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4.2L V8 5V (Engine Codes: Art, Awn, Bbd): Component Locations Audi A6 C5 facelift

Mechanical 11 illustrations ~945 words

Special tools and equipment

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

Scheme 430

Scheme 430: Removing
Scheme 430: Removing

Scheme 431

Scheme 431
Scheme 431
  1. Remove air intake hose to air cleaner.
  2. Remove front bumper. See «FRONT BUMPER»(ref-196283-S08508749282005100800000) .
  3. Adjust lock carrier to service position. See «LOCK CARRIER, SERVICE POSITION»(ref-196278-S34319672162005100800000) .
  4. Remove outer ring for viscous fan -arrows-.
  5. Remove electric fan.
  6. Counter-hold viscous fan pulley with pin wrench 3212 and remove fan with wrench 3312 (LEFT HAND THREAD).
  7. Remove fan with fan shroud.
  8. Remove belt pulley for fan. CAUTION: Mark the running direction of the belt with crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt. When installing a used ribbed belt be sure belt runs in right direction and is seated properly on belt pulleys.
  9. To loosen ribbed belt, turn tensioner in direction of arrow with 19 mm ring wrench until two holes are aligned. Hold in position with pin 3204.
  10. Remove ribbed belt.
  11. Move crankshaft by hand to TDC. Markings -A- and -B- must be aligned.
  12. Remove right and left timing belt covers by disengaging spring clips.
  13. Check position of camshafts: larger holes in securing plates on camshaft sprockets must be in line with each other and facing inward. If not, turn crankshaft for one revolution.
  14. Remove plug -arrow- from left side of cylinder block. TDC drilling in crankshaft must be behind sealing plug hole (feel to check).
  15. Screw clamping bolt 3242 for crankshaft into plug hole and tighten. NOTE: The toothed belt tensioning element is oil-damped and can be compressed slowly by applying constant pressure.
  16. Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until tensioning element -2- is compressed far enough to insert pin T40011 in drilling and plunger.
  17. Install camshaft bar T40005 on securing plates of both camshafts.
  18. Loosen both camshaft bolts by approximately 5 turns.
  19. Remove camshaft bar T40005.
  20. Pull off both camshaft sprockets with puller T40001.
  21. Remove toothed belt together with camshaft sprocket for cylinder bank 1-4.
  1. Dial indicator bracket VW 387
  2. Dial indicator

Scheme 432

Scheme 432: Checking procedure
Scheme 432: Checking procedure

Scheme 433

Scheme 433
Scheme 433
  1. Remove camshaft. See «CAMSHAFTS AND CAMSHAFT ADJUSTERS, REMOVING AND INSTALLING»(ref-196260-S04268046642005100700000) .
  2. Remove valve roller lever.
  3. Install camshaft without drive chain and secure with baring caps 2 and 4.
  4. Install dial indicator bracket VW 387 to cylinder head.
  5. Press camshaft by hand against dial indicator.
  6. Zero dial indicator.
  7. Press camshaft away from camshaft.
  8. Read measurement. CAMSHAFT AXIAL (END) PLAY SPECIFICATIONS New Wear limit 0.05-0.15 mm (0.0020-0.0059 in.) 0.20 mm (0.0079 in.) (0.0020-0.0059 in.)
  1. Special tool 3240
  2. Installation tool 3241
  1. Special tool 2085
  2. Installation tool 3241

Scheme 434

Scheme 434: Removing
Scheme 434: Removing
  1. Remove cover -1-.
  2. Remove air intake hose for air cleaner -2-.
  3. Counter-hold viscous fan pulley with pin wrench 3212 and tighten fan using open-end wrench 3312 and torque wrench (FAN HAS LEFT-HAND THREAD).
  4. Remove cover -arrows-.
  5. Remove right toothed belt cover.
  6. Disconnect connector for Camshaft Position (CMP) sensor.
  7. Remove bolts -1-.
  8. Loosen bolt -2-.
  9. Pull toothed belt cover toward front and remove CMP housing.
  10. Install bolt from seal extractor 2085/1.
  11. Remove seal with seal extractor 2085 and bolt 2085/1.

Scheme 435

Scheme 435: Installing
Scheme 435: Installing
  1. Clean running and sealing surfaces.
  2. Do not oil sealing lip before installing.
  3. Install sleeve from tool 3241 on camshaft.
  4. Install seal with sleeve 3241/1 and bolt 2085/1 until flush.
  5. Install Camshaft Position (CMP) sensor.
  6. Connect connector for CMP sensor.
  1. Special tool 2085
  2. Installation tool 3241

Scheme 436

Scheme 436: Removing
Scheme 436: Removing

Scheme 437

Scheme 437
Scheme 437

Scheme 438

Scheme 438
Scheme 438
  1. Disconnect connectors from ignition coils -arrows- and move harness aside.
  2. Disconnect connector from Camshaft Position (CMP) sensor.
  3. Remove CMP sensor housing (10 Nm/7ft lb).
  4. Remove CMP rotor (23 Nm/17 ft lb) and carefully lever off rotor with screwdriver.
  5. Screw in bolt from oil seal extractor 2085/1.
  6. Remove seal with seal extractor 2085 and bolt 2085/1

Scheme 439

Scheme 439: Installing
Scheme 439: Installing
  1. Clean contact and sealing surfaces. NOTE: Do not apply oil to sealing lip or outer circumference of seal before installing.
  2. Install guide sleeve (from tool set 3241) onto camshaft.
  3. Press in seal until flush using press sleeve 3241/1 and bolt 3241/3.
  4. Install Camshaft Position (CMP) sensor rotor.
  5. Install CMP sensor housing.
  6. Connect connector for CMP sensor.
  7. Tightening torques TIGHTENING TORQUES: CMP SENSOR HOUSING Component Nm/ft lb CMP sensor housing 10/7 CMP sensor rotor 23/17
  8. Unplug connector from CMP sensor.

Scheme 440

Scheme 440: Removing
Scheme 440: Removing
  1. Remove toothed belt from camshaft sprockets. See «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(ref-196260-S14760224332005100700000) .
  2. Remove camshaft sprockets from cylinder bank 5-8.
  3. Loosen bolts -1-.
  4. Remove bolts -2- and toothed belt cover.
  5. Remove cylinder head cover. See «CYLINDER HEAD COVER, LEFT, REMOVING AND INSTALLING»(ref-196260-S17832086442005100700000) .
  6. Remove Camshaft Position (CMP) sensor, item -30- and CMP rotor, item -27-. See «VALVE GEAR, SERVICING»(ref-196260-S22049538912005100700000) .
  7. Check TDC position of camshafts: Both markings on camshafts must align with arrows on bearing caps.

When re-using drive chain

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

Continuation

  1. Secure camshaft adjuster with bracket for chain tensioning tool 3366. CAUTION: Do not over-tighten bracket for chain tensioning tool, otherwise camshaft adjuster may be damaged
  2. Regardless of how bearing caps are marked, mark sequence and installation position of all bearing caps as shown in illustration.
  3. Remove bolts for camshaft adjuster -arrow-.
  4. Remove bearing cap 0.
  5. Remove bearing caps 1, 3, 5, 7 and 8 and place in order on clean surface.
  6. Loosen bearing caps 2, 4, and 6 diagonally and remove.
  7. Remove camshafts with camshaft adjuster.
  1. Spark plug wrench 3122 B
  2. Installation tool VAS 5161
  3. Removal tool 3364
  4. Installation tool 3365
  1. Electric drill with plastic brush attachment
  2. Silicone sealant D 176 404 A2
  3. Torque wrench, 10 Nm / 45 Nm
CAUTIONPart numbers are listed for reference only. Always check with your Parts department for latest information.

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