3.0L V6 (Engine Code: Avk): Other Audi A6 C5 facelift

Removing

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

Vehicles with automatic transmission

1. Shift selector lever into position "N".

All

1. Pull off rubber seal of plenum chamber cover in direction of arrow.
2. Remove plenum chamber cover -1- toward front. CAUTION: On vehicles equipped with Audi Telematics by OnStar®, switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting the vehicle battery. Switch-on the emergency (back-up) battery after reconnecting the vehicle battery. See «EMERGENCY BATTERY, SWITCHING OFF/ON»(ref-196292-S13683948542005100800000) .
3. Note radio code and determine if necessary (for vehicles with coded anti-theft radio / radio-navigation system -RNS-).
4. Switch ignition off and disconnect battery Ground (GND) strap (arrow). WARNING: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
5. Open cap of coolant expansion tank.
6. Remove both front wheels.
7. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
8. Loosen mounting parts -1 to 4- and remove noise insulation.
9. Remove bracket for noise insulation (arrows).
10. Remove front bumper: See «FRONT BUMPER»(ref-196283-S08508749282005100800000) or «FRONT BUMPER (AUDI RS6)»(ref-196283-S17637369012005100800000)
11. Place VAG1306 Drip Tray beneath engine.
12. Turn radiator drain plug -2- counterclockwise, if needed attach accessory hose to connection flange and drain coolant.
13. Pull off retaining clip -1- for lower coolant hose and Disconnect coolant hose from radiator.
14. Disconnect left coolant hose from radiator (arrow).
15. In addition, disconnect coolant hose at oil cooler (arrow) and drain remaining coolant.
16. Place oil pan underneath.
17. Disconnect hydraulic lines to cooling coil at rear of bumper (arrows).

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

See appropriate Automatic Transmission article

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

Scheme 354

1. Remove cover -1- in engine compartment (right side).
2. Remove bolts (arrows). see scheme 21
3. Remove air guide -1-.
4. Remove cover -1- in engine compartment (left side).
5. Disconnect top coolant hose from radiator (arrow).
6. Remove electrical harness connectors -1- and -2- from bracket and disconnect them.
7. Move cable clear.
8. Disconnect electrical harness connector (arrow) for headlights at both sides of the vehicle.
9. Remove air guides from left and right of radiator (arrows).
10. Unclip temperature sensor -2- for outside temperature display from bracket.
11. Unscrew bolts -1- and -2- and remove power steering cooling coil.
12. Disconnect harness connector -3- at High Pressure Sensor -G65-. WARNING: Do not open refrigerant circuit for A/C system.
13. Remove condenser mounting bolts (arrows). NOTE: To prevent damage to the condenser as well as to the coolant lines/hoses, make sure the lines and hoses are not over-stretched, kinked or bent.
14. Carefully swing condenser downward and move aside.
15. Unscrew bolts (arrows) at left and right.
16. Unhook hood cable from lock and move cable free.
17. Unscrew bolts (arrows) at impact absorbers at left and right. NOTE: A second technician is required to remove the lock carrier.
18. Remove lock carrier and set aside so it cannot topple.
19. Remove rear engine cover (arrows).
20. Remove bolts for holding plate -3- for solenoid valves (arrows).
21. Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
22. Disconnect hose -4- from air guide -2-.
23. Remove bolt (arrow) and disconnect air guide -2- at throttle valve control module.
24. Disconnect hose -1- from air guide if installed. NOTE: Illustration depicts air guide with the removed engine from rear.
25. Remove coolant hoses -1- and -2-. NOTE: Coolant hose -3- remains connected.
26. Unbolt coolant reservoir (arrow).
27. Disconnect electrical wiring to Engine Coolant Level (CELL) Warning Switch -F66- at bottom of expansion tank.
28. Disconnect Ground (GND) connection -3-.
29. Disconnect vacuum hoses -1- and -2-.
30. Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module

1. Disconnect electrical harness connector (arrow) and lay cable free.

1. Place oil pan underneath.
2. Disconnect hose -1- from power steering fluid reservoir.
3. Disconnect vacuum hose -2- to vacuum reservoir.
4. Disconnect electrical harness connector -1- at Secondary Air Injection (AIR) Pump Motor -V101- and move cable free.
5. Disconnect hose at tube to combination valve for Secondary Air Injection (AIR) -2-.
6. Disconnect electrical harness connectors -2- and -3- at Evaporative Emission (EVAP) canister purger regulator valve -N80- item 1 and at Mass Air Flow (MAF) sensor. (Scheme 375)
7. Disconnect vacuum hose -6- at Evaporative Emission (EVAP) canister purge regulator valve and unhook solenoid valve at air filter housing. WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
8. Disconnect fuel supply line -4- and fuel return line -5- and move free.
9. Disconnect hose connections, move wires free and remove air filter housing (arrows). NOTE: Place a rag under the hydraulic pressure lines, to catch escaping hydraulic fluid.
10. Unbolt hydraulic pressure line for power steering at rear coolant pipe -1- and disconnect the line at the height of right cylinder head -2-.

1. Disconnect electrical harness connector (arrow) at Brake Booster Pressure Sensor -G294-.
2. move cable clear.

1. Remove E-box cover in plenum chamber -arrows-.
2. Using a screwdriver, carefully pry off retaining bracket (arrow).
3. Disengage connector catch (arrows) and disconnect harness connectors -1- and -2- from Engine Control Module (ECM).
4. Disconnect connectors at rear of connector strip.
5. Unhook release catch (arrow) and remove secondary relay carrier in E-box upward.
6. Unhook engine wiring harness at E-box and at bulkhead and move it free.
7. Remove heat shield for harness connectors at left of bulkhead.
8. Remove harness connectors -1 to 4- from bracket at left of bulkhead.
9. Disconnect electrical harness connectors -1- and -4-.
10. Expose oxygen sensor wires.
11. Remove bracket for harness connectors.
12. Remove harness connectors -1 to 4- from bracket at right of bulkhead.
13. Disconnect electrical harness connectors -1-, -2- and -4-.
14. Expose oxygen sensor wires.
15. Remove bracket for harness connectors.
16. Remove nut -2- for left exhaust pipe/exhaust manifold which is accessible from top. NOTE: Illustration is shown with engine removed.
17. Remove nut -2- for front exhaust pipe/right exhaust manifold which is accessible from top. NOTE: Illustration is shown with engine removed.
18. Disconnect coolant hoses to heater core at rear coolant pipe and at right coolant pipe. To do so, remove wiring harness screw clip on the right side of the vehicle.
19. Remove upper mounting bolts for engine/transmission. One bolt remains tightened by hand.
20. Remove front engine cover (arrows). NOTE: Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.
21. Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using 3299 ribbed belt installation tool and 3299/1 claw for tensioner.
22. Remove ribbed belt from pulley of power steering pump.
23. Place engine oil drip tray beneath engine.
24. Drain engine oil.
25. Remove oil filter -2-.
26. Place VAG1306 Drip Tray beneath engine.
27. Remove coolant hose -3- from oil cooler.
28. Remove oil cooler -1-.
29. Unbolt bracket for refrigerant line at oil pan (arrow). NOTE: Depicted in illustration for a vehicle with manual transmission.
30. Disconnect harness connector -1- of electrical wire to clutch for A/C compressor. WARNING: Do not open refrigerant circuit for A/C system.
31. Unbolt A/C compressor from bracket (arrows).
32. Hang A/C compressor together with condenser with connected lines at right side of vehicle.
33. Disconnect electrical lines from generator.
34. Unscrew bolts (arrows) and remove generator.
35. Remove heat shield -1- for left and right drive axle.
36. Remove electrical wires -1- and -2- from starter.
37. Disconnect Ground (GND) connection -3-.
38. Remove heat shield -1- from magnetic switch.
39. Unscrew bolts -2- and -3- and remove starter.

Vehicles with automatic transmission 01V

1. Unscrew 3 Torx bolts (arrow) of torque converter in the opening of the removed starter (turn crankshaft 1/3 rotation in each case). NOTE: To loosen the torque converter bolts counterhold the main harmonic balancer bolt.

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

1. Disconnect exhaust system at double clamps (arrows).
2. Remove nuts -1- and -3- for front exhaust pipe/left exhaust manifold which are accessible from bottom. NOTE: Illustration is shown with engine removed.
3. Expose oxygen sensor wires.
4. Pull front exhaust pipe off of left exhaust manifold.
5. Remove nuts -1- and -3- for front exhaust pipe/right exhaust manifold which are accessible from bottom. NOTE: Illustration is shown with engine removed.
6. Expose oxygen sensor wires.
7. Pull front exhaust pipe off of right exhaust manifold.

Scheme 355

Vehicles with manual transmission

1. Where installed, unbolt heat shield for engine speed (RPM) sensor.
2. Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.
3. Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire. NOTE: Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.
4. Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of transmission. NOTE: Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.

Vehicles with automatic transmission 01J

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

1. Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS).

1. Unbolt angle bracket for wiring harness from left engine mount.
2. Mark installation positions of threaded connections -1- and positioning sleeves -2- below on engine mounts at right and left. NOTE: Different mounting bores are available depending upon the installed engine.
3. Remove nuts 1 at bottom on left and right engine mounts.
4. Loosen nuts (arrow) on top at left and right engine mounts several turns.
5. Unbolt torque support (arrows).
6. Tighten T10062 support on the threaded bores for torque support to 20 Nm.
7. Lift engine using VAG1383A engine/transmission jack just far enough so that the connecting bolts at engine/transmission can be removed from below. NOTE: When working on a vehicle with all wheel drive, make sure the front constant velocity joint for the drive shaft is not damaged when lifting engine.
8. Remove bottom engine/transmission connecting bolts (arrows).
9. Lower engine again.
10. Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
11. Hook 3147 engine support adapter into bolt hole at left of transmission housing.
12. Connect 3147 engine support adapter and 10222A engine support bridge with 10222A/2 additional hook. NOTE: Illustration is shown with engine removed.
13. Hook in 2024A engine sling at engine and at VAS6100 or 1202A workshop crane as depicted in illustration. NOTE: To properly balance assembly, mounting hooks must be inserted in rails as shown in illustration. WARNING: Take-up hooks and pins at engine sling must be secured using securing pins (arrows) as shown in illustration.
14. Remove final mounting bolt. NOTE: Verify that all hose connections and line connections between engine and chassis have been disconnected.
15. Using VAS6100 or VAG1202A workshop crane, lift engine far enough until the threaded bolts of the engine mount are free.
16. Turn 10-222A engine support bridge shaft.

Note. Make sure no lines are damaged at bulkhead.

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

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

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

Procedure

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

Installing

Installation is reverse of removal, noting the following

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

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

1. Clean input shaft splines and (in case of used clutch plates) clean hub splines. Remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
2. Check centering of clutch disc.
3. Check clutch release bearing for wear and replace if necessary.
4. If the plastic ring of the release bearing is loose, adhere to the bearing ring again using adhesive AMV-195-KD1-01 3 rectangular tabs (arrows) of the plastic ring reach into the cutouts of the bearing ring. If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.

Vehicles with SAC clutch pressure plate

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

See appropriate Clutch article

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

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

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

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

Scheme 356

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

1. Carefully guide engine into engine compartment.
2. Set engine onto engine mounts. WARNING: For vehicles with automatic transmission 01V, keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission flange. If the torque converter cannot be turned, it must be assumed that it has not been inserted properly and that the coupling plate of the torque converter or the ATF pump will be destroyed during final tightening of the bolts.

1. Bolt transmission to engine (see «TIGHTENING TORQUES»(ref-196254-S42440926872005100700000) ).
2. Tighten T10062 support on the threaded bores for torque support to 20 Nm.
3. Lift engine using VAG1383A engine/transmission jack just far enough so that the connecting bolts at engine/transmission can be installed from below. NOTE: When working on a vehicle with all wheel drive, make sure the front constant velocity joint for the drive shaft is not damaged when lifting engine.
4. Tighten bottom engine/transmission connecting bolts (arrows).
5. Lower engine again.
6. Install and align exhaust system tension-free (see «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(ref-196256-S19472206742005100700000) ).
7. Install starter. See appropriate Starters article
8. Install generator (see «RIBBED BELT FOR VANE PUMP, GENERATOR AND A/C SYSTEM»(ref-196254-S21603526782005100700000) ).
9. Install A/C compressor (see «RIBBED BELT FOR VANE PUMP, GENERATOR AND A/C SYSTEM»(ref-196254-S21603526782005100700000) ).
10. Install ribbed belt (see «INSTALLING»(ref-196254-S10883342812005100700000) ).
11. Install lock carrier (see «LOCK CARRIER, MOVING INTO SERVICE POSITION»(ref-196254-S41599485202005100700000) ).

1. Secure ATF line

1. For harness connectors and routing: See appropriate System Wiring Diagrams article.

Note. Be sure to activate vehicle features (radio/radio-navigation system, clock, electric window regulators) according to owner's manual when the battery is re-connected.

1. Check engine oil level before starting engine.
2. Top up coolant (see «FILLING»(ref-196255-S19755010692005100700000) ).

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

1. Fill up power steering fluid and bleed steering system: See «POWER STEERING FLUID LEVEL, CHECKING; STEERING SYSTEM, BLEEDING AND CHECKING FOR LEAKS»(ref-196277-S13231397802005100800000) .

1. Check ATF level

See appropriate Automatic Transmission article.

1. Adjust headlights

For models up to 2000, see HEADLIGHTS, ADJUSTING . For models 2001 and up, see HEADLIGHTS, ADJUSTING .

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
2. Loosen mounting parts -1 to 4- and remove noise insulation.
3. Remove cover -1- in engine compartment (right side).
4. Remove bolts (arrows).
5. Remove air guide -1-.
6. Remove cover -1- in engine compartment (left side).
7. Pull off hood seal from lock carrier and fender edges.
8. Remove front bumper: See «FRONT BUMPER»(ref-196283-S08508749282005100800000) or «FRONT BUMPER (AUDI RS6)»(ref-196283-S17637369012005100800000)
9. Unscrew bolts (arrows) at left and right.
10. Thread 3369 support tool into empty bores at left and right.
11. Unscrew bolts (arrows) at impact absorbers at left and right.
12. Carefully pull lock carrier toward front.
13. To secure lock carrier -1-, thread in corresponding M6 bolts -2- into rear bores of lock carrier and into fender bores. Returning to normal position is the reverse of moving to the service position, noting the following
14. Tighten bolts for lock carrier to long members to 50 Nm and at fenders to 10 Nm.
15. Let torque support stop rest on rubber buffer for torque support with its own weight and tighten bolts to 28 Nm (arrows).
16. Install front bumper: See «FRONT BUMPER»(ref-196283-S08508749282005100800000) or «FRONT BUMPER (AUDI RS6)»(ref-196283-S17637369012005100800000)
17. Adjust headlights: For models up to 2000, see «HEADLIGHTS, ADJUSTING»(ref-196297-S20011632252005100900000) . For models 2001 and up, see «HEADLIGHTS, ADJUSTING»(ref-196302-S08741107802005100900000)

Scheme 357

Ribbed belt for vane pump, generator and A/C system

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

The following list pertains to see scheme 100.

1. Ribbed belt Removing and installing (see «RIBBED BELT, REMOVING AND INSTALLING»(ref-196254-S34290437782005100700000) Check for wear
2. 23 Nm
3. Generator Removing See appropriate Generators & Regulators article
4. 45 Nm
5. 23 Nm
6. Bracket for generator
7. 40 Nm
8. Ribbed belt tensioner
9. 23 Nm
10. Belt pulley for power steering pump Use 3212 spanner wrench to counterhold when removing and installing Identification: Front
11. Seal Always replace
12. Banjo fitting - 47 Nm
13. Pressurized line to power steering
14. Power steering vane pump Removing and installing: See «STEERING»(ref-196277)
15. Bracket for power steering pump
16. 23 Nm
17. 23 Nm
18. Bracket for A/C compressor
19. 23 Nm
20. 23 Nm
21. 25 Nm
22. A/C compressor Do not unscrew or disconnect refrigerant lines After removing, secure compressor to chassis (i.e. with wire) Do not hang on refrigerant lines
23. Socket for A/C compressor 2x
24. Harmonic balancer Version dependent with/without thrust washer between harmonic balancer and toothed belt gear (see «HARMONIC BALANCER, REMOVING AND INSTALLING»(ref-196254-S37420162542005100700000) ). Removing and installing (see «HARMONIC BALANCER, REMOVING AND INSTALLING»(ref-196254-S37420162542005100700000) )
25. 23 Nm
26. 23 Nm

Installation is reverse of removal, noting the following

1. First install ribbed belt on crankshaft pulley. Slide belt onto tensioning roller last. Belt path Generator Ribbed belt Power steering vane pump A/C compressor Crankshaft tensioning roller NOTE: When installing ribbed belt, ensure correct seating on belt pulley.
2. Start engine and check path of belt.

Scheme 358

Harmonic balancer, removing and installing

1. Lock carrier in service position (see «LOCK CARRIER, MOVING INTO SERVICE POSITION»(ref-196254-S41599485202005100700000) ).
2. Ribbed belt removed (see «RIBBED BELT, REMOVING AND INSTALLING»(ref-196254-S34290437782005100700000) ).

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

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

Scheme 359

Installation is reverse of removal, noting the following

1. Insert thrust washer in such a way that the convex edge points toward the harmonic balancer.
2. When installing the harmonic balancer, make sure notches (arrows) in harmonic balancer are aligned with locating lugs on toothed belt sprocket.

Toothed belt cover, removing and installing

The following list pertains to (Scheme 422).

1. 10 Nm
2. 10 Nm
3. Front coolant pipe Only remove bolts item 1 and item 2 to remove toothed belt guide. coolant hoses remain connected at coolant pipe
4. Toothed belt guard, front right
5. Toothed belt guard, front left
6. Socket
7. 6 Nm Self-locking Always replace
8. Lower toothed belt cover
9. 10 Nm

1. Lock carrier in service position (see «LOCK CARRIER, MOVING INTO SERVICE POSITION»(ref-196254-S41599485202005100700000) ).
2. Ribbed belt removed (see «RIBBED BELT, REMOVING AND INSTALLING»(ref-196254-S34290437782005100700000) ).

Scheme 360

Scheme 361

1. Unscrew bolts (arrows) and remove ribbed belt tensioner.
2. Remove ribbed belt gear of vane pump (arrows) using 3212 spanner wrench as retainer.
3. Remove 8 bolts -1-.
4. Remove harmonic balancer -2- and thrust washer -3-. NOTE: Thrust washer -3- is only installed on toothed belt gear with part number 06C 105 063.-No thrust washer must be installed for toothed belt gear with part number 06C 105 063 B.
5. Unscrew bolts -1 to 12- and remove toothed belt guards.
6. Remove rear engine cover (arrows).
7. Remove coolant reservoir (arrows).
8. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of expansion tank.
9. Tie coolant expansion tank with connected coolant hoses -1 to 3- to side.
10. Disconnect Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air filter housing.
11. Disconnect electrical harness connector -2- at Mass Air Flow (MAF) sensor.
12. Remove air guide hose -3- together with Mass Air Flow (MAF) sensor.
13. Remove air filter housing (arrows).
14. Remove bolts -1- and -3-.
15. Disconnect hose -4- from line of secondary air injection.
16. Pull out guide tube for oil dipstick -2- from the oil pan (upper part) toward top and swing it forward for removal.
17. Remove bolts -5- and -6- at right cylinder head cover.
18. Disconnect electrical harness connectors -1- to -4-.
19. Remove ignition coils (arrows).
20. Remove hose of crankshaft housing ventilation (arrow). see scheme 122
21. Unscrew bolts for right cylinder head cover in the sequence 12 to 1.
22. Remove cylinder head cover.
23. Unscrew bolts -4- and -5- at left cylinder head cover.
24. Disconnect electrical harness connectors -1- to -3- and -6-.
25. Remove ignition coils (arrows).
26. Remove hose of crankshaft housing ventilation (arrow). see scheme 124
27. Unscrew bolts for left cylinder head cover in the sequence 12 to 1.
28. Remove cylinder head cover. CAUTION: Turning of the engine must only occur in direction of engine rotation (clockwise) at the crankshaft.
29. Turn engine until the cams (arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder bank) point upward uniformly. NOTE: Turn engine at crankshaft central bolt.
30. Insert T40030 camshaft adjuster gauge at camshafts of right cylinder head. NOTE: Slightly turn crankshaft back and forth so that the claw of T40030 camshaft adjuster gauge can properly grab the camshafts.
31. Spread T40030 camshaft adjuster gauge with threaded shaft (tightening torque 10 Nm) until it is seated without axial play.
32. Insert T40030 camshaft adjuster gauge at left cylinder head in the same manner.
33. If installed, disconnect electrical harness connector at after-run coolant pump.
34. Unscrew sealing plug of TDC mark at cylinder block.
35. Thread T40026 locking pin into the hole of the removed sealing plug and tighten. NOTE: Slightly turn crankshaft back and forth to do so. NOTE: Catch escaping oil using a rag.
36. Pry off securing rings -1- for caps -2- at all camshaft gears.
37. Loosen but do not remove bolts -1- to -4- for camshaft gears.
38. Using an 8 mm hex socket wrench, turn toothed belt tensioner in direction of arrow until the tensioning lever pushes the tensioner together far enough so that the T40011 pin can be inserted into the bore of the pistons and housing. NOTE: The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure. Mark rotational direction of toothed belt. Reversing the direction in which it runs can ruin it.
39. Loosen bolt (arrow) of eccentric pulley.
40. Remove toothed belt.

Scheme 362

Installing (adjusting valve timing)

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

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

1. Bolt in camshaft gears 1 to 4 far enough so they can still just be turned without canting.
2. Install toothed belt as depicted in illustration. see scheme 133 For exact valve timing adjustment, the toothed belt must make exact contact with front edge of all toothed belt gears.
3. Using 3387 pin wrench, turn eccentric pulley -1- in clockwise direction until the handle of the pin wrench is exactly above the center axle of coolant pump gear -2-.
4. Hold pin wrench in this position and tighten bolt -3- to 45 Nm.
5. Place torque wrench horizontally on socket-head of tensioning lever.
6. Turn with 45 Nm in direction of arrow to pre-tension toothed belt.
7. Using 8 mm socket head wrench, turn toothed belt tensioning roller in direction of arrow until T40011 pin can pulled out.
8. Place torque wrench horizontally on socket-head of tensioning lever.
9. Turn with 25 Nm in direction of arrow to tension toothed belt.
10. Insert T40028 socket at camshaft adjuster of exhaust camshaft on left cylinder bank.
11. Turn rotor of camshaft adjuster clockwise to 10 Nm up to stop (arrow).
12. Turn rotor of camshaft adjuster at right cylinder bank clockwise to 10 Nm up to stop (arrow).
13. Tighten bolts for all four camshaft gears to 100 Nm.
14. Insert caps -2- with new O-rings -1- at camshaft gears and secure them with the securing ring.
15. Remove T40030 camshaft adjuster gauge.
16. Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O-ring into cylinder block.
17. Installation is reverse of removal, noting the following
18. Install cylinder head covers, see «INSTALLING»(ref-196254-S32205047082005100700000) or «INSTALLING»(ref-196254-S38205107462005100700000).
19. Install toothed belt guards (see «TOOTHED BELT COVER, REMOVING AND INSTALLING»(ref-196254-S35451058232005100700000) ).
20. Install harmonic balancer (see «HARMONIC BALANCER, REMOVING AND INSTALLING»(ref-196254-S37420162542005100700000) ).
21. Install ribbed belt (see «INSTALLING»(ref-196254-S10883342812005100700000) ).

Scheme 363

Sealing flange and flywheel/drive plate, removing and installing

Note. Servicing clutch.

See appropriate Clutch article

The following list pertains to see scheme 142.

1. 10 Nm
2. 30 Nm Self-locking Always replace
3. Seal for crankshaft Removing and installing, see «CRANKSHAFT OIL SEAL - RIBBED BELT SIDE, REPLACING»(ref-196254-S25326595632005100700000)
4. Locking bolt - 10 Nm
5. Seal Always replace
6. O-ring Always replace
7. Chain tensioner -Removing and installing, see «DRIVE CHAIN OR CHAIN TENSIONER FOR OIL PUMP, REMOVING AND INSTALLING»(ref-196254-S18511755102005100700000)
8. Washer
9. 12 Nm
10. 40 Nm
11. Stop for torque support
12. 28 Nm
13. Torque support
14. Oil pan (upper part) Removing and installing, see «OIL PAN (UPPER PART), REMOVING AND INSTALLING»(ref-196254-S01314103342005100700000)
15. 45 Nm
16. M7 = 16 Nm, M8 = 22 Nm
17. O-ring Always replace
18. Dual-mass flywheel or drive plate Flywheel, removing and installing, see «FLYWHEEL OR DRIVE PLATE, REMOVING AND INSTALLING»(ref-196254-S30732606932005100700000) Drive plate, removing and installing, see «REMOVING»(ref-196254-S05825403802005100700000)
19. Special bolt Always replace Tightening torque, see «TIGHTENING TORQUES»(ref-196254-S32167498632005100700000) or «TIGHTENING TORQUES»(ref-196254-S23305894852005100700000)
20. Needle bearing Pulling out and driving in, see «DUAL-MASS FLYWHEEL PILOT NEEDLE BEARING, REMOVING AND INSTALLING»(ref-196254-S25532273742005100700000) Not for automatic transmission 01V For automatic transmission 01V, a centering bushing is bolted into the crankshaft instead of the needle bearing, see «CENTERING BUSHING OF DRIVE PLATE FOR AUTOMATIC TRANSMISSION 01V»(ref-196254-S01377729702006041700000)
21. 10 Nm
22. Sealing flange rear with oil seal Removing and installing, see «REAR SEALING FLANGE, REMOVING AND INSTALLING»(ref-196254-S31149488872005100700000) Lightly oil lip of O-ring. To install, slide guide sleeve from kit onto crankshaft
23. Cylinder block see «CRANKSHAFT, REMOVING AND INSTALLING»(ref-196254-S36882508242005100700000) Pistons and connecting rods, dissembling and assembling, see «PISTONS AND CONNECTING RODS, DISASSEMBLING AND ASSEMBLING»(ref-196254-S20265029222005100700000)
24. 20 Nm
25. Guide tube for oil dipstick
26. Sheet metal screw
27. Gasket Always replace
28. Sealing flange, front Removing and installing, see «FRONT SEALING FLANGE, REMOVING AND INSTALLING»(ref-196254-S09043254742005100700000)

Centering bushing of drive plate for automatic transmission 01V

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

Scheme 364

1. Engine installed.

1. Toothed belt, removing, see «TOOTHED BELT, REMOVING AND INSTALLING»(ref-196254-S00113299912005100700000) .
2. Remove center bolt -1- for crankshaft toothed belt gear -2-.
3. Remove toothed belt gear.
4. Remove diamond disc -3- from toothed belt gear.
5. Unscrew inner portion of 3203 seal remover six rotations from outer portion and secure with knurled-head screw.
6. Oil threaded head of 2085 seal puller, position and with forced pressure screw into oil seal as far as possible.
7. Loosen knurled bolt and turn inner part against crankshaft until oil seal is removed.
8. Clamp seal puller into vise at flattened regions. Remove O-Ring with pliers.

Scheme 365

1. Clean running surface and sealing surface.
2. Do not oil sealing lip or outer edge of sealing ring before pressing in.
3. Slide on sealing ring using 3202/1 pull sleeve.
4. Press in sealing ring with 3265 seal installer and central bolt up to stop.
5. Install crankshaft toothed belt gear -2- with new diamond disc -3- and new center bolt -1-. NOTE: Contact surfaces between toothed belt gear, diamond disc and crankshaft must be free of oil. Do not additionally oil bolt for toothed belt gear for crankshaft.
6. Install toothed belt (adjust timing), see «INSTALLING (ADJUSTING VALVE TIMING)»(ref-196254-S18761640162005100700000) .

1. Lock carrier in service position. See «LOCK CARRIER, MOVING INTO SERVICE POSITION»(ref-196254-S41599485202005100700000) .

Scheme 366

1. Toothed belt, removing, see «TOOTHED BELT, REMOVING AND INSTALLING»(ref-196254-S00113299912005100700000).
2. Remove right camshaft gears.
3. Unscrew bolts -1- and remove bracket with idler roller.
4. Unscrew bolts -2- and remove toothed belt guard are rear right.
5. Remove oil pan (upper part), see «OIL PAN (UPPER PART), REMOVING AND INSTALLING»(ref-196254-S01314103342005100700000).
6. Remove center bolt -1- for crankshaft toothed belt gear -2-. see scheme 151
7. Remove toothed belt gear and diamond disc -3-.
8. Unbolt eccentric roller -3-, tensioning lever -2- with tensioning roller and tensioner -1-.
9. Unscrew locking bolt from adjustment hole -3-.
10. Press chain tensioner -1- in direction of arrow until a drill bit 3 mm diameter -2- can be slid into alignment hole of sealing flange and chain tensioner.
11. Remove bolts -1- and -2-.
12. Remove front sealing flange.
13. Drive out sealing ring with the flange removed.

Note. Remove chain tensioner to replace sealing flange, see DRIVE CHAIN OR CHAIN TENSIONER FOR OIL PUMP, REMOVING AND INSTALLING .

Installation is reverse of removal, noting the following

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

1. Clean sealing surfaces before installing sealing flange.
2. Install front sealing flange with secured chain tensioner.
3. Replace bolt -2-.
4. Tighten bolts -1- to 10 Nm and bolt -2- to 30 Nm.
5. Do not oil sealing lip or outer edge of sealing ring before pressing in.
6. Slide on sealing ring using 3202/1 pull sleeve.
7. Press in sealing ring with 3265 seal installer and center bolt up to stop.
8. Next, install eccentric roller -3- loosely. NOTE: Note washer below tensioning lever -2-.
9. Install tensioning lever -2- with tensioner roller and tensioner -1-.
10. Install crankshaft toothed belt gear -2- with new diamond disc -3- and new center bolt -1-. NOTE: Contact surfaces between toothed belt gear, diamond disc and crankshaft must be free of oil. Do not additionally oil bolt for toothed belt gear for crankshaft.
11. Install oil pan (upper part), see «INSTALLING»(ref-196254-S09691363142005100700000) .
12. After installing oil pump, remove drill bit from adjusting hole and thread in locking bolt with new sealing ring.
13. Install toothed belt (adjust timing), see «INSTALLING (ADJUSTING VALVE TIMING)»(ref-196254-S18761640162005100700000) .

Scheme 367

Note. The following footnotes refer to items in see scheme 159.

1) REPLACE bolts

2) 180° correspond to 1/2 rotation

Required equipment

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

See Parts catalog

1. Engine removed.

1. Remove flywheel (see «FLYWHEEL OR DRIVE PLATE, REMOVING AND INSTALLING»(ref-196254-S30732606932005100700000) ) or remove drive plate (see «REMOVING»(ref-196254-S05825403802005100700000) ).
2. Remove oil pan (upper part). See «OIL PAN (UPPER PART), REMOVING AND INSTALLING»(ref-196254-S01314103342005100700000) .
3. Unbolt rear sealing flange (arrow).
4. Using rotating plastic brush, remove remaining sealant from rear sealing flange and at cylinder block. WARNING: Wear protective glasses.
5. Clean sealing surfaces so they are free of oil and grease.

Installation is reverse of removal, noting the following

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

Scheme 368

Scheme 369

1. Cut tube nozzle at front marking (jet diameter approx. 1 mm).
2. Apply silicon sealant bead to clean sealing surface of sealing flange as depicted in illustration. Thickness of sealant bead (arrow): approx. 1.5 mm NOTE: Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.
3. To install, slide guide sleeve from kit onto crankshaft.
4. Install oil pan (upper part), see «INSTALLING»(ref-196254-S09691363142005100700000) .
5. Install flywheel (see «INSTALLING»(ref-196254-S21259759042005100700000) ) or install drive plate (see «INSTALLING»(ref-196254-S30329670162005100700000) ).

Damper unit, removing and installing

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

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

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

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

Note. For removal and installation of the flywheel -B-, see FLYWHEEL OR DRIVE PLATE, REMOVING AND INSTALLING .

Install in reverse order, paying attention to following

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

See parts catalog

1. Align damper unit -A- with flywheel -B-. The two lugs -2- must line up with each other.
2. Hand-tighten bolts -1- (9 pcs.).
3. Tighten bolts to 25 Nm in diagonal sequence.

1. Transmission removed

1. Turn crankshaft via center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 3 marking. Notch -1- is opposite marking -2-. see scheme 167
2. If installed, disconnect electrical harness connector at after-run coolant pump.
3. Unscrew sealing plug of TDC mark at cylinder block.
4. Thread T40026 locking pin into the hole of the removed sealing plug and tighten. NOTE: Slightly turn crankshaft back and forth to do so.
5. Remove clutch pressure plate. See appropriate Clutch article
6. Remove damper unit, see «DAMPER UNIT, REMOVING AND INSTALLING»(ref-196254-S34231082762005100700000).
7. Mark flywheel to engine.
8. Unbolt flywheel.

Installation is reverse of removal, noting the following

Note. Needle bearing is located in the flywheel and must be driven in when flywheel is replaced, see DUAL-MASS FLYWHEEL PILOT NEEDLE BEARING, REMOVING AND INSTALLING .

1. Replace bolts and tighten.
2. Install clutch pressure plate. See appropriate Clutch article
3. Install damper unit, see «INSTALLING»(ref-196254-S03070431832005100700000) .
4. Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O-ring into cylinder block.

Scheme 370

Note. The following footnotes refer to items in see scheme 169.

1) 90° corresponds to 1/4 rotation

2) REPLACE all torque-to-yield bolts.

3) 180° correspond to 1/2 rotation

1. Transmission removed

1. Turn crankshaft via central bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 3 marking. Notch -1- is opposite marking -2
2. If installed, disconnect electrical harness connector at after-run coolant pump.
3. Unscrew sealing plug of TDC mark at cylinder block.
4. Thread T40026 locking pin into the hole of the removed sealing plug and tighten. NOTE: Slightly turn crankshaft back and forth to do so.
5. Mark drive plate to engine.
6. Remove drive plate.

Scheme 371

Installation is reverse of removal, noting the following

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

Scheme 372

Scheme 373

Note. The following footnotes refer to items in see scheme 173.

1) 90° corresponds to 1/4 turn

2) REPLACE all torque-to-yield bolts.

3) 180° corresponds to 1/2 turn

1. Transmission removed

Scheme 374

1. Remove clutch pressure plate. See appropriate Clutch article.
2. Pull out needle bearing using Kukko 21/1 and Kukko 22/1.
3. Drive needle bearing into flywheel using 3264 bearing driver. Installation depth, see «INSTALLING»(ref-196254-S03070431832005100700000) . Needle bearing installation depth -2
4. To measure the installation depth, place a metal ruler onto plastic ring -1- of dual-mass flywheel. Measurement x = 0.5 mm.

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

Scheme 375

Crankshaft, removing and installing

Note. For engine disassembly and assembly, mount engine to assembly stand using VAS6095 holding fixture (see ENGINE, ATTACHING TO ENGINE STAND ).

The following list pertains to see scheme 179.

1. Bolt for bearing cap Always replace Tightening sequence, see «CRANKSHAFT BEARING CAPS, INSTALLING»(ref-196254-S11751432322006041700000)
2. Bushing Insert in cylinder block
3. Drive chain gear for oil pump Removing- and installing, see «DRIVE CHAIN GEAR FOR OIL PUMP, REMOVING AND INSTALLING»(ref-196254-S16248364322005100700000)
4. Bearing caps Note identification, see «IDENTIFICATION OF CRANKSHAFT BEARING CAPS»(ref-196254-S38165427432006041700000) Removing, see «REMOVING CRANKSHAFT BEARING CAPS»(ref-196254-S34027300252006041700000) Installing, see «CRANKSHAFT BEARING CAPS, INSTALLING»(ref-196254-S11751432322006041700000)
5. Nut for bearing cap Always replace Tightening sequence, see «CRANKSHAFT BEARING CAPS, INSTALLING»(ref-196254-S11751432322006041700000)
6. Thrust washer Only on 4th crankshaft bearing Lubricating grooves face outward Check locating point Measuring crankshaft axial play, see «AXIAL AND RADIAL PLAY, MEASURING»(ref-196254-S07642457962005100700000)
7. Bearing shell For bearing cap without lubrication groove Do not interchange run-in connecting rod bearing shells (mark) Insert new bearing shells for cylinder block with proper color marking, see «APPLICATION OF CRANKSHAFT BEARING SHELLS FOR BEARING CAPS»(ref-196254-S32679949042006041700000)
8. Crankshaft Measuring axial play and radial play, see «AXIAL AND RADIAL PLAY, MEASURING»(ref-196254-S07642457962005100700000) Do not turn crankshaft when measuring radial play. See «CRANKSHAFT MEASUREMENTS»(ref-196254-S17935074442005100700000)
9. Thrust washer Only on 4th crankshaft bearing Lubricating grooves face outward Measuring crankshaft axial play, see «AXIAL AND RADIAL PLAY, MEASURING»(ref-196254-S07642457962005100700000)
10. Bearing shell For engine block with lubrication groove Do not interchange run-in connecting rod bearing shells (mark) Insert new bearing shells for cylinder block with proper color marking, see «APPLICATION OF CRANKSHAFT BEARING SHELLS FOR CYLINDER BLOCK»(ref-196254-S06886898372006041700000)
11. Stud
12. Bolt for bearing cap Always replace Tightening sequence, see «CRANKSHAFT BEARING CAPS, INSTALLING»(ref-196254-S11751432322006041700000)

Removing crankshaft bearing caps

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

Crankshaft bearing caps, installing

1. Replace bolts -A- and nuts -1 to 8-.
2. Inserting alignment bushings into cylinder block
3. Tighten bearing cap nuts or bolts in the following sequence: Tighten bolts -A- by hand. see scheme 184 Tighten nuts -1 to 8- to 35 Nm. Using rigid wrench turn nuts -1 to 8- an additional 90° (1/4 turn). At the same time, tighten bolts -A- to 20 Nm. Using rigid wrench turn nuts -A- an additional 90° (1/4 turn).

Crankshaft measurements

Distance in mm

Scheme 376

Axial clearance

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

CRANKSHAFT AXIAL CLEARANCE (END PLAY) AND WEAR LIMIT

Scheme 377

Radial clearance

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

1. Plastigage

1. Main bearing cap, removing. Clean bearing caps and journals.
2. Place Plastigage over entire width of bearing journal or into bearing shells. Plastigage must rest in center of bearing shell
3. Install main bearing cap and tighten to 30 Nm. DO NOT turn the crankshaft.
4. Remove main bearing caps again.
5. Compare width of Plastigage with calibrated scale.
6. Read clearance.

CRANKSHAFT RADIAL CLEARANCE AND WEAR LIMIT

1. Remove front sealing flange, see «FRONT SEALING FLANGE, REMOVING AND INSTALLING»(ref-196254-S09043254742005100700000) .
2. Using standard claw remover -2-, remove crankshaft chain sprocket while protecting crankshaft end with appropriate washer -1-.

Scheme 378

Installation is reverse of removal, noting the following

1. Warm chain sprocket in 220°C oven for approx. 15 minutes. WARNING: Wear protective gloves!
2. Using pliers install chain sprocket on crankshaft end and slide onto crankshaft to stop using 30-100 press tube.

Scheme 379

Piston ring-Checking end gap

1. Insert ring at a right angle to cylinder wall from above to lower cylinder opening approx. 15 mm cylinder edge. When inserting, use pistons without rings

PISTON RING END GAP SPECIFICATIONS

Piston ring-Checking height play

1. Before measuring, clean piston ring groove

PISTON RING HEIGHT PLAY (SIDE CLEARANCE) SPECIFICATIONS

Checking piston

Special tools and equipment

1. External micrometer 75-100 mm

Scheme 380

1. Measure approx. 10 mm from lower edge, at a 90° angle to piston pin axis. Deviation from nominal dimension: max. 0.04 mm

Specified dimension, see PISTON AND CYLINDER MEASUREMENTS .

Checking cylinder bore

Special tools and equipment

1. Inner bore gauge 50-100 mm

Scheme 381

1. Measure diagonally at 3 positions horizontally -A- and lengthwise -B-. Deviation from nominal dimension: max. 0.08 mm

Specified dimension, see PISTON AND CYLINDER MEASUREMENTS .

Installed position and allocation piston/cylinder

1. Mark installed position and 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.

1. Installation position: Arrow on piston head points to belt pulley side

Marking connecting rod

Note. Replace the connecting rods only as a set. Do not interchange the connecting rod bearings.

1. Before removing, mark allocation of connecting rod and connecting rod bearing caps to each other and to cylinder using a color marker.

Oil injector jet for piston cooling

1. Bolt - 10 Nm
2. Oil injector jet for piston cooling

Piston and cylinder measurements

PISTON AND CYLINDER SPECIFICATIONS

Cylinder head, removing and installing

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

Part I

The following list pertains to see scheme 200.

1. Intake manifold Removing and installing, see «INTAKE MANIFOLD, REMOVING AND INSTALLING»(ref-196254-S06782678992005100700000)
2. Resonator
3. 10 Nm
4. O-rings Always replace
5. Fuel return line
6. Fuel supply line Union nut, tighten to 25 Nm
7. Socket
8. 10 Nm
9. Holding plate for solenoid valves
10. Fuel distributor
11. Air duct
12. 10 Nm
13. O-ring Always replace
14. 10 Nm
15. 10 Nm tighten diagonally in sequence
16. Gasket for intake manifold Always replace

Part II

The following list pertains to see scheme 201.

1. Cylinder head gasket Replacing, see «LEFT CYLINDER HEAD, REMOVING»(ref-196254-S23260292882005100700000) Installation position: Part number to cylinder head After replacing, replace coolant
2. Cylinder head Removing left cylinder head, see «LEFT CYLINDER HEAD, REMOVING»(ref-196254-S23260292882005100700000) Removing right cylinder head, see «RIGHT CYLINDER HEAD, REMOVING»(ref-196254-S40832172222005100700000) Check for warpage, see «CYLINDER HEAD, CHECKING FOR WARPAGE»(ref-196254-S07887667322006041700000) Refacing measurements, see «CYLINDER HEAD REFACING DIMENSION»(ref-196254-S13212943972006041700000) Sealing cap (core plug) in cylinder head, installing, see «SEALING CAP (CORE PLUG) IN CYLINDER HEAD, INSTALLING»(ref-196254-S00007449232006041700000) Installing, see «CYLINDER HEADS, INSTALLING»(ref-196254-S28371225432005100700000) After replacing, replace coolant
3. Lifting eye
4. 23 Nm
5. Cylinder head bolt Always replace Follow order of removal (see «CYLINDER HEADS, INSTALLING»(ref-196254-S28371225432005100700000) or «RIGHT CYLINDER HEAD, REMOVING»(ref-196254-S40832172222005100700000) ) Follow tightening sequence, see «CYLINDER HEADS, INSTALLING»(ref-196254-S28371225432005100700000)
6. Centering pin For intake manifold
7. Special bolt - 10 Nm Follow tightening sequence (see «INSTALLING»(ref-196254-S32205047082005100700000) or «INSTALLING»(ref-196254-S38205107462005100700000) )
8. Gasket Replace if damaged or leaking
9. Cap
10. O-ring Always replace
11. Hose of crankcase housing ventilation
12. Ignition coil
13. Cylinder head cover See «LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING»(ref-196254-S30023212172005100700000) See «RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING»(ref-196254-S04705591322005100700000)
14. Cylinder head cover gasket Replace if damaged or leaking
15. 10 Nm
16. Rear coolant pipe
17. Combination valve for secondary air injection (AIR)
18. 10 Nm
19. Gasket Always replace
20. O-ring Always replace

Cylinder head, checking for warpage

1. Using straightedge and feeler gauge, check cylinder head for warpage at multiple points. Maximum permissible warpage: 0.1 mm

Cylinder head refacing dimension

1. Refacing cylinder head can only be done to minimum dimension -a-. Minimum dimension: a = 139.25 mm

Sealing cap (core plug) in cylinder head, installing

Special Tools and Equipment

1. VW295 needle bearing drift

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

1. Coat lip of sealing cap with sealant. Sealant See Parts catalog
2. Drive sealing cap flush into cylinder block using VW295 needle bearing drift.

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

1. Drain coolant, see «COOLANT, DRAINING AND REFILLING»(ref-196255-S13544342892005100700000). CAUTION: On vehicles equipped with Audi Telematics by OnStar ®, switch-off the emergency (back-up) battery for the Telematic/Telephone Control Module prior to disconnecting the vehicle battery. Switch-on the emergency (back-up) battery after reconnecting the vehicle battery. See «EMERGENCY BATTERY, SWITCHING OFF/ON»(ref-196292-S13683948542005100800000).
2. Note radio code and determine if necessary (for vehicles with coded anti-theft radio / radio-navigation system -RNS-).
3. Switch ignition off and disconnect battery Ground (GND) strap.
4. Remove rear engine cover (arrows).
5. Remove front engine cover (arrows).
6. Remove cover -1- in engine compartment (right side).
7. Remove bolts (arrows).
8. Remove air guide -1-.
9. Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air filter housing.
10. Disconnect electrical harness connector -2- at Mass Air Flow (MAF) sensor.
11. Remove air guide hose -3- together with Mass Air Flow (MAF) sensor.
12. Remove air filter housing (arrows).
13. Disconnect vacuum hoses -2- and -3- at intake manifold change-over valve -N156-. see scheme 210
14. Disconnect vacuum hose -6- from check valve.
15. Disconnect electrical harness connector -5-.
16. Move hose of crankshaft housing ventilation free (arrow).
17. Remove bolts -1-, -4- and -7- for holding plate for solenoid valves.
18. Remove holding plate for solenoid valves.
19. Disconnect electrical harness connector -1-.
20. Disconnect vacuum hose -2- from T-piece.
21. Remove all harness connectors to injectors.
22. Disconnect vacuum line at fuel pressure regulator and remove mounting bolts of fuel pressure regulator (arrows).
23. Remove fuel distributor together with fuel injectors from intake manifold simultaneously upward and place it on a clean rag in engine compartment.

Note. Carefully protect removed fuel injectors from contamination.

Scheme 382

1. Disconnect electrical harness connector -1- at throttle valve control module -J338-.
2. Disconnect vacuum hoses -2- and -3-.
3. Disconnect hose -1- from air guide.
4. Remove bolt -4- and disconnect air guide -2- at throttle valve control module.
5. If installed, disconnect vacuum hose -3- from air guide at bottom.
6. Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.
7. Remove bolts -1- and -3-.
8. Pull out guide tube for oil dipstick -2- toward top from the oil pan (upper part) and swing it forward.

Note. Hose 4 remains connected.

Scheme 383

1. Remove bolts at right side of engine (arrows) at line for secondary air injection.
2. Remove bolts -1- and -2- at lines of secondary air injection.
3. Unscrew bolts -3- and -5- and remove resonator -4-.
4. Disconnect vacuum hose -1- from EVAP valve.
5. Disconnect coolant hoses -2- and -3-.
6. Unbolt intake manifold (arrows) and remove.

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

Scheme 384

Installation is reverse of removal, noting the following

Note. Secure all hose connections using hose clamps appropriate for the model type: See Parts catalog Always replace seals and gaskets. Bolt in intake manifold in diagonal sequence in stages (arrows). Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).

Scheme 385

Note. Be sure to activate vehicle features (radio/radio-navigation system, clock, electric window regulators) according to owner's manual when the battery is re-connected.

1. Top off coolant, see «FILLING»(ref-196255-S19755010692005100700000) .

Scheme 386

Scheme 387

1. Remove rear engine cover (arrows).
2. Remove cover -1- in engine compartment (left side).
3. Remove coolant reservoir (arrows).
4. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of expansion tank.
5. Tie coolant expansion tank with connected coolant hoses - 1 to 3- to side.
6. Remove front engine cover (arrows).
7. Unbolt toothed belt guard at front left from cylinder head cover (arrows).
8. Remove bolts -4- and -5-.
9. Disconnect electrical harness connectors -1- to -3- and -6-.
10. Remove ignition coils (arrows).
11. Remove hose of crankshaft housing ventilation (arrow).
12. Unscrew bolts for left cylinder head cover in the sequence 12 to 1.
13. Remove cylinder head cover.

Installation is reverse of removal, noting the following

Note. Always replace self-locking bolts. Replace cylinder head cover gasket if damaged. Tighten cylinder head cover in sequence 1 to 12.

1. Remove rear engine cover (arrows).
2. Remove cover -1- in engine compartment (right side).
3. Remove bolts (arrows).
4. Remove air guide -1-.
5. Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air filter housing.
6. Disconnect electrical harness connector -2- at Mass Air Flow (MAF) sensor.
7. Remove air guide hose -3- together with Mass Air Flow (MAF) sensor.
8. Remove air filter housing (arrows).
9. Remove bolts -1- and -3-. see scheme 234
10. Disconnect hose -4- from line of secondary air injection.
11. Pull out guide tube for oil dipstick -2- from oil pan (upper part) toward top and swing it forward for removal.
12. Unbolt toothed belt guard at front right of cylinder head cover (arrows).
13. Remove bolts -5- and -6-.
14. Disconnect electrical harness connectors -1- to -4-.
15. Remove ignition coils (arrows).
16. Remove hose of crankshaft housing ventilation (arrow).
17. Unscrew bolts for right cylinder head cover in sequence 12 to 1.
18. Remove cylinder head cover.

Installation is reverse of removal, noting the following

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

Scheme 388

1. Tighten cylinder head cover in sequence 1 to 12.
2. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
3. Loosen mounting parts -1 to 4- and remove noise insulation.
4. Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).

1. Engine installed.

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

Scheme 389

1. Remove intake manifold, see «INTAKE MANIFOLD, REMOVING AND INSTALLING»(ref-196254-S06782678992005100700000) .
2. Remove cover -1- in engine compartment (left side).
3. Disconnect coolant hoses -1 to 3-.
4. Unbolt coolant reservoir (arrow).
5. Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of expansion tank.
6. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) Sensor 2 -G163- and Camshaft Position (CMP) Sensor 4 -G301-.
7. Unbolt Ground (GND) wire at rear of cylinder head.
8. Toothed belt, removing, see «TOOTHED BELT, REMOVING AND INSTALLING»(ref-196254-S00113299912005100700000) .
9. Remove camshaft gears from left cylinder head.
10. Unscrew bolts -1- and -2- and remove toothed belt guard at rear left.
11. Unbolt front coolant pipe from cylinder head (arrows).

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

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

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

Scheme 390

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

Note. Illustration is shown with engine removed.

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

Scheme 391

1. Disconnect exhaust system at left double clamp (left arrow).
2. Remove nuts -1- and -3- for front exhaust pipe/left exhaust manifold which are accessible from bottom.

Note. Illustration is shown with engine removed.

1. Press front exhaust pipe off of exhaust manifold.
2. Follow sequence 1 to 8 when loosening cylinder head bolts.
3. Carefully remove cylinder head.

1. Engine installed.

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

1. Remove intake manifold, see «INTAKE MANIFOLD, REMOVING AND INSTALLING»(ref-196254-S06782678992005100700000) .

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

Scheme 392

1. Remove power steering pressure line from vane pump at cylinder head and at rear of coolant pipe (arrows).
2. Lay pressure line to side.
3. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) Sensor -G40- and Camshaft Position (CMP) Sensor 3 -G300-.
4. Toothed belt, removing, see «TOOTHED BELT, REMOVING AND INSTALLING»(ref-196254-S00113299912005100700000).
5. Remove camshaft gears from right cylinder head.
6. Unscrew bolts -1- and remove bracket with idler roller. see scheme 256
7. Unscrew bolts -2- and remove toothed belt guard at rear right.
8. Remove bolts -3- and remove combination valve for secondary air injection with flange from cylinder head.
9. Unbolt coolant pipe at rear of cylinder head (bolts -1- and -2-).

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

Scheme 393

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

Note. Illustration is shown with engine removed.

Scheme 394

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

1. Disconnect exhaust system at right double clamp (right arrow).
2. Remove nuts -1- and -3- for front exhaust pipe/right exhaust manifold which are accessible from bottom.

Note. Illustration is shown with engine removed.

1. Press front exhaust pipe off of exhaust manifold.
2. Follow sequence 1 to 8 when loosening cylinder head bolts.
3. Carefully remove cylinder head.

Cylinder heads, installing

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

Installation is reverse of removal, noting the following

1. Before installing cylinder head, set crankshaft and camshafts to TDC cylinder 3
2. T40030 camshaft adjuster gauge must be inserted at both cylinder heads...
3. ...and T40026 locking pin must be threaded in.
4. Install cylinder head gasket. Pay close attention to centering pins in cylinder block (arrows). Pay attention to installed position of cylinder head gasket, marking "oben" (top) or part number must face toward cylinder head.
5. Install cylinder head.
6. Insert NEW cylinder head bolts and hand-tighten.
7. Tighten cylinder head bolts in depicted sequence in two stages as follows
8. Tighten using torque wrench: 1. Stage: 40 Nm
9. Tighten using a solid wrench: 2. Stage: 180° (1/2 additional turn)

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

1. Install toothed belt (adjust timing), see «INSTALLING (ADJUSTING VALVE TIMING)»(ref-196254-S18761640162005100700000) .

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

1. Install left front exhaust pipe with catalytic converter. See «INSTALLING»(ref-196256-S19156613442005100700000) .
2. Install right front exhaust pipe with catalytic converter. See «INSTALLING»(ref-196256-S23700047402005100700000) .
3. Align exhaust system tension-free, see «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (FRONT WHEEL DRIVE VEHICLES)»(ref-196256-S09784201522005100700000) or «EXHAUST SYSTEM, ALIGNING FREE OF STRESS (ALL WHEEL DRIVE VEHICLES)»(ref-196256-S19472206742005100700000) .
4. Install centering pin for intake manifold.
5. Install intake manifold, see «INSTALLING»(ref-196254-S04999496782005100700000) .

Note. Be sure to activate vehicle features (radio/radio-navigation system, clock, electric window regulators) according to owner's manual when the battery is re-connected.

1. Replace coolant, see «FILLING»(ref-196255-S19755010692005100700000) .
2. Fill up power steering fluid and bleed steering system: See «POWER STEERING FLUID LEVEL, CHECKING; STEERING SYSTEM, BLEEDING AND CHECKING FOR LEAKS»(ref-196277-S13231397802005100800000) .

Scheme 395

For items marked with a "1)" in see scheme 266, REPLACE bolts.

Valve train, servicing

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

Part I

The following list pertains to see scheme 277.

1. 10 Nm
2. Seals Always replace, see «CAMSHAFT OIL SEALS, REPLACING»(ref-196254-S24667496902005100700000)
3. Housing For camshaft adjustment valves
4. Gasket Always replace
5. Exhaust camshaft Axial play, checking, see «CAMSHAFT AXIAL PLAY, CHECKING»(ref-196254-S33000054842005100700000) Removing and installing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196254-S11217339502005100700000) Check radial clearance using Plastigage (hydraulic valve lifters removed) Wear limit: 0.1 mm Max. run-out: 0.01 mm
6. Piston rings For camshaft adjuster Engage piston ring ends with each other, see «ENGAGE PISTON RING ENDS»(ref-196254-S01978515742006041700000)
7. Intake camshaft Axial play, checking, see «CAMSHAFT AXIAL PLAY, CHECKING»(ref-196254-S33000054842005100700000) Removing- and installing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196254-S11217339502005100700000) Check radial clearance using Plastigage (hydraulic valve lifters removed) Wear limit: 0.1 mm Max. run-out: 0.01 mm
8. 10 Nm Tighten in several stages from inside out
9. Guide frame With integrated camshaft bearings Removing and installing: Camshafts and camshaft adjusters, removing and installing, see «CAMSHAFT OIL SEALS, REPLACING»(ref-196254-S24667496902005100700000)
10. Sensor wheel Note position (notch on camshaft)
11. 23 Nm
12. Hydraulic valve lifter Checking, see «HYDRAULIC VALVE LIFTERS, CHECKING»(ref-196254-S34714947822005100700000) Removing and installing, see «VALVE STEM OIL SEALS, REPLACING»(ref-196254-S01804073502005100700000) Do not interchange Install with journal surface facing down Before installing, check axial play of camshafts, see «CAMSHAFT AXIAL PLAY, CHECKING»(ref-196254-S33000054842005100700000) Oil contact surface
13. Valve keepers
14. Valve spring retainer
15. Valve spring
16. Valve stem oil seal Always replace. See «VALVE STEM OIL SEALS, REPLACING»(ref-196254-S01804073502005100700000) .
17. Camshaft Position (CMP) sensor Cylinder bank 1 (right) - Camshaft Position (CMP) Sensor -G40-: Cylinder bank 2 (left) - Camshaft Position (CMP) Sensor 2 -G163
18. 10 Nm
19. Camshaft Position (CMP) sensor for exhaust camshaft Cylinder bank 1 (right) - Camshaft Position (CMP) Sensor 3 -G300- Cylinder bank 2 (left) - Camshaft Position (CMP) Sensor 4 -G301
20. O-ring Always replace
21. 10 Nm
22. Camshaft Position (CMP) sensor housing
23. Gasket Always replace
24. Cylinder head See note in «VALVE TRAIN, SERVICING»(ref-196254-S00537520582005100700000) Check valve guides; hand-lap valve seats. See «VALVE GUIDES, CHECKING»(ref-196254-S13108537072005100700000) . See «VALVE SEATS, REFACING»(ref-196254-S10241835862005100700000) .
25. Intake valve Do not reface, only hand-lapping is permitted Mark installation position for reinstalling Valve dimensions, see «VALVE DIMENSIONS»(ref-196254-S27279747542006041700000) Check valve guides, hand-lap valve seats, see «VALVE GUIDES, CHECKING»(ref-196254-S13108537072005100700000)
26. Exhaust valves Do not reface, only hand-lapping is permitted Mark installation position for reinstalling Valve dimensions, see «VALVE DIMENSIONS»(ref-196254-S27279747542006041700000) Check valve guides; hand-lap valve seats. See «VALVE GUIDES, CHECKING»(ref-196254-S13108537072005100700000) .

Part II

The following list pertains to see scheme 278.

1. Seals Always replace, see «CAMSHAFT OIL SEALS, REPLACING»(ref-196254-S24667496902005100700000)
2. Housing for camshaft adjustment valves
3. O-rings green between solenoid valve housing and solenoid valves Always replace
4. O-rings Black Always replace
5. O-rings green Always replace
6. 4 Nm
7. Camshaft adjustment valve - intake side Cylinder bank 1 (right) - Valve -1- for camshaft adjustment -N205- Cylinder bank 2 (left) - Valve -2- for camshaft adjustment -N208- Do not interchange with a valve for camshaft adjustment (exhaust side) Note identification 12. 100 338
8. Gasket Replace if damaged
9. Connector adapter Must be replaced after disconnecting from camshaft adjustment valves Carefully press onto harness connectors of camshaft adjustment valves until they engage
10. 4 Nm
11. Camshaft adjustment valve - exhaust side Cylinder bank 1 (right) - Camshaft Adjustment Valve 1 (exhaust) -N318- Cylinder bank 2 (left) - Camshaft Adjustment Valve 2 (exhaust) -N319- Do not interchange with a camshaft adjustment valve (intake side) Note identification 12. 100 339
12. Gasket Always replace
13. 10 Nm

Scheme 396

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

Scheme 397

Engage piston ring ends

1. Check whether piston rings at camshafts are installed and whether piston ring ends are engaged with each other.
2. If necessary, engage ends of installed piston rings (arrows), as depicted in illustration.

1. Remove toothed belt, see «TOOTHED BELT, REMOVING AND INSTALLING»(ref-196254-S00113299912005100700000) .
2. Mark installed position of camshaft gears for re-installation.
3. Remove camshaft gears.

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

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

1. Press in sealing ring for camshaft gear flush to housing using T10053 assembly tool and bolt -1-.
2. Install toothed belt (adjust timing), see «INSTALLING (ADJUSTING VALVE TIMING)»(ref-196254-S18761640162005100700000) .

Scheme 398

1. Remove toothed belt, see «TOOTHED BELT, REMOVING AND INSTALLING»(ref-196254-S00113299912005100700000) .
2. Remove respective camshaft gears.
3. Remove combination valve for Secondary Air Injection. See «LEFT COMBINATION VALVE FOR SECONDARY AIR INJECTION, REMOVING AND INSTALLING»(ref-196256-S11518964442005100700000) or «RIGHT COMBINATION VALVE FOR SECONDARY AIR INJECTION, REMOVING AND INSTALLING»(ref-196256-S09073227952005100700000) .

Right-side cylinder head

1. Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) Sensor -G40- and Camshaft Position (CMP) Sensor 3 -G300-.
2. Unscrew bolts -1- and remove bracket with idler roller.
3. Unscrew bolts -2- and remove toothed belt guard at rear right.

Scheme 399

Left-side cylinder head

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

All

1. Remove T40030 camshaft adjuster gauge from camshafts.
2. Unscrew bolts -1 to 6- and remove housing for camshaft adjustment valves.
3. Unscrew bolts -1 to 6- and remove housing for Camshaft Position (CMP) sensor.
4. Loosen bolts of guide frame in the sequence of the numbers and follow arrows.
5. Press off guide frame with M6 bolts (arrows).
6. Carefully remove guide frame.

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

Scheme 400

Note. Replace gaskets and O-rings.

1. Crankshaft aligned using T40026 locking pin.

1. Oil camshaft journal surface.

Left-side cylinder head

1. Insert camshaft into cylinder head as depicted in illustration. Cams at cylinder 5 point downward evenly (arrows).

Scheme 401

Right-side cylinder head

1. Insert camshaft into cylinder head as depicted in illustration. Cams at cylinder 3 point upward evenly (arrows).

Scheme 402

All

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

Scheme 403

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

1. Apply sealant to clean sealing surface of guide frame as depicted in illustration. Thickness of sealant bead: Aprrox. 1.2 mm Distance of sealant bead to the camshaft bearings at the specified locations -1 to 8-: at least 5 mm In addition, sealing surfaces around the spark plug bores obtain a sealant ring each, -9- to -11
2. Immediately set guide frame in place and align using T40029 locating pin.

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

Scheme 404

1. Tighten bolts of guide frame in sequence of numbers and follow arrows uniformly by hand. Guide frame must make full contact with cylinder head surface
2. Tighten bolts of guide frame to final tightening torque (10 Nm).
3. Using T10055 extractor, remove T40029 locating pin from cylinder head.

Left-side cylinder head

Scheme 405

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

Scheme 406

Right-side cylinder head

1. Install camshaft gear of exhaust camshaft.
2. In each case, turn exhaust camshaft -arrow 1- and intake camshaft -arrow 2- 30° in direction of arrow until cams (arrows) of cylinder 3 at intake and exhaust camshafts are as shown in illustration.
3. Insert T40030 camshaft adjuster gauge at camshafts.
4. Remove exhaust camshaft gear again.

All

1. Install Camshaft Position (CMP) Sensor housing and tighten bolts -1 to 6-.
2. Check whether piston rings are installed at camshafts and whether piston ring ends are engaged with each other.
3. If necessary, engage ends of installed piston rings (arrows), as depicted in illustration.

Scheme 407

Note. If the camshaft sealing rings are being replaced, they must be removed from Camshaft adjustment housing before installation, using T40017 lever. Installing camshaft sealing rings, see CAMSHAFT OIL SEALS, REPLACING .

Scheme 408

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

Installation is reverse of removal, noting the following

1. Install combination valve for Secondary Air Injection. See «LEFT COMBINATION VALVE FOR SECONDARY AIR INJECTION, REMOVING AND INSTALLING»(ref-196256-S11518964442005100700000) or «RIGHT COMBINATION VALVE FOR SECONDARY AIR INJECTION, REMOVING AND INSTALLING»(ref-196256-S09073227952005100700000) .
2. Install toothed belt (adjust timing), see «INSTALLING (ADJUSTING VALVE TIMING)»(ref-196254-S18761640162005100700000) .

Scheme 409

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

Tightening torques

TIGHTENING TORQUES: CAMSHAFTS AND CAMSHAFT ADJUSTERS

1. Cylinder head installed

1. Camshafts, removing, see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196254-S11217339502005100700000) .

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

1. Remove valve lifters from guides and place aside with contact surface facing down.
2. Using 3122B spark plug removal tool, remove spark plugs.
3. Adjust piston of the respective cylinder to BDC.
4. Thread T40012 adapter into the spark plug thread and apply constant pressure; at least 6 bar positive pressure.
5. Insert VAS5161/3 drift into valve lifter guide.
6. Loosen by hitting all stuck valve keys at all five valves using a plastic hammer.

Intake side

1. Thread VAS5161/6 engaging device with VAS5161/5 engaging fork into one threaded bore at cylinder head.
2. At valve to be removed, slide VAS5161/13 guide bushing into valve lifter guide up to stop. Installation position: Hatched areas point horizontally to direction of travel
3. Slide VAS5161/17 knurled spacer ring onto VAS5161/8 installation cartridge.
4. Slide installation cartridge into guide bushing.
5. Hook in VAS5161/2 pressure fork at VAS 5161/6 engaging device and press installation cartridge downward.
6. At the same time, turn knurled bolt of installation cartridge toward the right, until points engage in valve keys.
7. Lightly move knurled bolt back and forth, this causes valve keys to be pressed apart and captured in cartridge.
8. Release pressure fork.
9. Remove installation cartridge with spacer ring, guide bushing, valve plate and valve spring.

Exhaust side

1. Thread VAS5161/6 engaging device with VAS5161/5 engaging fork into one threaded bore at cylinder head.
2. At valve to be removed, slide VAS5161/14 guide bushing into valve lifter guide up to stop. Installation position: Hatched areas point horizontally to direction of travel
3. Slide VAS5161/17 knurled spacer ring onto VAS5161/8 installation cartridge.
4. Slide installation cartridge into guide bushing.
5. Hook in VAS5161/2 pressure fork at VAS 5161/6 engaging device and press installation cartridge downward.
6. At the same time, turn knurled bolt of installation cartridge toward the right, until points engage in valve keys.
7. Lightly move knurled bolt back and forth, this causes the valve keys to be pressed apart and captured in the cartridge.
8. Release pressure fork.
9. Remove installation cartridge with spacer ring, guide bushing, valve plate and valve spring.

1. Pull off valve stem oil seals using 3364 valve seal removal tool.

Scheme 410

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

1. Drive out spring dowl sleeve (arrow) at 3364 valve stem removal tool using a drift and remove impact extractor device.
2. Position lower part of 3364 valve stem removal tool at valve stem oil seal.
3. Secure 3364 valve stem removal tool using a drift or cotter pin driver -1- as shown in illustration.
4. Position a lever at 3364 valve stem removal tool and remove valve stem oil seal (arrow).

Scheme 411

Note. A plastic sleeve -A- supplements 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 sealing lip of valve stem oil seal.
3. Slide valve stem oil seal onto plastic sleeve.
4. Carefully press valve stem oil seal onto valve guide using 3365 valve stem seal driver.
5. Remove plastic sleeve.
6. If valve keepers were removed from installation cartridge, they must be inserted into VAS5161/18 insertion device next.

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

Scheme 412

1. Press VAS5161/8 installation cartridge onto insertion device from top and take up valve keepers.
2. Set VAS5161/8 installation cartridge into VAS5161/13 guide sleeve or VAS5161/14.
3. Press down pressure fork and pull knurled bolt upward while turning left and right - the valve keepers are inserted in this manner.
4. Release pressure fork with the knurled bolt still pulled.
5. Insert valve lifters.
6. Camshafts, see «INSTALLING»(ref-196254-S13979520652005100700000) .

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

Valves, checking

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

Valve seats, refacing

Note. If a perfect contact pattern isn't created after hand-lapping valve seats, reface valve seats.

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

Determining maximum allowable refacing dimension

1. Insert valve and press tightly against valve seat.

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

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

MINIMUM ALLOWABLE VALVE SEAT REFACING DIMENSIONS

Distance measured minus minimum dimension = maximum permissible refacing dimension.

Scheme 413

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

Scheme 414

Valve seats, refacing

Scheme 415

Checking internal resistance

Valve for camshaft adjustment (intake)

1. Connect multimeter between terminals 1 and 2 for resistance measurement. Specification: 7.4 to 8.2 ohms

Valve for camshaft adjustment (exhaust)

1. Connect multimeter between terminal 2 and 3 for resistance measurement. Specification: 12.8 to 14.2 ohms

Scheme 416

All

If specified value is not obtained

1. Replace valve.

If specified value is obtained, go to CHECKING VOLTAGE SUPPLY .

Checking voltage supply

Test requirement

1. Fuse for valves for camshaft adjustment OK.

See appropriate System Wiring Diagrams article

1. Connect VAG1527B voltage tester as follows: CAMSHAFT ADJUSTMENT VALVE CIRCUIT TEST: TERMINAL 2 Harness connector Terminal Measure to 2 Engine Ground (GND)
2. Switch ignition on. LED must light up.

If LED does not light up

Scheme 417

1. Check wire connection from terminal 2 of connector via fuse to Motronic Engine Control Module (ECM) Power Supply Relay -J271- for open circuit: See appropriate System Wiring Diagrams article.
2. Repair open circuit if necessary.

If LED lights up, go to CHECKING ACTIVATION .

Scheme 418

1. Connect VAG1527B voltage tester as follows: CAMSHAFT ADJUSTMENT VALVE CIRCUIT TEST: ACTIVATION Valve for camshaft adjustment Harness connector Terminal Intake bank 1, Valve -1- for camshaft adjustment -N205- 1 + 2 Intake bank 2, Valve -1- for camshaft adjustment -N208- 1 + 2 Exhaust bank 1, Camshaft Adjustment Valve 1 (exhaust) -N318- 2 + 3 Bank 2, Camshaft Adjustment Valve 1 (exhaust) -N319- 2 + 3
2. Initiate output Diagnostic Test Mode (DTM) and activate the valve for camshaft adjustment. LED must blink.

If LED does not blink or if it remains constantly lit

1. Connect VAG1598/31 test box to harness connectors of wiring harness (do not connect ECM). Connect Ground (GND) clip at test box (not visible in illustration) to Ground (GND). See «WIRING AND COMPONENT CHECK WITH TEST BOX VAG1598/31»(ref-216420-S38846759252006012100000) .
2. Check the following wire connections for open circuit and short circuit to Ground (GND) and B+: CAMSHAFT ADJUSTMENT VALVE CIRCUIT TEST: OPEN/SHORT CIRCUITS Valve for camshaft adjustment Harness connector Terminal VAG1598/31 test box Socket Intake bank 1, Valve -1- for camshaft adjustment - N205- 1 115 Intake bank 2, Valve -1- for camshaft adjustment - N208- 1 120 Exhaust bank 1, Camshaft Adjustment Valve 1 (exhaust) -N318- 1 22 Bank 2, Camshaft Adjustment Valve 1 (exhaust) -N319- 1 18
3. Repair short circuit to Ground (GND) connection or open circuit if necessary.

If wire connection is OK

1. Replace Engine Control Module (ECM).

If no malfunctions are detected

1. Replace mechanical camshaft adjuster (see «VALVE GUIDES, CHECKING»(ref-196254-S13108537072005100700000) ) i.e. camshafts, removing and installing, (see «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196254-S11217339502005100700000) ).

1. Bolt - 10 Nm
2. Oil injector jet for piston cooling

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

See Parts catalog

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
2. Loosen mounting parts -1 to 4- and remove noise insulation.
3. Place engine oil drip tray beneath engine.
4. Drain engine oil.

Scheme 419

Scheme 420

1. Remove bracket for ATF lines, to do so remove nuts -1- and -2-. NOTE: Union nuts -3- of ATF lines must not be disconnected. All
2. Unbolt bracket for refrigerant line at oil pan (arrows). NOTE: Depicted in illustration for a vehicle with manual transmission.
3. Disconnect electrical harness connector at Oil level thermal sensor (arrow) and lay cable free.
4. Place engine oil drip tray beneath engine, since oil will escape again.
5. Unbolt oil pan (lower part) -1- and carefully remove.
6. Using rotating plastic brush, remove any remaining sealant from oil pan (lower part) and at upper part. WARNING: Wear protective glasses.
7. Clean sealing surfaces so they are free of oil and grease.

Installation is reverse of removal, noting the following

Note. Replace gaskets and O-rings.

1. Cut tube nozzle at front marking (jet diameter approx. 1 mm).
2. Apply silicon sealant bead to clean sealing surfaces of oil pan (lower part) as depicted in illustration. Thickness of sealant bead (arrow): approx. 1.5 mm NOTE: The oil pan (lower part) must be installed within 5 minutes after application of silicon sealant. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.
3. Install oil pan (lower part) and pre-tighten all bolts diagonally to 5 Nm.
4. Tighten bolts of oil pan (lower part) in diagonal pattern to 10 Nm.
5. Add engine oil and check oil level.

Tightening torques

TIGHTENING TORQUES: OIL PAN (LOWER PART)

1. Remove oil pan (lower part), see «OIL PAN (LOWER PART), REMOVING AND INSTALLING»(ref-196254-S40777391472005100700000)
2. Turn crankshaft via central bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 3 marking. Notch -1- is opposite marking -2
3. If installed, disconnect electrical harness connector at after-run coolant pump.
4. Unscrew sealing plug of TDC mark at cylinder block.
5. Thread T40026 locking pin into the hole of the removed sealing plug and tighten. NOTE: Slightly turn crankshaft back and forth to do so.
6. Unscrew bolts -3- and -6- and remove oil tubes. see scheme 385 NOTE: Oil escapes from oil tubes when removing.
7. Unscrew bolts -1-, -2-, -4- and-5- and remove front baffle plate.
8. Remove bolt -4- and remove gear -3- for differential gear shaft drive.
9. Remove diamond disc from toothed gear.
10. Remove bolts -1- and -2- and nuts -5- and -6-.
11. Install T10055 extractor into M8 holes alternating (arrows) at oil pan and pull oil pump off of cylinder block.

Installation is reverse of removal, noting the following

Note. Always replace seals and gaskets.

Scheme 421

1. Clean threads of studs -3- from remaining locking fluid.
2. Replace O-ring -arrow 1-.
3. Coat circumference of hole (arrow 2) with sealant. see scheme 388
4. Remove bolts -1- and -2- and nuts -5- and -6- of oil pump threaded connection. see scheme 389
5. Insert nuts -5- and -6- with locking fluid.
6. Bolt in oil pump uniformly at all mounting points, so that shear pin does not cant.
7. Tighten threaded connection to final torque.
8. Replace diamond disc on toothed gear -3-for differential gear shaft drive.
9. Insert collar of toothed gear for differential gear shaft drive through chain sprocket onto oil pump shaft.
10. Loosely thread in bolt -4-. NOTE: To install toothed gear, press piston of chain tensioner back using a screwdriver (arrow).
11. Turn differential shaft -2-, until a pin 5 mm diameter item 3 (e.g. drill bit) can be slid into alignment hole. see scheme 391
12. Tighten bolt -1-.
13. Remove pin (drill bit) from alignment hole.
14. Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O-ring into cylinder block.
15. Install front baffle plate -bolts -1-, -2-, -4- and -5-. see scheme 392
16. Install oil tubes -bolts 3 and 6-.
17. Install oil pan (lower part), see «INSTALLING»(ref-196254-S23046667222005100700000).

Scheme 422

Note. The following footnotes apply to table in see scheme 393.

1) 120° corresponds to 1/3 turn

2) Insert nuts using locking fluid; Locking fluid see Parts catalog

3) Replace bolts

4) 90° corresponds to 1/4 turn

1. Remove oil pan (upper part), see «OIL PAN (UPPER PART), REMOVING AND INSTALLING»(ref-196254-S01314103342005100700000) .
2. Remove front sealing flange, see «FRONT SEALING FLANGE, REMOVING AND INSTALLING»(ref-196254-S09043254742005100700000) .
3. Unscrew bolts -4- and remove chain tensioner -3- from front sealing flange -1-.
4. Remove chain from drive chain gear.

1. Replace O-ring -2-.
2. Bolt in chain tensioner -3- with bolts -4-(with washers) to front sealing flange -1-.
3. Unscrew locking bolt from adjustment hole -3-.
4. Press chain tensioner -1- in direction of arrow until a drill bit 3 mm diameter -2- can be slid into alignment hole of sealing flange and chain tensioner.
5. Install front sealing flange. See «INSTALLING»(ref-196254-S35549502472005100700000) .
6. Install oil pan (upper part). See «INSTALLING»(ref-196254-S09691363142005100700000) .

Tightening torque

TIGHTENING TORQUE: OIL PUMP CHAIN TENSIONER

1. Lock carrier in service position, see «LOCK CARRIER, MOVING INTO SERVICE POSITION»(ref-196254-S41599485202005100700000) .

Scheme 423

Scheme 424

1. Note radio code and determine if necessary (for vehicles with coded anti-theft radio / radio-navigation system -RNS-).
2. Switch ignition off and disconnect battery Ground (GND) strap.
3. Remove ribbed belt. See «RIBBED BELT, REMOVING AND INSTALLING»(ref-196254-S34290437782005100700000).
4. Disconnect Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air filter housing.
5. Remove air filter housing (arrows).
6. Remove bolts -1- and -3-. see scheme 399
7. Disconnect hose -4- from line of secondary air injection.
8. Pull out guide tube for oil dipstick -2- from oil pan (upper part) toward top and swing it forward for removal.
9. Pull off sealing rubber at bolted flanges of fender.
10. Insert a 5 mm backing plate between lower edge of fender and web plate.
11. Position 10-222A engine support bridge on bolted flanges of fenders.
12. Remove eyelet for 2024A engine sling.
13. Insert bolt -1- in the center bore of 2024A engine sling again and secure with a cotter pin.
14. Attach bolt of 2024A engine sling at 10222A engine support bridge spindle.
15. Attach 2024A Engine Sling to sling clamps at front and rear of engine. WARNING: Take-up hooks and pins at engine sling must be secured using securing pins (arrows) as shown in illustration.
16. Slightly pre-tension engine using engine support bridge spindle.
17. Place engine oil drip tray beneath engine.
18. Drain engine oil.
19. Loosen oil filter (arrow) using tension strap; e.g. Hazet 3171-1.
20. Place VAG1306 Drip Tray beneath engine.
21. Clamp coolant hoses -2- and -3- using 3094 hose clamps.
22. Disconnect coolant hoses from oil cooler -1-.
23. Remove oil cooler.

1. Remove bracket for ATF lines, to do so remove nuts -1- and -2-. NOTE: Union nuts -3- of ATF lines must not be disconnected.

1. Unbolt bracket for refrigerant line at oil pan (arrow). NOTE: Depicted in illustration for a vehicle with manual transmission.
2. Disconnect harness connector -1- of electrical wire to clutch for A/C compressor.
3. Unbolt A/C compressor from bracket (arrows).
4. Hang A/C compressor (with refrigerant lines attached) to stabilizer using wire.
5. Unbolt angle bracket for wiring harness from left engine mount.
6. Mark installation positions of threaded connections -1- and positioning sleeves -2- below on engine mounts at right and left. NOTE: Different mounting bores are available depending upon the installed engine.
7. Remove nuts 1 at bottom on left and right engine mounts.
8. If installed, unclip operating rod of sensor for vehicle level sensor at lower lateral control arm (arrow).
9. Cut cable ties (arrows), open bracket for starter wiring and remove electrical wiring.
10. First remove front bolts -2- and -3- from left and right sides of subframe. Then remove bolts -1-. NOTE: Only loosen or lower subframe at front side to avoid having to perform a wheel alignment.
11. Lower front subframe.
12. Disconnect electrical harness connector from oil pressure switch (arrow).
13. If installed, unscrew bolts -1- and remove after-run coolant pump -2- at oil pan (upper part). NOTE: Coolant hose to cylinder block can remain connected.
14. Disconnect electrical lines from generator.
15. Unscrew bolts (arrows) and remove generator.

1. Remove heat shield -1- for right drive axle.

Scheme 425

Scheme 426

1. Remove electrical wires -1- and -2- from starter. NOTE: Ground (GND) wire -3- remains connected.
2. Remove heat shield -1- from magnetic switch.
3. Unscrew bolts -2- and -3- and remove starter.
4. Disconnect electrical harness connector at Oil level thermal sensor (arrow) and lay cable free.
5. Place engine oil drip tray beneath engine.
6. Unbolt oil pan (lower part) -1- and carefully remove.
7. Remove oil pump, see «OIL PUMP, REMOVING AND INSTALLING»(ref-196254-S11869233372005100700000) .
8. Using 10-222A engine support bridge spindle, lift engine slightly. NOTE: Make sure rear air guide at intake manifold is not damaged when lifting engine.
9. Remove bracket for noise insulation (arrows).
10. Remove bottom engine/transmission connecting bolts in area of oil pan (upper part).
11. Check whether a 10 mm wrench socket, e.g. 3220 hinged socket can be slid in through assembly hole (arrows) - if necessary rework assembly hole.
12. Remove bolts -1- and -2- for oil pan (upper part).
13. Press oil pan (upper part) off from the cylinder block roll pins.
14. Using rotating plastic brush, remove remaining sealant from oil pan (upper part) and at cylinder block. WARNING: Wear protective glasses.
15. Clean sealing surfaces so they are free of oil and grease.

Installation is reverse of removal, noting the following

Note. Replace gaskets and O-rings.

1. Cut tube nozzle at front marking (jet diameter approx. 1 mm).
2. Apply silicon sealant bead to clean sealing surface of oil pan (upper part) as depicted in illustration. Thickness of sealant bead (arrow): approx. 1.5 mm NOTE: The oil pan (upper part) must be installed within 5 minutes after application of silicon sealant. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer. Apply sealant bead in area of hole (arrow) in cylinder block with special care.
3. Install oil pan (upper part) and pre-tighten all bolts for oil pan (upper part)/cylinder block in diagonal sequence to 5 Nm.
4. Tighten bolts of oil pan (upper part)/transmission to 45 Nm.
5. Tighten bolts -1- to 16 Nm and bolts -2- to 22 Nm in diagonal sequence.
6. Install oil pump, see «OIL PUMP, REMOVING AND INSTALLING»(ref-196254-S11869233372005100700000) .
7. Install oil pan (lower part), see «INSTALLING»(ref-196254-S23046667222005100700000) .
8. Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).
9. Install starter. See appropriate Starter article
10. Install generator. See «RIBBED BELT FOR VANE PUMP, GENERATOR AND A/C SYSTEM»(ref-196254-S21603526782005100700000) .
11. Install subframe. See «SUBFRAME & SUBFRAME BUSHINGS»(ref-153103-S20265328262004110200000) .
12. Install A/C compressor. See «RIBBED BELT FOR VANE PUMP, GENERATOR AND A/C SYSTEM»(ref-196254-S21603526782005100700000) .
13. Install ribbed belt. See «INSTALLING»(ref-196254-S10883342812005100700000) .
14. Install lock carrier. See «LOCK CARRIER, MOVING INTO SERVICE POSITION»(ref-196254-S41599485202005100700000) .
15. Add engine oil and check oil level. NOTE: Be sure to activate vehicle features (radio/radio-navigation system, clock, power windows) according to owner's manual when the battery is re-connected. CAUTION: On vehicles equipped with Audi Telematics by OnStar®, switch on the emergency (back-up) battery after reconnecting the vehicle battery. See «EMERGENCY BATTERY, SWITCHING OFF/ON»(ref-196292-S13683948542005100800000) .
16. Top off coolant, see «FILLING»(ref-196255-S19755010692005100700000) . NOTE: Only reuse drained coolant if cylinder head or engine block were not replaced. Dirty coolant cannot be reused.

Tightening torques

TIGHTENING TORQUES: OIL PAN (UPPER PART)

Oil pressure switch, checking

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.
2. Loosen mounting parts -1 to 4- and remove noise insulation.
3. Disconnect electrical harness connector from oil pressure switch (arrow).
4. Unscrew oil pressure switch and install VAG1342 oil pressure tester.
5. Thread oil pressure switch -2- into VAG1342 oil pressure tester.
6. Connect brown wire -1- of tester to Ground (GND).
7. Using VAG1594A connect test kit, connect VAG1527B voltage tester to oil pressure switch and Battery (+). LED must not be lit.
8. If LED is lit, replace oil pressure switch.
9. Start engine. NOTE: While starting engine, watch Pressure Tester and LED as oil pressure switch may open during start. Black oil pressure switch: T 1.2 to 1.6 bar pressure, LED must light up.
10. If LED does not light up, replace oil pressure switch.

Oil pressure, checking

1. Disconnect electrical wire from oil pressure switch.
2. Unscrew oil pressure switch and install VAG1342 oil pressure tester.
3. Thread oil pressure switch -2- into VAG1342 oil pressure tester.
4. Start engine (engine oil temperature approx. 80° C). Oil pressure at idle: at least 1.5 bar Oil pressure at 2000 RPM: at least 3.0 bar

If specified values are not obtained

1. Pressure relief valve or oil pump faulty, replace oil pump.

Oil level, checking

Test requirements

1. Engine oil temperature at least 60° C.
2. Vehicle on level ground.
3. After stopping engine, wait a few minutes to allow oil to flow back into oil pan.

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.

Range of markings on oil dipstick

1. Oil must not be topped off.
2. Oil may be topped off. After topping off, oil may be in range -a-.
3. Oil must be topped off. 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.

Scheme 427