Connect voltage tester V.A.G 1527 B using adapter cables from connector test kit V.A.G 1594 C to oil pressure switch and battery plus ("+").

1. LED must not light up

1. If LED is lit, oil pressure switch must be replaced.
2. Start engine.

Note. While starting engine, watch Pressure Tester and LED as oil pressure switch may open during start. At 1.2 to 1.6 bar pressure, LED must light up.

1. If LED is not lit, oil pressure switch must be replaced.

Oil pressure, checking

1. Start engine (engine oil temperature approximately 90° C).

1. Oil pressure at 2000 RPM: min. 2.0 bar.
2. Oil pressure at 3500 RPM: min. 3.5 bar.

Note. Replace sealing ring when installing oil pressure switch.

Torque specifications

Engine oil

Oil quantities, oil specifications and viscosity classes Fluid Capacity Chart.

Oil level, checking

Test conditions

1. Engine oil temperature min. 60° C.
2. Vehicle in level position.
3. After stopping engine, wait a few minutes to allow oil to flow back into oil pan.

Test sequence

1. Pull out oil dipstick, wipe off with a clean cloth and re-insert dipstick again up to stop.
2. Withdraw dipstick again and read oil level.

Scheme 1099

Range of markings on dipstick

a - Oil must not be added.

b - Oil may be topped off. After topping off, oil may be in range - a -.

c - Oil must be added. After topping off, it is sufficient if oil level is somewhere in range - b - (shaded area).

Note. Oil level must not exceed mark - a - on oil dipstick.

Cooling system components, removing and installing

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Secure all hose connections using hose clamps appropriate for the model type . Always replace gaskets and seals. Arrows on coolant pipes and coolant hoses must line up across from each other.

Scheme 1100

1 - Bleeder screw

1. Tighten by hand

2 - Cap

1. Pressure relief valve in cap, checking «Pressure relief valve in cap, checking»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk)

3 - Expansion tank

4 - Radiator

1. Removing and installing --> «Radiator, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__radiator-removing-and-installing)
2. Replace coolant after replacing

5 - Coolant thermostat

1. Removing and installing --> «Coolant thermostat, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__coolant-thermostat-removing-and-installing)

6 - Coolant pump

1. Removing and installing --> «Coolant pump, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__coolant-pump-removing-and-installing)

7 - Generator

8 - Oil cooler

1. Removing and installing --> «Oil cooler, removing and installing»(/audi/a6/6-2004-2008/remont/cooling-fan/#42l-v8-5v-fuel-injection-and-ignition-engine-codes-bat-bnk__oil-cooler-removing-and-installing)

9 - Cylinder head/cylinder block

1. Replace coolant after replacing

10 - Pump valve unit

1. Checking, removing and installing --> «87 - AIR CONDITIONING»(/audi/a6/6-2004-2008/remont/ac-compressor/#heating-air-conditioning)

11 - Heater unit heat exchanger

1. Replace coolant after replacing

Scheme 1101