Starters: Removal & Installation Audi A6 C5 facelift

REMOVAL & INSTALLATION

Removal & Installation (2.7L & 2.8 V6)

1. Determine the correct coding for the anti-theft radio.
2. Disconnect the battery Ground (GND) strap.

Vehicles With V6 Engine (2.7-Liter Biturbo And 2.8-Liter)

Removing

Note. In order to remove the starter the generator must be removed. Refer to for 2.7L Bi-Turbo or refer to for 2.8L.

Scheme 1

Scheme 2

1. Remove wire for terminal B+ -1-. (Scheme 1): View Of Starter
2. Tightening torque: 16 Nm (12 ft lb)
3. Remove electrical connector from terminal 50 -2-.
4. Remove mounting bolts -1- and -2- from transmission housing. (Scheme 2): Identifying Transmission Housing Mounting Bolts
5. Remove right-front wheel.
6. Remove bolt -1- from right wheelhousing.
7. Remove bolt -2- from engine side.
8. Remove starter from below.

Installing

Scheme 3

1. Install in reverse order of removal. Starter bolt size Tightening torques M10 X 135 45 Nm (33 ft lb) M12 X 130 (upper bolt) 65 Nm (48 ft lb)
2. Remove rear noise insulation (arrows). (Scheme 3): Removing Rear Noise Insulation
3. Remove mounting bolts -1- and -2- from transmission housing. see scheme 4: Identifying Transmission Housing Mounting Bolts
4. Remove starter from rear.

Installing

1. Install in reverse order of removal. Starter bolt size Tightening torques M10 X 135 45 Nm (33 ft lb) M12 X 130 (upper bolt) 65 Nm (48 ft lb)
2. Install in reverse order of removal. Starter bolt size Tightening torques M10 x 135 45 Nm (33 ft lb) M12 x 130 (upper bolt) 65 Nm (48 ft lb)

Removing

Scheme 4

Scheme 5

1. Remove noise insulation (arrows). (Scheme 4): Removing Noise Insulation
2. Remove right wheel.
3. Remove heat shield for right drive axle (arrows). (Scheme 5): Removing Heat Sheild For Right Drive Axle
4. Unbolt right drive shaft from transmission flange.
5. Repair Manual, Suspension, Wheels, Steering, Repair Group 40
6. Remove bolt -1- located above right wheel housing (16 mm). see scheme 7: Identifying Transmission Housing Mounting Bolts
7. Tightening torques: 65 Nm
8. You can unbolt bolts -2- (16 mm) from the engine side.
9. Tightening torques: 65 Nm
10. Remove the starter downward.
11. To install, perform the steps described for removal in reverse order.

Scheme 6

1. Obtain radio anti-theft code. On models equipped with Audi Telematics by OnStar®, switch off emergency (back-up) battery. See «BATTERY DISCONNECT PRECAUTIONS»(ref-166037-S01084238552004091000000). Disconnect negative battery cable. Remove generator. See «GENERATORS & REGULATORS»(ref-164737) article in ELECTRICAL.
2. Disconnect electrical connections at starter solenoid. Disconnect insulator from B+ connection of starter. Remove bolt (1) securing ground wire to right engine mount. (Scheme 6) Remove bolts securing starter to transmission. Remove starter.
3. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-166037-S26394731692004091000000).

Removal & Installation (4.2L V8)

1. Obtain radio anti-theft code. On models equipped with Audi Telematics by OnStar®, switch off emergency (back-up) battery. See «BATTERY DISCONNECT PRECAUTIONS»(ref-166037-S01084238552004091000000). Disconnect negative battery cable. Raise and support vehicle.
2. Remove noise insulation panel. (Scheme 7) Remove cable retainer (2) from engine mount. (Scheme 8) Disconnect electrical connector (1) at engine mount.
3. Remove bolt securing ground wire to frame. (Scheme 9) Remove bolt securing starter bracket. (Scheme 10) Disconnect electrical connections at starter solenoid.
4. Remove bolts securing starter to transmission. (Scheme 11) Turn starter to right (clockwise) and downward. Remove starter. To install, reverse removal procedure. Tighten all bolts/nuts to specifications. See «TORQUE SPECIFICATIONS»(ref-166037-S26394731692004091000000).

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11