4.2l v8 5v (engine Codes: Art, Awn, Bbd) Audi A6 C5 рестайлинг

Engine number

The engine number (engine code and serial number) is located on the left side of the cylinder block.

Scheme 428

The engine number is also listed on a label on the belt cover.

The engine code is included on the vehicle data label.

Scheme 429

Scheme 430

Engine, removing and installing

Special tools and equipment

1. Drip tray VAG 1306
2. Hose clamps 3094
3. Pin wrench 3212
4. Open-end wrench 3312
5. Drift 3204
6. Engine lifting appliance VAG 3033
7. Workshop crane VAG 1202A
8. Engine/transmission jack VAG 1383

Engine, removing

See Caution before beginning repairs on the electrical system . See ENGINE, REMOVING AND INSTALLING

Note. Remove engine together with transmission from the front. Replace all cable ties detached or cut when removing the engine in the same position when installing. The battery is located behind a cover on the right side of the luggage compartment.

1. With ignition switched off, disconnect battery ground strap.
2. Unscrew grille on left side -arrow-, unclip on right side.

Scheme 431

Scheme 432

Scheme 433

1. Remove noise insulation.
2. Remove both front wheels.
3. Remove both front wheel housings.
4. Remove front bumper behind wheel housings.
5. Unbolt bumper on left and right sides. Vehicles with headlight washers
6. Clamp off washer hose for headlight washers with clamp 3094.
7. Disconnect hose to jets at bumper in right air intake grille.
8. Disconnect hoses for headlight washers (in right grille).

1. Open cap of coolant expansion tank.
2. Place drip tray VAG 1306 under engine.
3. Drain coolant from radiator (bottom left) -arrow-. Install drain hose if necessary.
4. Open drain plugs -arrows- and drain coolant.

Scheme 434

1. Disconnect coolant hose connection -arrow-.
2. Remove radiator shroud at left and right sides -arrows
3. Remove engine cover -arrows
4. Remove air intake duct for air cleaner -arrows-.
5. Remove bracket for hydraulic oil lines -arrow-.
6. Disconnect temperature sensor -1-. (Scheme 441)
7. Remove long loop for hydraulic oil -arrows- and move aside.
8. Disconnect connector -1- for pressure switch.

1. DO NOT open air conditioning refrigerant circuit.
2. Disconnect A/C refrigerant line brackets and support points only.
3. Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.

1. Remove condenser and hang up with wire.
2. Disconnect left and right headlights
3. Disconnect connectors for left and right indicator lights.

Automatic transmission only

1. Disconnect ATF lines for automatic transmission -arrows-.

Scheme 435

All vehicles

Scheme 436

Scheme 437

1. Remove coolant hose at upper right radiator -arrow-.
2. Disconnect thermal switch -arrow-.
3. Disconnect connectors at horns.
4. Remove cover -1- in front of ABS unit.
5. Disconnect connectors in front of ABS unit -arrows-.
6. Remove bolt -arrow- on left and right sides.
7. Remove left and right impact absorbers -arrows-.
8. Disengage hood release cable.
9. Remove air shroud bolts -arrows- on left and right sides.
10. Remove air shroud with radiator.
11. Remove hose -1-.
12. Remove hose -2- to throttle body.
13. Remove hose -1- from air cleaner by turning it in direction of arrow. (Scheme 452)
14. Remove bracket for frequency valve -2- from air cleaner housing.. (Scheme 452)
15. Disconnect connector from mass air flow sensor -3-.
16. Remove bolt -arrow- and remove air cleaner housing together with mass air flow sensor and air intake duct.
17. Disconnect connector -1- from oil level sensor and move wiring aside.
18. Counter-hold pulley for viscous fan with pin wrench 3212 and remove fan with wrench 3312 (FAN HAS LEFT HAND THREAD).

Scheme 438

1. To loosen ribbed belt, turn belt tensioner with 19mm wrench in direction of arrow until both holes are aligned. Insert 3204 to hold tensioner in position.
2. Remove ribbed belt.
3. Remove pulley of hydraulic pump using pin wrench 3212 to counter-hold. NOTE: Be aware of washers behind belt pulley. Install washers again when pulley is reinstalled.
4. Remove hydraulic pump from bracket and move it aside.
5. Remove clamp for refrigerant line -arrow-.

1. DO NOT open air conditioning refrigerant circuit.
2. Disconnect A/C refrigerant line brackets and support points only.
3. Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.

Scheme 439

1. Remove A/C compressor and hang up with wire. Watch out for centering dowels to locate A/C compressor on bracket.

Scheme 440

Automatic transmission only

1. Remove bolts -arrow- for bracket for ATF lines at engine.

Scheme 441

All vehicles

1. Remove torque support -arrows-.
2. Disconnect connector -1- for oxygen sensor after Three Way Catalytic Converter (TWC) and free wiring to oxygen sensor.
3. Disconnect connector -2- for oxygen sensor after Three Way Catalytic Converter (TWC) and free wiring to oxygen sensor.
4. Disconnect connector -3- for right oxygen sensor and free wiring.

Scheme 442

1. Disconnect fuel supply and return lines.
2. Remove hose -2- and move it aside.
3. Remove hoses -arrows- from coolant expansion tank
4. Remove coolant expansion tank.
5. Disconnect connector from coolant level sensor at expansion tank.
6. Disconnect connector for left oxygen sensor -arrow- and set wiring aside.
7. Remove coolant hose -1-. (Scheme 465)
8. Disconnect connector -2-.
9. Disconnect ground wire -3-at cylinder head.
10. Disconnect connector -4-.
11. Disconnect connector -5-.
12. Disconnect connector -1- from Camshaft Position (CMP) sensor.
13. Disconnect connector -2-.
14. Disconnect connector -3-.
15. Disconnect connector -3-.
16. Disconnect connector -4- from ignition coils.
17. Disconnect connector -6-.
18. Disconnect connector -1- for knock sensor at cylinder bank 5-8.
19. Disconnect connectors -arrows- from fuel injectors of cylinder bank 5-8 and set wiring harness aside.
20. Disconnect connectors for knock sensor at cylinder bank 1-4.
21. Disconnect connectors from fuel injectors of cylinder bank 1-4
22. Remove clamp -arrow-from coolant line and set wiring harness aside.

1. Remove upper exhaust pipe bolts, left and right.
2. Remove exhaust pipe bolts -arrows-at left from below.
3. Remove exhaust pipe from retainer -arrow-.
4. Loosen double clamp-1-and push it forward.
5. Carefully remove exhaust pipe.

Scheme 443

1. From below, remove bolts -arrow- between exhaust pipe and exhaust manifold.
2. Remove exhaust pipe from retainer -arrow-.
3. Loosen double clamp -2- and push forward.
4. Carefully remove exhaust pipe with Three Way Catalytic (TWC) converter.

Scheme 444

1. Disconnect cable -1- from generator.
2. Disconnect cable -2- from generator.
3. Remove bracket -3-.
4. Remove bracket for protective cover.
5. Remove oil filter.
6. Disconnect ground cable -arrow-.
7. Remove bracket for starter motor.
8. Disconnect electrical wiring from starter motor.
9. Remove starter motor.

Note. Before unbolting torque converter, mark alignment with drive plate.

1. Remove bolts of torque converter -arrow-(three bolts). Tightening torque: 85 Nm (63 ft lb)

If engine or transmission are replaced separately

Scheme 445

1. With engine separated, turn crankshaft to TDC and align markings on torque converter and bell housing.
2. Remove left and right engine mounts.
3. Attach engine sling VAG 3033 at two engine lifting points shown.
4. Position workshop crane VAG 202A and hook up sling VAG 3033.

1. Carefully lift engine and transmission and remove toward front.

Engine, attaching to engine stand

1. Engine holding fixture VW 540.
2. Mount engine to engine stand using VW 540/1 holding fixture to repair stand VW 540.

Scheme 446

Engine, installing

Install engine in reverse order of removal - but note the following

1. Check clutch release bearing for wear and replace if necessary.

There is no needle bearing in the crankshaft on vehicles with an automatic transmission.

Scheme 447

1. When installing an exchange engine with manual transmission, check for a needle bearing in crankshaft. Install one if not yet installed.
2. Check that dowel sleeves for centering engine/transmission are installed in cylinder block; install if necessary.
3. Check level of hydraulic fluid and fill up if necessary.
4. Fill cooling system.
5. Install torque support without tension - use additional shims if necessary.
6. Align engine by shaking engine before tightening engine mounts.
7. Check oil level before starting engine.
8. Check ATF level (automatic transmission).

See SERVICING - A/T (01L, AWD) .

See Caution for connecting Telematics battery in ENGINE, REMOVING AND INSTALLING .

1. After connecting battery, enter anti-theft code for radio See Radio operating instructions
2. Close windows fully using electric window switches.
3. Operate all electric window switches again for at least one second in the "close" direction to activate "one-touch" opening and closing function.
4. Set clock to correct time.

Tightening torques

1. Engine/transmission attaching points (transmission flange shown) Centering sleeves (A and B)

Ribbed belt, removing and installing

Special tools and equipment

1. Pin wrench 3212
2. Open end wrench 3312
3. Pin 3204

Removing

Scheme 448

Scheme 449

1. Remove noise insulation.
2. Remove front bumper. See «FRONT BUMPER»(/audi/a6/c5-2001-2004/remont/exterior-body-panels/#bumper) .
3. Adjust lock carrier to service position. See «LOCK CARRIER, SERVICE POSITION»(/audi/a6/c5-2001-2004/remont/exterior-body-panels/#body-front__lock-carrier-service-position) .
4. Remove air intake hose to air cleaner.
5. Remove engine cover panel.
6. Remove outer ring for viscous fan -arrows-.
7. Remove electric fan.
8. Counter-hold pulley for viscous fan with pin wrench 3212 and remove fan with wrench 331 (FAN HAS LEFT HAND THREAD).
9. Remove viscous fan and air shroud for fan. CAUTION: Mark the running direction of the belt with crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt. When installing a used ribbed belt be sure the belt runs in the right direction and is seated correctly on the belt pulleys.
10. To loosen ribbed belt, turn belt tensioner with 19mm wrench in direction of arrow until both holes are aligned. Insert drift 3204 to hold tensioner in position.
11. Remove belt.

Installing

Install ribbed belt in the reverse order of removal, but note the following

Note. When installing a used ribbed belt, be sure that the belt runs in the correct direction and seats properly on the belt pulleys.

Scheme 450

1. Install ribbed belt on crankshaft pulley and idler wheels first. Install belt on tensioning roller last.
2. To tension ribbed belt, turn tensioner clockwise (arrow) with 19 mm ring wrench and remove pin 3204.
3. Start engine and check that belt runs correctly.
4. Install viscous fan with outer ring (fan has left-hand thread).
5. Counter-hold fan pulley with pin wrench 3212 and tighten fan using open-end wrench 3312 and torque wrench (FAN HAS LEFT-HAND THREADS).
6. Install noise insulation.
7. Install engine cover panel.

Tightening torques

TIGHTENING TORQUES: VISCOUS FAN

Toothed belt, removing and installing

Special tools and equipment

1. Spring pin from 2024 A
2. Pin wrench 3212
3. Open end wrench 3312
4. Wrench 3078 (22 mm)
5. Clamping bolt 3242
6. Camshaft bar T40005
7. Puller T40001
8. Torque wrench VAG 1410
9. Socket attachment VAS 5122
10. Tensioning roller key T40009
11. Pin T40011

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

1. Remove engine cover -arrows-.
2. Remove cylinder head cover -1- and -2-.
3. Disengage spring clips at toothed belt cover.
4. Remove toothed belt cover.
5. Remove noise insulation -arrows-.
6. Removing and installing ribbed belt, see «RIBBED BELT, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__ribbed-belt-removing-and-installing) .
7. Remove ribbed belt pulley for viscous fan.
8. Turn crankshaft to TDC by hand. Markings -A- and -B- must be aligned.
9. Check position of camshafts: larger holes -arrow- in securing plates on camshaft sprockets must be in line with each other and facing inward. If not, turn crankshaft one revolution.
10. Remove sealing plug -arrow- from left side of cylinder block.
11. TDC drilling in crankshaft must be behind sealing plug hole (feel to check).
12. Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.
13. Remove tensioner for ribbed belt.
14. Remove vibration damper.
15. Remove torque support -arrows-. NOTE: Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when reinstalled. The toothed belt tensioning element is oil-damped. To compress tensioning element apply constant pressure (compresses slowly).
16. Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until tensioning element -2- is compressed far enough to insert pin T40011 in the drilling and in plunger.
17. Install camshaft bar T40005 onto securing plates of the camshafts.
18. Loosen two camshaft bolts and unscrew approximately 5 turns.
19. Remove camshaft bar T40005.
20. Pull off both camshaft sprockets using puller T40001.
21. Loosen toothed belt tensioning roller (arrow).
22. Remove toothed belt together with camshaft sprocket for cylinder bank 1-4.

Scheme 457

Scheme 458

Scheme 459

1. First install toothed belt on crankshaft sprocket, idler wheel for tensioner, tensioning roller, camshaft sprocket for cylinder bank 5-8, coolant pump and damper wheel.
2. Then take camshaft sprocket for cylinder bank 1-4, install toothed belt and bolt sprocket onto camshaft.
3. Lightly secure both camshaft sprockets with securing plates by tightening hand-tight. NOTE: The camshaft sprockets must be tight enough on the camshaft tapers to be turned but not to be moveable axially.
4. Attach camshaft bar T40005.
5. Insert a 5 mm drill bit between tensioner and hydraulic piston -arrow-.
6. Tension toothed belt initially to 4 Nm (35 in. lb) using tensioning key T40009 and torque wrench VAG 1410 with socket attachment VAS 5122 by turning in direction of arrow. Then tighten eccentric wheel to 22 Nm (16 ft lb).
7. Remove 5 mm drill bit.
8. Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until T40011 can be removed.
9. Using 8 mm Allen key, turn toothed belt tensioning lever in direction of arrow until 7 mm drill bit can be inserted between toothed belt tensioning lever and hydraulic tensioning element.
10. Tighten bolts on camshaft sprockets. NOTE: Use camshaft bar T40005 to prevent camshafts from turning.
11. Remove camshaft bar T40005.
12. Remove 7 mm drill bit.
13. Remove crankshaft clamping bolt 3242 and install sealing plug in hole.
14. Turn crankshaft 2 revolutions.
15. Measure dimension -a- between toothed belt tensioning lever and hydraulic tensioning element. Dimension a = 5 mm.
16. If distance is not correct, re-adjust tensioning roller to 5 mm.
17. Check dimension -a- of belt guard with feeler gauge. Dimension -a- = 1 mm (0.0393 in.) Right cover, adjusting
18. Turn crankshaft until all bolts -arrows- are exposed.
19. Loosen all bolts -arrows- of cover.
20. Adjust dimension -a- using feeler gauge to 1mm (0.0393 in.).
21. Check dimension -a- of belt guard with feeler gauge. Dimension -a- = 1 mm (0.0393 in.) Left cover, adjusting
22. Turn crankshaft until all bolts -arrows- are exposed.
23. Loosen all bolts -arrows- of cover.
24. Adjust dimension -a- using feeler gauge to 1 mm (0.0393 in.).

Scheme 460

TIGHTENING TORQUES: TOOTHED (TIMING) BELT

Scheme 461

1. Ribbed belt, removing and installing, see «RIBBED BELT, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__ribbed-belt-removing-and-installing) . NOTE: It is not necessary to loosen the center bolt to remove the vibration damper.
2. Remove vibration damper. When installing, the notch -arrow- in the vibration damper must be aligned with the locating lug on the toothed belt sprocket.
3. Install vibration damper. Tightening torque: 20 Nm (15 ft lb)
4. Ribbed belt, installing, see «RIBBED BELT, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__ribbed-belt-removing-and-installing) .

Special tools and equipment

1. Pin wrench 3212
2. Open end wrench 3312
3. Socket attachment 3078 (22 mm)
4. Set screw 3242
5. Camshaft clamps T40005
6. Special tool T40001
7. Pin T40011

Scheme 462

Scheme 463

1. Remove air intake hose to air cleaner.
2. Remove front bumper. See «FRONT BUMPER»(/audi/a6/c5-2001-2004/remont/exterior-body-panels/#bumper) .
3. Adjust lock carrier to service position. See «LOCK CARRIER, SERVICE POSITION»(/audi/a6/c5-2001-2004/remont/exterior-body-panels/#body-front__lock-carrier-service-position) .
4. Remove outer ring for viscous fan -arrows-.
5. Remove electric fan.
6. Counter-hold viscous fan pulley with pin wrench 3212 and remove fan with wrench 3312 (LEFT HAND THREAD).
7. Remove fan with fan shroud.
8. Remove belt pulley for fan. CAUTION: Mark the running direction of the belt with crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt. When installing a used ribbed belt be sure belt runs in right direction and is seated properly on belt pulleys.
9. To loosen ribbed belt, turn tensioner in direction of arrow with 19 mm ring wrench until two holes are aligned. Hold in position with pin 3204.
10. Remove ribbed belt.
11. Move crankshaft by hand to TDC. Markings -A- and -B- must be aligned.
12. Remove right and left timing belt covers by disengaging spring clips.
13. Check position of camshafts: larger holes in securing plates on camshaft sprockets must be in line with each other and facing inward. If not, turn crankshaft for one revolution.
14. Remove plug -arrow- from left side of cylinder block. TDC drilling in crankshaft must be behind sealing plug hole (feel to check).
15. Screw clamping bolt 3242 for crankshaft into plug hole and tighten. NOTE: The toothed belt tensioning element is oil-damped and can be compressed slowly by applying constant pressure.
16. Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until tensioning element -2- is compressed far enough to insert pin T40011 in drilling and plunger.
17. Install camshaft bar T40005 on securing plates of both camshafts.
18. Loosen both camshaft bolts by approximately 5 turns.
19. Remove camshaft bar T40005.
20. Pull off both camshaft sprockets with puller T40001.
21. Remove toothed belt together with camshaft sprocket for cylinder bank 1-4.

1. Place toothed belt over camshaft sprocket for cylinder bank 1-4 and install sprocket on camshaft.
2. Hand-tighten both camshaft sprockets with securing plates. NOTE: The camshaft sprockets must be tight enough on the camshaft tapers to be turned but not moveable axially.
3. Attach camshaft bar T40005.
4. Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until pin T40011 can be removed. NOTE: Camshaft clamp T40005 is used to prevent camshafts from turning.
5. Remove camshaft bar T40005.
6. Remove crankshaft clamping bolt 3242 and install sealing plug.
7. Turn crankshaft by 2 revolutions.
8. Check dimension -a- of belt guard with feeler gauge. Dimension -a- = 1 mm (0.0393 in.) Right cover, adjusting
9. Turn crankshaft until all bolts -arrows- are exposed.
10. Loosen all bolts -arrows- of cover.
11. Adjust dimension -a- using feeler gauge to 1 mm (0.0393 in.).
12. Check dimension -a- of belt guard with feeler gauge. Dimension -a- = 1 mm (0.0393 in.) Left cover, adjusting
13. Turn crankshaft until all bolts -arrows- are exposed.
14. Loosen all bolts -arrows- of cover.
15. Adjust dimension-a- using feeler gauge to 1 mm (0.0393 in.).

Note. When installing a used ribbed belt, be sure that the belt runs in the correct direction and seats properly on the belt pulleys.

Scheme 464

1. Install ribbed belt on crankshaft pulley and idler wheels first. Install belt on tensioning roller last.
2. To tension ribbed belt, turn tensioner clockwise (arrow) with 19 mm ring wrench and remove pin 3204.
3. Start engine and check that belt runs correctly.
4. Install viscous fan with outer ring (FAN HAS LEFT-HAND THREAD).
5. Counter-hold fan pulley with pin wrench 3212 and tighten fan using open-end wrench 3312 and torque wrench (fan has left-hand thread).
6. Install noise insulation.
7. Install engine cover panel.

TIGHTENING TORQUES: TOOTHED (TIMING BELT)

Scheme 465

1. With crankshaft at Top Dead Center (TDC), install 3242 crankshaft holder.
2. Mark position of dual-mass flywheel and engine cylinder block (arrows).
3. Remove bolts.

Note. Replacement dual-mass flywheels are not supplied with the pilot needle bearing installed. When replacing the flywheel, always install a new pilot needle bearing.

TIGHTENING TORQUES: DUAL-MASS FLYWHEEL

Note. Always replace dual-mass flywheel mounting bolts.

B - Drive plate

1. Hold crankshaft in position using 3242 crankshaft holder, see «A - DUAL-MASS FLYWHEEL»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
2. Mark positions of shim -1- (in front of drive plate) and washer -2- (behind drive plate).
3. Install drive plate together with washer -2- and shim -1-. Washer -2-: Part No. 035 105 303 A Shim -1-: 3.00 mm, Part No. 054 105 301 Shim -1-: 4.00 mm, Part No. 054 105 202 Always replace drive plate mounting bolts Drive plate to crankshaft bolts tightening torque: 60 (44 ft lb) + 1/4 -turn (90°)

Note. Short engines and exchange engines are supplied without a bushing in the crankshaft. For vehicles equipped with an automatic transmission, install the bushing before installing the drive plate.

1. Measure distance -a- at three points and calculate average value. Dimension -a-: approx. 12.3 mm (0.484 in.).
2. If necessary, install different shim.

Note. Before installing the engine, make sure the engine to transmission centering sleeves are installed in the engine block.

Scheme 466

Cylinder head, removing and installing

Note. Cylinder heads with cracks between valve seats or between valve seat inserts and spark plug threads can continue to be used without reduced service life, if cracks are not wider than 0.3 mm (0.012 in.) or when no more than 4 turns of the spark plug threads are cracked.

Scheme 467

Scheme 468

1. Remove engine cover panel -arrows-.
2. Remove cover -2-.
3. Remove coolant expansion tank -arrows-.
4. Disconnect connector for coolant level sensor and set expansion tank aside.
5. Remove hose -1-. see scheme 112
6. Remove hose -2-.
7. Remove bracket -3-.
8. Disconnect connectors -4- from ignition coils.
9. Remove ignition coils -5-.
10. Remove cylinder head cover.

Install cylinder head cover in reverse order of removal but note the following

Note. Replace cylinder head cover gaskets if damaged.

Scheme 469

1. Apply a small amount of sealant D 545 300 A2 to sealing points - arrows- on upper surface of cylinder head. see scheme 113 CAUTION: Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
2. Tighten bolts for cylinder head cover crosswise and in sequence shown. TIGHTENING TORQUES: CYLINDER HEAD COVER, LEFT Tightening torques Nm/ft lb Cylinder head cover to cylinder head 10/7 Ignition coil to cylinder head cover 10/7

Scheme 470

Scheme 471

Scheme 472

1. Remove engine cover panel -arrows-.
2. Remove cover -1-.
3. Remove intake air duct for air cleaner.
4. Disconnect fuel supply and fuel return lines -1-.
5. Disconnect hose -2-.
6. Disconnect connectors -1- from ignition coils.
7. Remove bracket -2-.
8. Remove ignition coils -3-.
9. Disconnect crankcase breather hose.
10. Remove right cylinder head cover.

Install cylinder head in reverse order of removal but note the following

Note. Replace cylinder head cover gaskets if damaged.

Scheme 473

Scheme 474

1. Apply a small amount of sealant D 454 300 A2 to sealing points -arrows- on sealing surface of cylinder head.
2. Tighten cylinder cover according to number sequence in illustration. TIGHTENING TORQUES: RIGHT CYLINDER HEAD COVER Tightening torques Nm/ft lb Cylinder head cover to cylinder head 10/7 Ignition coil to cylinder head cover 10/7

Cylinder head, left, removing

Note. Secure all hose connections with original equipment hose clamps. Always replace opened or cut ties wraps in the same position when installing. Replace cylinder head bolts. Replace seals, gaskets, self-locking nuts and bolts which have specified tightening instructions. When installing a new cylinder head or cylinder head gasket, drain all old coolant and re-fill with new coolant. See COOLING SYSTEM, DRAINING AND FILLING .

Scheme 475

Scheme 476

1. Unbolt guide tube for oil dipstick from cylinder head.
2. Remove engine cover -arrows-.
3. Remove cylinder head covers -1- and -2-.
4. Remove intake air duct for air cleaner. WARNING: Fire hazard! Do not have anything in the area that can ignite fuel of fumes. Clean fuel connections and cover with rag to catch fuel spray.
5. Disconnect fuel supply and return lines -1-.
6. Disconnect hose -2-.
7. Remove upper bolt between exhaust manifold and exhaust pipe.
8. Disconnect connector for left oxygen sensor -arrow- and move wiring aside.
9. Disconnect connector -2- for oxygen sensor and free wiring to oxygen sensor.
10. From below remove bolts -arrows- between exhaust manifold and exhaust pipe.
11. Remove exhaust pipe from retainer -arrow-.
12. Loosen double clamp -1- and move it forward.
13. Carefully remove exhaust pipe. CAUTION: DO NOT bent swivel joint of exhaust pipe by more than 10° to prevent damage.
14. Remove toothed belt guard.
15. Disconnect connector -2-. see scheme 128
16. Disconnect connector -3-.
17. Remove toothed belt from camshafts, see «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd).
18. Remove camshaft sprocket for cylinder bank 5-8.
19. Loosen bolts -1-.
20. Remove bolts -2- and remove toothed belt cover.
21. Disconnect hose -1-. see scheme 130
22. Remove bolts -2-.
23. Disconnect connector -3-.
24. Remove bolt -4- and remove oil pipe.
25. Remove bolts -5- and take out combination valve.
26. Remove coolant line -arrows-.
27. Disconnect hose -1-. see scheme 132
28. Disconnect hose -2-. see scheme 132
29. Remove bracket -3-. see scheme 132
30. Disconnect connectors -4- from ignition coils. see scheme 132
31. Remove ignition coils -5-.
32. Disconnect connector -6-.
33. Remove cylinder head cover.
34. Disconnect connector -1- for knock sensor, cylinder bank 5-8. see scheme 133
35. Disconnect connectors -arrows- from injectors, cylinder bank 5-8, and move wiring harness clear. see scheme 133
36. Disconnect connector for knock sensor, cylinder bank 1-4. see scheme 133
37. Disconnect connectors from injectors, cylinder bank 1-4. see scheme 133
38. Disconnect connector -1-. see scheme 134
39. Disconnect hose -2-. see scheme 134
40. Remove bolts -8-. see scheme 134
41. Disconnect connector -9-.
42. Remove coolant pipe.
43. Remove intake manifold.
44. Loosen cylinder head bolts in sequence shown.
45. Remove cylinder head and place on suitable soft surface.

Cylinder head, installing, see CYLINDER HEAD, INSTALLING

Scheme 477

Cylinder head, right, removing

Note. Secure all hose connections with correct hose clips (same as original equipment). See Parts catalog Replace all cable ties which are opened or cut during removing in the same position when installing. Replace cylinder head bolts. Always replace seals, gaskets, self-locking nuts and bolts with specified tightening instructions. When installing a new cylinder head or cylinder head gasket, drain all old coolant and re-fill with new coolant.

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

1. Drain coolant, see «DRAINING»(/audi/a6/c5-2001-2004/remont/cooling-fan/#engine-cooling-42l-v8-5v-art-awn-bbd__draining).
2. Remove engine cover -arrows-.
3. Remove cylinder head covers -1- and -2-.
4. Remove intake air duct between air cleaner and throttle body. WARNING: Fire hazard! Do not have anything in the area that can ignite fuel or fumes. Clean fuel connections and cover with rag to catch fuel spray.
5. Disconnect fuel supply and return lines -1-.
6. Disconnect hose -2-.
7. Remove engine cover -arrows
8. Remove cylinder head covers -1- and -2-.
9. Remove intake air duct to air duct to air cleaner. WARNING: Fire hazard! Keep away anything that could ignite fuel or fumes. Clean connections before disconnecting. Cover with rag while disconnecting to prevent fuel spray.
10. Disconnect fuel supply and return lines -1-.
11. Disconnect hose -2-.
12. Remove upper bolt between exhaust pipe and exhaust manifold.
13. Disconnect connector for oxygen sensor at left -arrow- and free wiring.
14. Disconnect connector -2-for oxygen sensor after Three Way Catalytic (TWC) converter and free wiring down to oxygen sensor.
15. Remove toothed belt guard.
16. Disconnect connector -1- from Camshaft Position (CMP) sensor. see scheme 143
17. Disconnect connector -2-.
18. Disconnect connector -3-.
19. Remove toothed belt from camshafts, see «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd).
20. Remove idler wheel -1-.
21. Remove toothed belt cover -arrows-.
22. Disconnect connectors -1- from ignition coils.
23. Remove bracket -2-.
24. Remove ignition coils -3-.
25. Disconnect crankcase breather hose.
26. Remove cylinder head cover.
27. Disconnect connector -1- for oxygen sensor for cylinder bank 5-8. see scheme 146
28. Disconnect connectors -arrow- from fuel injectors of cylinder bank 5-8 and move wiring aside.
29. Disconnect connector for knock sensor for cylinder bank 1-4. see scheme 146
30. Disconnect connectors from fuel injectors of cylinder bank 1-4.
31. Remove coolant line -arrows-.
32. Remove hose -2-. see scheme 148
33. Disconnect connector -1-.
34. Remove bracket -3-.
35. Disconnect connector -4-.
36. Disconnect ground cable -5- from cylinder head. see scheme 148
37. Remove bolts -6-.
38. Disconnect hose -7- from combination valve.
39. Remove bolts -8-.
40. Disconnect connector -9-. see scheme 148
41. Remove coolant line.
42. Remove intake manifold.
43. Loosen cylinder head bolt in numerical sequence.
44. Remove cylinder head and place on soft surface.

Cylinder head, installing, see CYLINDER HEAD, INSTALLING

Cylinder head, installing

Note. REPLACE CYLINDER HEAD BOLTS. Remove old sealer carefully to avoid long scratches. Remove all grinding compound. Remove all oil or coolant from cylinder head bolt holes in crankcase. Handle gaskets carefully. Damage to silicone can cause leaks. Place cylinder head gasket on spacer sleeves. Marking on gasket "Oben" (top) or part number must face cylinder head. After repairs do not start engine before turning crankshaft carefully for two full turns to avoid valves from contacting pistons.

Install cylinder head in reverse order of removal but note the following

Identification markings on cylinder head gasket. "Oben" (top) or part number must face cylinder head.

Scheme 483

Scheme 484

1. Install cylinder head.
2. Insert NEW cylinder head bolts and tighten by hand.
3. Tighten cylinder head bolts in four stages in sequence shown as follows: Tighten with torque wrench: 1st stage: 35 Nm (26 ft lb) 2nd stage: 60 Nm (44 ft lb) Tighten with normal fixed wrench: 3rd stage: 1/4 turn (90°) further 4th stage: 1/4 turn (90°) further NOTE: It is not necessary to re-tighten cylinder head bolts after repairs have been performed.
4. To replace gaskets for intake manifold, remove bolts -1-. Tightening torque 0.6 Nm (5 in. lb). Locating stud for intake manifold -2-; tightening torque 7 Nm (62 in. lb). NOTE: Replace cylinder head cover gaskets if damaged.
5. Apply a small amount of sealant D 454 300 A2 to sealing points -arrows- on upper surface of cylinder head.
6. Tighten bolts for cylinder head cover crosswise and in stages.
7. Install toothed belt on camshafts, see «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
8. Relieving tension in exhaust system, see «EXHAUST SYSTEM, ALIGNING TO RELIEVE STRESS»(/audi/a6/c5-2001-2004/remont/exhaust/#exhaust-system-42l-v8-5v-art-awn-bbd) . CAUTION: Part numbers are listed here for reference only. Always check with your Parts department for the latest information.
9. Tighten cylinder head bolts in sequence shown.

Scheme 485

TIGHTENING TORQUES: CYLINDER HEADS

Valve gear, servicing

Note. Cylinder heads with cracks between valve seats or between valve seat inserts and spark plug threads can continue to be used without reduced service life, if the cracks are not wider than 0.3 mm (0.012 in.) or when no more than 4 turns of the spark plug threads are cracked.

The following list pertains to see scheme 154.

1. Double bearing cap Lightly coat with sealant AMV 100 001 02. See «BEARING CAP, APPLYING SEALER»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__bearing-cap-applying-sealer) .
2. Bolt, 10 Nm (7 ft lb)
3. Hydraulic valve lifter Removing and installing, see «VALVE STEM SEALS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) Do not interchange. Lubricate contact surface with oil.
4. Exhaust camshaft Check axial play. See «CAMSHAFT AXIAL PLAY, CHECKING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) . Removing and installing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) Check radial clearance using Plastigage (lever removed): Wear limit: 0.1 mm (0.0039 in.) Max. run-out: 0.01 mm (0.0004 in.)
5. Intake camshaft bearing cap Note installation position and numbering. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) . Observe dowel pin.
6. Exhaust camshaft bearing cap Observe dowel pin. Note installation position and numbering. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd)
7. Bolt, 10 Nm (7 ft lb)
8. Double bearing cap
9. Cap Always replace To remove: remove bearing cap. With cap installed, lightly drive in with 3202
10. Bearing cap Before installing, lightly coat with sealer AMV 100 001 02. See «BEARING CAP, APPLYING SEALER»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__bearing-cap-applying-sealer) CAUTION: Part numbers are listed for reference only. Always check with your Parts department for latest information.
11. Valve roller lever for exhaust camshaft
12. Drive chain Installing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd)
13. Valve roller lever for intake camshaft
14. Intake camshaft Check axial play. See «CAMSHAFT AXIAL PLAY, CHECKING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) . Removing and installing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) Check radial clearance using Plastigage (lever removed): Wear limit: 0.1 mm (0.0039 in.) Max. run-out: 0.01 mm (0.0004 in.)
15. Bolt, 10 Nm (7 ft lb)
16. Mechanical camshaft adjuster With valve for camshaft adjustment -N205- Before removing, secure with 3366 bracket tensioner. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
17. Rubber/metal seal Always replace.
18. Valve keepers
19. Valve spring plate
20. Valve spring
21. Valve stem seal Replacing, see «VALVE STEM SEALS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd)
22. Seal Always replace.
23. Cylinder head See note under «VALVE GEAR, SERVICING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__valve-gear-servicing) . Valve guides, checking, see «VALVE GUIDES, CHECKING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__valve-guides-checking) . Valve seats, reworking, see «VALVE SEATS, REFACING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__valve-seats-refacing) .
24. Exhaust valve Do not rework, only lapping is permitted Valve dimensions, see «VALVE DIMENSIONS»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) . Valve guides, checking, valve seats lapping, see «VALVE GUIDES, CHECKING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__valve-guides-checking) .
25. Intake valve Do not rework, only lapping is permitted Valve dimensions, see «VALVE DIMENSIONS»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) . Valve guides, checking, valve seats lapping, see «VALVE GUIDES, CHECKING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__valve-guides-checking) .
26. Seal For intake camshaft Removing and installing, see «OIL SEAL FOR RIGHT CAMSHAFT POSITION (CMP) SENSOR, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) and «OIL SEAL FOR LEFT CAMSHAFT POSITION (CMP) SENSOR, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
27. Rotor for Camshaft Position (CMP) sensor Note position
28. Rotor for Camshaft Position (CMP) sensor
29. Washer Conical
30. Bolt, 23 Nm (17 ft lb)
31. Camshaft Position (CMP) sensor -G40
32. Bolt, 5 Nm (44 in. lb) + 90°
33. Shaft for valve roller lever, intake side
34. Bolt, 9 Nm (80 in. lb)
35. Bolt, 9 Nm (80 in. lb)
36. Shaft for valve roller lever, exhaust side
37. Bolt, 55 Nm (41 ft lb)
38. Camshaft sprocket
39. Seal For exhaust camshaft Removing and installing, see «CAMSHAFT OIL SEALS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
40. O-ring For valve roller lever shaft

Scheme 486

Note. Do not reface valves. Only hand-lapping is permissible.

VALVE DIMENSIONS

Bearing cap, applying sealer

1. Coat gray surfaces of front and rear bearing caps for intake camshaft lightly with sealant AMV 100 001 02. Install bearing caps, observe dowel pins. CAUTION: Part numbers are listed for reference only. Always check with your Parts department for the latest information.

1. Dial indicator bracket VW 387
2. Dial indicator

Scheme 487

Scheme 488

1. Remove camshaft. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
2. Remove valve roller lever.
3. Install camshaft without drive chain and secure with baring caps 2 and 4.
4. Install dial indicator bracket VW 387 to cylinder head.
5. Press camshaft by hand against dial indicator.
6. Zero dial indicator.
7. Press camshaft away from camshaft.
8. Read measurement. CAMSHAFT AXIAL (END) PLAY SPECIFICATIONS New Wear limit 0.05-0.15 mm (0.0020-0.0059 in.) 0.20 mm (0.0079 in.) (0.0020-0.0059 in.)

1. Special tool 3240
2. Installation tool 3241

Removing

Note. If one oil seal is leaking, replace seals on both sides.

Scheme 489

1. Remove toothed belt from camshaft sprockets, see «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
2. Align inner part of 3240 with outer part and secure with set screw.
3. Lubricate threaded part of 3240 with oil, apply to seal and with pressure screw into seal as far as possible.
4. Release set screw and turn inner part against camshaft until seal is extracted.
5. Place extractor in vice (at flat surfaces) and remove seal with pliers.
6. Clean sealing surface on camshaft.

Note. Do not lubricate sealing lip and outside seal ring.

Scheme 490

1. Install guide sleeve 3241/2 (from press sleeve 3241/1) on camshaft.
2. Press seal flush into cylinder head with press sleeve 3241/1 and bolt 3241/6.
3. Install toothed belt, see «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .

1. Special tool 2085
2. Installation tool 3241

Scheme 491

1. Remove cover -1-.
2. Remove air intake hose for air cleaner -2-.
3. Counter-hold viscous fan pulley with pin wrench 3212 and tighten fan using open-end wrench 3312 and torque wrench (FAN HAS LEFT-HAND THREAD).
4. Remove cover -arrows-.
5. Remove right toothed belt cover.
6. Disconnect connector for Camshaft Position (CMP) sensor.
7. Remove bolts -1-.
8. Loosen bolt -2-.
9. Pull toothed belt cover toward front and remove CMP housing.
10. Install bolt from seal extractor 2085/1.
11. Remove seal with seal extractor 2085 and bolt 2085/1.

Scheme 492

1. Clean running and sealing surfaces.
2. Do not oil sealing lip before installing.
3. Install sleeve from tool 3241 on camshaft.
4. Install seal with sleeve 3241/1 and bolt 2085/1 until flush.
5. Install Camshaft Position (CMP) sensor.
6. Connect connector for CMP sensor.

TIGHTENING TORQUES: CMP SENSOR HOUSING

1. Special tool 2085
2. Installation tool 3241

Scheme 493

Scheme 494

Scheme 495

1. Disconnect connectors from ignition coils -arrows- and move harness aside.
2. Disconnect connector from Camshaft Position (CMP) sensor.
3. Remove CMP sensor housing (10 Nm/7ft lb).
4. Remove CMP rotor (23 Nm/17 ft lb) and carefully lever off rotor with screwdriver.
5. Screw in bolt from oil seal extractor 2085/1.
6. Remove seal with seal extractor 2085 and bolt 2085/1

Scheme 496

1. Clean contact and sealing surfaces. NOTE: Do not apply oil to sealing lip or outer circumference of seal before installing.
2. Install guide sleeve (from tool set 3241) onto camshaft.
3. Press in seal until flush using press sleeve 3241/1 and bolt 3241/3.
4. Install Camshaft Position (CMP) sensor rotor.
5. Install CMP sensor housing.
6. Connect connector for CMP sensor.
7. Tightening torques TIGHTENING TORQUES: CMP SENSOR HOUSING Component Nm/ft lb CMP sensor housing 10/7 CMP sensor rotor 23/17
8. Unplug connector from CMP sensor.

Scheme 497

1. Remove toothed belt from camshaft sprockets. See «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
2. Remove camshaft sprockets from cylinder bank 5-8.
3. Loosen bolts -1-.
4. Remove bolts -2- and toothed belt cover.
5. Remove cylinder head cover. See «CYLINDER HEAD COVER, LEFT, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
6. Remove Camshaft Position (CMP) sensor, item -30- and CMP rotor, item -27-. See «VALVE GEAR, SERVICING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__valve-gear-servicing) .
7. Check TDC position of camshafts: Both markings on camshafts must align with arrows on bearing caps.

When re-using drive chain

1. Clean drive chain and camshaft sprockets. Mark position with paint. CAUTION: DO NOT mark chain with punch or scriber, use paint only.

Continuation

1. Secure camshaft adjuster with bracket for chain tensioning tool 3366. CAUTION: Do not over-tighten bracket for chain tensioning tool, otherwise camshaft adjuster may be damaged
2. Regardless of how bearing caps are marked, mark sequence and installation position of all bearing caps as shown in illustration.
3. Remove bolts for camshaft adjuster -arrow-.
4. Remove bearing cap 0.
5. Remove bearing caps 1, 3, 5, 7 and 8 and place in order on clean surface.
6. Loosen bearing caps 2, 4, and 6 diagonally and remove.
7. Remove camshafts with camshaft adjuster.

Install camshaft adjuster in reverse order of removal but note the following

1. Replace half-round cap.
2. Replace rubber-metal gasket for camshaft adjuster and coat the hatched area lightly with sealer AMV 100 001 02. see scheme 184 CAUTION: Part numbers are listed for reference only. Always check with your Parts department for latest information.
3. Place drive chain on camshaft sprockets as follows

When using the old chain

1. Align paint markings -arrows-.

When using a new drive chain

1. The distance between camshaft markings -A- and -B- must be 16 rollers of the drive chain. Position rollers 1 and 16 according to illustration. Chain rollers 1 and 16 are offset by 1/2 tooth width to the left in relation to markings -A- and -B-.

Continuation

Scheme 498

Scheme 499

1. Insert camshaft adjuster next to chain (requires second technician).
2. Place camshafts with drive chain and camshaft adjuster into cylinder head.
3. Lubricate running surfaces of camshafts with oil. NOTE: Be sure locating dowels for bearing caps and camshaft adjuster are installed in cylinder head.
4. Tighten camshaft adjuster (observe locating dowels).
5. Install bearing caps 3, 5, and 7 according to markings.
6. Tighten bearing caps 3, 5, and 7 of intake and exhaust camshafts diagonally (observe locating dowels).
7. Install remaining bearing caps of intake and exhaust camshafts and tighten them from inside to outside in alternating diagonal sequence.
8. Tighten camshaft adjuster -10- (pay attention to alignment bushings).
9. Remove bracket for chain tensioner 3366.
10. Check camshafts for correct adjustment.
11. Both markings at camshafts must align with markings on bearing caps -arrows-. NOTE: To make sure that alignment is correct, turn camshaft in direction of engine operation.
12. Coat gray area of double bearing cap -6- and outer bearing cap -1- next to camshaft adjuster lightly with sealer AMV 100 001 02. see scheme 189 Install bearing cap with camshaft seals (observe locating dowels).
13. Install remaining bearing caps (observe locating dowels). CAUTION: Part numbers are listed for reference only. Always check with your Parts department for latest information.
14. Tighten remaining bearing caps.
15. Install toothed belt (adjust timing). See «INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd). NOTE: Observe all notes regarding removing and installing toothed belt. See «TOOTHED BELT, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__toothed-belt-removing-and-installing).
16. Install cylinder head cover. See «CYLINDER HEAD COVER, LEFT, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__cylinder-head-removing-and-installing). NOTE: DO NOT immediately start engine after installing camshafts. Wait for at least 30 minutes, otherwise valves may hit pistons. The hydraulic lifters have to settle first. After completing work on the valve train, carefully turn crankshaft by hand for two revolutions to be sure that no valve contacts a piston.

TIGHTENING TORQUES: CAMSHAFTS AND CAMSHAFT ADJUSTERS

1. Spark plug wrench 3122 B
2. Installation tool VAS 5161
3. Removal tool 3364
4. Installation tool 3365

1. Cylinder head installed

Scheme 500

1. Remove camshafts. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .
2. Remove spark plugs with spark plug wrench 3122B.
3. Turn valve roller lever up and secure with rubber band.
4. Install mounting plate VAS 5161/7 from VAS 1561 to cylinder head.
5. Secure plate with serrated screws VAS 516/12.
6. Using drift VAS 5161/3, loosen valve keepers by tapping with plastic hammer.
7. Install serrated support VAS 5161/6 with VAS 5161/5 into plate 5161/7.
8. Install cartridge VAS 5161/8 into plate VAS 5161/7.
9. Install pressure hose adapter T40012/1 with sealing ring into applicable spark plug hole and hand tighten.
10. Attach air hose and apply steady pressure.
11. Minimum air pressure 6 bar (87 psi)
12. Insert lever VAS 5161/2 into lever support VAS 5161/6 and lightly press down on cartridge VAS 5161/VAS 5161/8. Turn cartridge at serrated part until points engage in slots between valve keepers.

By slightly turning serrated part of cartridge, the valve keepers are separated and captured by the cartridge.

1. Release pressure on lever.
2. Remove valve spring and plate.
3. Remove valve stem seal with 3364.

1. To prevent damage to new seal, place plastic sleeve -A- on valve stem.
2. Lightly lubricate sealing lip and valve stem with oil.
3. Install valve stem seal -B- without oiling outside of seal, into seal driver 3129 and carefully push seal down over valve stem down to valve guide.

Valve guides, checking

Special tools and equipment

1. Dial indicator bracket VW 387
2. Dial indicator

Scheme 501

1. Install valve in valve guide so that end of valve stem is flush with end of guide.
2. Measure amount of rock (axial play).

Wear limit

VALVE GUIDE WEAR LIMIT

Note. If the wear limit is exceeded, repeat measurement with new valves. If the measurement is again exceeded, replace cylinder head. valve guides cannot be replaced. If you intend to replace the valve, measure with new valve.

Valves, checking

1. Carefully check valve for wear at stem and seat. Replace valve when worn.

Valve seats, refacing

Special tools and equipment

1. Depth gauge
2. Valve lapping tool NOTE: Repairing engines with leaking valves, especially engines with high mileage must include measuring valve guides. See «VALVE GUIDES, CHECKING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd__valve-guides-checking) . Before refacing, calculate maximum permissible refacing dimension. If the maximum permissible refacing dimension is exceeded, the function of the hydraulic valve lifters can no longer be guaranteed and the cylinder head must be replaced. Reface valve seats just enough to produce a good seating pattern.

Maximum permissible refacing dimension, calculating

1. Install valve and press it firmly onto the valve seat. NOTE: If valve is to be replaced, use new valve for measurement.
2. Install valve and press firmly against valve seat.
3. Measure distance between end of valve stem and top surface of cylinder head.
4. Calculate maximum permissible refacing dimension from measured distance and minimum dimension.

Minimum dimensions

MINIMUM DIMENSIONS: DISTANCE BETWEEN END OF VALVE STEM AND TOP SURFACE OF CYLINDER HEAD

The measured distance minus the minimum dimension equals the maximum permissible refacing dimension.

Example

Outer intake valve

Measured distance 34.4 mm (1.354 in.)

Minimum dimension -34.0 mm (1.338 in.)

Maximum permissible refacing =0.4 mm (0.0157 in.)

Note. If the measured distance is less than the minimum dimension, repeat the measurement with new valves or replace the cylinder head.

Scheme 502

VALVE SEAT SPECIFICATIONS

Component layout

Note. Always replace gaskets and seals.

The following list pertains to see scheme 202.

1. Oil pan - lower section
2. 10 Nm (7 ft lb)
3. Oil pan - upper section
4. 10 Nm (7 ft lb)
5. Grid section
6. Circlip
7. Rubber tube
8. Strainer
9. Oil pump Removing, see «OIL PUMP, REMOVING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) . If faulty, always replace whole pump
10. 25 Nm (18 ft lb)
11. Baffle plate
12. Oil level sensor
13. 35 Nm (26 ft lb)
14. 25 Nm (18 ft lb)
15. 10 Nm (7 ft lb)
16. 25 Nm (18 ft lb)
17. 60 Nm (44 ft lb) + additional 90° Apply sealant D 454 300 02 before inserting ALWAYS REPLACE BOLTS
18. Plate
19. Drive plate When assembling, make sure that dowel for ignition timing is correctly inserted in drive plate. Dowel should project 20 - 22 mm (0.78 to 0.86 in.) from drive plate
20. 10 Nm (7 ft lb)
21. Rear sealing flange with oil seal

Oil filter/oil cooler

Note. Always replace seals and gaskets.

The following list pertains to see scheme 203.

1. 20 Nm (15 ft lb)
2. Coolant outlet pipe
3. 10 Nm (7 ft lb)
4. 25 Nm (18 ft lb)
5. 50 Nm (37 ft lb)
6. Seal
7. Oil filter cover
8. Oil filter element
9. 10 Nm (7 ft lb)
10. Valve plate With pressure relief valve for oil filter and oil cooler
11. Gasket
12. 50 Nm (37 ft lb)
13. Seal
14. Housing for oil filter and oil cooler
15. Oil pressure switch White; 1.8 bar
16. Oil pressure switch Brown; 0.3 bar
17. 25 Nm (18 ft lb)
18. Seal
19. Oil cooler Oil/coolant heat exchanger
20. Gasket
21. Housing for oil cooler With coolant drain plug
22. Seal
23. Line connection For coolant supply
24. Seal
25. Seal

1. Electric drill with plastic brush attachment
2. Silicone sealant D 176 404 A2
3. Torque wrench, 10 Nm / 45 Nm

1. Remove noise insulation.
2. Drain engine oil
3. Disconnect connector -1- from oil level sensor.
4. Remove lower oil pan -arrow-.

Install oil pan in reverse order but note the following

1. Clean oil and grease from sealing surfaces.

1. Remove remaining sealant from oil pan and engine block using electric drill and plastic brush attachment.

Note. Oil pan must be installed within 5 minutes of applying silicone sealer D 176 404 A2.

1. Cut off nozzle of tube at front marking (nozzle dia. approx. 3 mm or 5/16 in.). Thickness of sealant bead: 2 to 3 mm (approx. 1/8 in.)

Scheme 503

Note. The bead of sealant must not be thicker than 3 mm (approx. 1/8 in.), as otherwise excess sealant will enter the oil pan and obstruct the strainer in the oil intake pipe.

1. Install oil pan immediately and tighten all bolts initially to 5 Nm (44 in. lb).
2. Tighten bolts in crosswise sequence - final torque: 15 Nm (11 ft lb).
3. Replace seal on oil drain plug and tighten to 30 Nm (22 ft lb).

Note. After installing the oil pan, wait for about 30 minutes for the sealant to cure before filling with engine oil.

1. Fill with engine oil. See «ENGINE OIL, FILLING»(/audi/a6/c5-2001-2004/remont/procedures/#maintenance__engine-oil-filling) .

TIGHTENING TORQUES: LOWER OIL PAN

Scheme 504

Scheme 505

1. Remove noise insulation.
2. Remove dipstick.
3. Drain engine oil.
4. Disconnect connector -1- from oil level sensor.
5. Remove oil pan lower part -arrow-.
6. Remove oil grid -arrows-.
7. Loosen bolt for oil pump pulley.
8. Secure chain tensioner with spring pin -arrow-.
9. Remove oil pump pulley.
10. Remove oil pump and take out downward.

Install oil pump in reverse order of removal but note the following

Sealing surface must be free of oil or sealing compound.

1. Clean sealing surfaces with electric drill and plastic brush insert.

Scheme 506

Note. Oil pan must be installed within 5 minutes of applying silicone sealer D 176 404 A2.

1. Cut off nozzle of tube at front marking (nozzle dia. approx. 3 mm or 5/16 in.). Thickness of sealant bead: 2 to 3 mm (approx. 1/8 in.)

Scheme 507

Note. The bead of sealant must not be thicker than 3 mm (approx. 1/8 in.), as otherwise excess sealant will enter the oil pan and obstruct the strainer in the oil intake pipe.

1. Install oil pan immediately and tighten all bolts to initially 5 Nm (44 in. lb).
2. Tighten bolts in crosswise sequence - final torque: 15 Nm (11 ft lb).
3. Replace seal on oil drain plug and tighten to 30 Nm (22 ft lb).

Note. After installing the oil pan, wait for about 30 minutes for the sealant to cure before filling with engine oil.

1. Fill with engine oil.

TIGHTENING TORQUES: OIL PUMP

1. Install lower oil pan. See «INSTALLING»(/audi/a6/c5-2001-2004/remont/mechanical/#42l-v8-5v-engine-codes-art-awn-bbd) .

Oil pressure switches, checking

Oil pressure indicator with audible and visible warning

Read measured value block. For model years up to 2000, see READ MEASURING VALUE BLOCK (SCAN TOOL FUNCTION 08) . For model years 2001 and up, see READ MEASURING VALUE BLOCK (FUNCTION 08) .

Test requirements

1. Measured value block OK.
2. Oil level OK.
3. Oil pressure warning lamp (K3) should light up when ignition is switched on.
4. On vehicles with auto-check system, "OK" should appear in the display (call up symbol).
5. Engine oil temperature about 80°C (176°F). Radiator fan must have started at least once.

Scheme 508

Scheme 509

1. Remove engine cover panel.
2. Remove upper section of air cleaner and set aside.
3. Remove lower section of air cleaner.
4. Remove oil pressure switch and install adapter VAG 1342/3 in its place.
5. Install VAG 1342 into adapter VAG 1342/3.
6. Install oil pressure switch into VAG 1342.
7. Connect brown wire -2- to Ground (GND).
8. Connect blue wire -1- to oil pressure switch.
9. Connect diode test light VAG 1527 to wire -1- and battery (+).
10. Install lower section of air cleaner.
11. Install upper section of air cleaner.
12. Start engine and test switching points of switch by varying engine speed as required.

OIL PRESSURE SPECIFICATION

Note. Brown oil pressure switch (0.3 bar) should open at 0.15 to 0.45 bar. White oil pressure switch (1.8 bar) should close at 1.6 to 2.0 bar.

Scheme 510

Scheme 511

1. Remove engine cover panel.
2. Remove upper section of air cleaner and set aside.
3. Remove lower section of air cleaner.
4. Remove oil pressure switch and install adapter VAG 1342/3 in its place.
5. Install VAG 1342 into adapter VAG 1342/3.
6. Install oil pressure switch in VAG 1342.
7. Install lower section of air cleaner.
8. Install upper section of air cleaner.
9. Start engine.
10. Engine oil temperature must be at least 80°C (176°F).

OIL PRESSURE SPECIFICATION

Note. If the oil pressure is excessively high (for example if pressure relief valve is sticking or has been installed incorrectly) the hydraulic lifters will jam. The engine will cut out soon after starting. When attempting to start the engine again it will be noticed that the engine turns over too quickly due to lack of compression.

Engine oil

The engine was filled at the factory with high quality multi-grade oil. This oil can be used all year round, except in extremely cold climates.

The specifications for the oil listed must appear on the container - either singly or together with other specifications.

Different types of oil may be mixed when topping up.

Select the viscosity grade of the oil according to the chart. The oil does not need to be changed for brief temperature variations.

1. Light oils
2. Multi-grade oils

Oil level, checking

Note. Always check the oil level when the engine is warm (oil temperature must be above 60°C (140°F). Check the oil level with the car on level ground. Wait for a few minutes after switching off the engine to allow the oil to flow back into the oil pan.

1. Pull out dipstick, wipe dip stick with a clean cloth and insert dipstick again as far as it will go.
2. Pull out dipstick again and read oil level.

Markings on dipstick

1. Do not add any oil.
2. Oil can be topped up (as far as -a-)
3. Oil must be topped up. It is enough when the oil level is within area -b- (grooved area on dipstick).

Scheme 512

Oil capacity (with new oil filter)

See ENGINE OIL, FILLING .

See also:
• EMERGENCY BATTERY, SWITCHING OFF/ON
• SERVICING - A/T (01L, AWD)
• FRONT BUMPER
• LOCK CARRIER, SERVICE POSITION
• COOLING SYSTEM, DRAINING AND FILLING
• DRAINING
• EXHAUST SYSTEM, ALIGNING TO RELIEVE STRESS
• ENGINE OIL, FILLING
• READ MEASURING VALUE BLOCK (FUNCTION 08)
• ENGINE, REMOVING AND INSTALLING
• RIBBED BELT, REMOVING AND INSTALLING
• CYLINDER HEAD, INSTALLING
• BEARING CAP, APPLYING SEALER
• VALVE GEAR, SERVICING
• VALVE GUIDES, CHECKING
• VALVE SEATS, REFACING
• TOOTHED BELT, REMOVING AND INSTALLING
• CYLINDER HEAD COVER, LEFT, REMOVING AND INSTALLING