4.2l v8 4v Engine Mechanical, Engine Code(s): Bvj Audi A6 C6 рестайлинг

Scheme 339

1. Engine number ("engine code" and "serial number") is located at front on cylinder block at top - arrow -.
2. The engine code is also located on vehicle data plate.

Note. The engine number is only visible if the front engine cover is removed.

Engine data

Safety precautions

Note the following when working on the fuel system

To prevent personal injury and damage to the injection and ignition system, observe the following

1. The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
2. Only clean engine with ignition switched off.
3. If electrical connectors were disconnected, faults are saved in ECM

1. Connect Vehicle Diagnosis, testing info. system VAS 5051.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

Note the following when working on the cooling system

If it is necessary to use testing and measuring devices on road tests, observe the following

Procedure before opening fuel injection system high pressure area

1. The fuel injection system is separated into a high-pressure section (max. approx. 120 bar) and a low-pressure section (approx. 6 bar).
2. Before a component in the fuel injection system high pressure area is remove, the fuel pressure must be definitely reduced to a residual pressure of approx. 6 bar, as described in the following.

Special tools, testers and auxiliary items required

1. Vehicle diagnostic, testing, and information system VAS 5051

Work procedure

1. Start engine and run at idle speed.

Scheme 340

1. Connect Vehicle Diagnosis, testing info. system VAS 5051.

Scheme 341

Display on VAS 5051

1. Click on Vehicle Self-Diagnosis button.

Scheme 342

Display on VAS 5051

1. In selection - 1 - , press vehicle system "01 - Engine electronics".
2. Wait until next display appears.

Scheme 343

Display on VAS 5051

1 - Control module identification of engine control module (ECM)

1. Click on --> button.

Scheme 344

Display on VAS 5051

1 - Selection of diagnostic functions

1. In selection - 1 - , click on diagnostic function "08 - Read measuring value block".

Scheme 345

Display on VAS 5051

1. In button field - 2 - , press buttons 1 4 0 for "display group 140" and confirm entry by pressing Q button.

Scheme 346

Display on VAS 5051

1. Check display for fuel pressure in fuel rail in display field - 3 -.

Example

3 - 40.63 bar

Scheme 347

1. Disconnect electrical connector - arrow - at Fuel Metering Valve 2 N402 on left high pressure pump.

Scheme 348

1. Disconnect electrical connector - arrow - at Fuel Metering Valve N290 on right high pressure pump.

Display on VAS 5051

1. Check indication in display field - 3

1. Fuel pressure in fuel rail must sink to approx. 6 bar.

1. Switch off ignition.

The fuel rail will continue to be filled with fuel, but it will no longer be under high pressure.

Now components or lines can be opened. Lay a clean cloth around connection points and collect escaping fuel.

Final procedures

1. Reconnect electrical harness connectors.

Faults are saved in ECM when electrical connectors are disconnected

1. Connect Vehicle Diagnosis, testing info. system VAS 5051.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

Rules for cleanliness

Even minor contaminations can lead to malfunctions in the fuel injection system. When working on coolant supply and fuel injection system, observe the following rules of cleanliness

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Immediately seal off lines and connections with clean plugs or protective caps.
3. Place removed parts on a clean surface and cover them with lint-free cloths.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpackaged (e.g. in tool boxes etc.).

1. If system is open, do not work with compressed air and do not move the vehicle.
2. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

Engine, removing

Note. With lock carrier installed, engine is removed downward with transmission and subframe. Drained coolant must be stored in a clean container for disposal or reuse. During installation, all cable ties must be re-installed at the same location.

Scheme 349

Special tools, testers and auxiliary items required

1. Pry lever 80 - 200
2. Old oil collecting and extracting device V.A.G 1782
3. Hose clamp pliers V.A.G 1921
4. Spring-type clip pliers VAS 5024 A

1. Step ladder VAS 5085
2. Scissor Lift Table VAS 6131 with Support Set VAS 6131/10 and Supplementary Set VAS 6131/11 and VAS 6131/12

Special tools, testers and auxiliary items required

Scheme 350

1. Drip tray for workshop crane VAS 6208

Scheme 351

1. Tension strap T10038

Work procedure

1. Reduce fuel pressure in high pressure area --> «Procedure before opening fuel injection system high pressure area»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__procedure-before-opening-fuel-injection-system) .

Note. So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted. In order for the driveshaft to be able to rotate for removal, the electronic parking brake must be released before disconnecting battery.

1. Remove luggage compartment floor trim.
2. If battery is secured with a retaining strap, open strap.

Scheme 352

1. Release retaining clips - arrows - with a screwdriver - 2 - and remove cover - 1 -.

Scheme 353

1. With ignition switched off, disconnect Battery Ground (GND) wire - arrow -.
2. Discharge refrigerant circuit Refrigerant R134a - Servicing.
3. Extract hydraulic oil from power steering reservoir using Used Oil Collecting and Extracting Device V.A.G 1782.

Scheme 354

1. Pull rear engine cover - arrows - off.

Scheme 355

1. Pull front engine cover - arrows - off.

1. Open cap on coolant expansion tank.

Scheme 356

1. Remove both front wheels.
2. Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.
3. Place drip tray for workshop crane VAS 6208 under engine.

Scheme 357

1. Remove drain plug - 1 - on Map Controlled Engine Cooling Thermostat F265 and allow coolant to drain.

Note. Ignore - 2 -.

Scheme 358

1. Remove drain plug - arrow - at front coolant pipe and drain coolant.
2. Place old oil collecting and extracting device V.A.G 1782 under engine.

Note. Observe the rules of cleanliness for working on automatic transmissions --> 00 - GENERAL, TECHNICAL DATA .

Scheme 359

1. Disconnect ATF lines - 1 and 2 - and power steering hydraulic line - 3 -.

Note. To prevent dirt and moisture from entering, seal off open lines and connections with clean plugs or protective caps.

Scheme 360

1. Remove coolant hoses - 1 and 2 - from Map Controlled Engine Cooling Thermostat F265.

Scheme 361

1. Remove bolts - 1 and 2 -.
2. Disconnect refrigerant lines from A/C compressor.

Note. To prevent dirt and moisture from entering, seal off open lines and connections with clean plugs or protective caps.

Scheme 362

1. Remove Ground (GND) strap - arrow - from right longitudinal member.

Scheme 363

1. Disconnect electrical connector - 2 - on Secondary Air Injection (AIR) Pump Motor V101 and free up wire.
2. Remove air guide hose - 1 - and free it up.

Scheme 364

1. Disconnect fuel line - arrow -.

Scheme 365

1. Free up fuel line and line to EVAP canister on air filter housing and air guide pipe.
2. Disconnect electrical connector - 2 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and remove vacuum hose - 1 -.
3. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 from bracket and lay aside with hose and fuel line connected.

Note. Disregard - arrow -.

Scheme 366

1. Remove bolts - arrows -.
2. Remove air duct - 1 and 2 -.

Scheme 367

1. Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70.
2. Remove vacuum line - 3 - to air guide pipe.

1. Lay aside air guide hose with connected crankcase ventilation hose - 2 - by loosening hose clamps - 4 - and opening clips - arrows -.

Note. Ignore - 5 -.

Scheme 368

1. Open clips - arrows - and remove upper part of air filter housing.

Scheme 369

1. Disconnect vacuum line - 1 -.
2. Remove pin from spreader clips - 4 -.
3. Remove lower part of air filter housing and on backside, disconnect electrical connection - 2 - at intake air switch-over valve N335.
4. Disconnect air guide hose - 3 - to Secondary Air Injection (AIR) pump.

Scheme 370

1. Remove coolant hose - 1 - from radiator and right coolant pipe - 2 -.
2. Lay coolant hose on lock carrier.

Scheme 371

1. Disconnect vacuum hose - 1 -.
2. Disconnect coolant hose - 2 -.
3. Remove power steering hydraulic hose - 3 -.

Scheme 372

1. Disconnect electrical harness connector - arrow - to Brake System Vacuum Pump V192.
2. Free up electrical wiring.

Note. To improve clarity, the illustration is shown with headlamp removed.

Scheme 373

1. Remove coolant hose - 2 - from coolant reservoir.
2. Remove coolant reservoir - arrow - and disconnect electrical connector on Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir.
3. Lay aside coolant reservoir with connected coolant hoses - 1 and 3 -.

Scheme 374

1. Remove vacuum hoses - 1 and 2 - from T-piece on bulkhead.

Scheme 375

1. Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.

Scheme 376

1. Pry out cover caps on windshield wiper arms with a screwdriver and loosen nuts - arrows - a few turns.
2. Loosen wiper arms by tilting slightly from windshield wiper axle.
3. Remove nuts completely and remove wiper arms.

Note. If wiper arms cannot be removed in this way, use a standard puller.

Scheme 377

1. Remove bolts - arrows - and remove cowl grille - 1 - from windshield.

Scheme 378

1. If vehicle is equipped with dome braces, remove bolts - 1 and 3 - and remove dome braces - 2 -.

Scheme 379

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

Scheme 380

1. Release retaining tabs and pull fuse holder - 1 - and 3-socket relay carrier - 4 - upward and off.
2. Remove electrical wire connection - 3 -.
3. Disconnect all electrical connections - 2 - at rear on connector strip.
4. Disengage and free up engine wiring harness at E-Box.

Scheme 381

1. Disconnect electrical harness connector - arrow - at Brake Booster Pressure Sensor G294.

Scheme 382

1. Disconnect vacuum line - arrow - to brake booster at bulkhead.

Scheme 383

1. Remove nut - 1 - and remove left electrical connectors bracket from bulkhead.
2. Remove Ground (GND) wire - arrow - from left strut tower.

Scheme 384

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

Scheme 385

1. Carefully pry off retaining clip - 3 - with a screwdriver - arrows 1 and 2 - and remove ECM from E-box.

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

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

Scheme 386

1. Release locking mechanisms - arrows - and remove relay carrier upward.

Scheme 387

1. Remove nuts - 3 - and remove right electrical connectors bracket from bulkhead.
2. Remove nut - 1 - on positive terminal pick-off.
3. Remove Ground pins - 2 -.

Scheme 388

1. Free electrical wiring up to generator using pry lever 80-200.

Note. If necessary, use silicon-free spray lubricant to facilitate removal of wiring clips.

1. Set both wiring harnesses on engine and secure Engine Control Module (ECM) against falling down.
2. Have a second technician press brake pedal.

Scheme 389

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

Scheme 390

1. Evenly remove left and right nuts - 1 -.
2. Remove left and right bolts - 2 - and remove stabilizer bar.

Scheme 391

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

Scheme 392

1. Tie up wheel bearing housing with Tension Strap T10038 as shown in illustration.

Scheme 393

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

Scheme 394

1. Remove guide control arm - 1 - and control arm - 2 - from subframe.

Scheme 395

1. Pivot guide control arm - 1 - and control arm - 2 - outward.
2. Repeat work procedure on opposite side of vehicle.
3. Remove drive axle from transmission flanged shaft.

1. Remove drive shaft.
2. Repeat work procedure on opposite side of vehicle.

Scheme 396

1. Remove front transverse beam - arrows -.

Scheme 397

1. Remove left front muffler nuts - 1 -.

Note. Ignore - 2 and 3 -.

Scheme 398

1. Remove right front muffler nuts - 1 -.

Note. Ignore - 2 -.

Scheme 399

1. Remove bolts - 1 and 2 -.

Scheme 400

1. Loosen left clamping sleeve - 1 - , slide back and remove left front muffler.
2. Loosen right clamping sleeve - 2 - , slide back and remove right front muffler.

Scheme 401

1. Remove subframe transverse beam - arrows -.

Scheme 402

1. Remove heat shield - A - for drive axle - arrows -.
2. Remove bolts that connect driveshaft to transmission.
3. Slide driveshaft back to rear final drive; constant velocity joints can move axially.

Scheme 403

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

Scheme 404

1. Remove bolts - arrows - for torque support.

Note. The torque support can be removed at a later time.

Vehicles with auxiliary heater

1. Remove left front wheelhousing liner --> «66 - EXTERIOR EQUIPMENT»(ref-281388-S35527536922008031100000) .

Scheme 405

1. Remove bolt - arrow - for corrugated exhaust pipe.

Scheme 406

1. Loosen nut - A - on clamp for corrugated exhaust pipe.
2. Remove bolt - B - and remove muffler with corrugated exhaust pipe.

Prepare scissor lift platform

Scheme 407

1. Equip Scissor Lift Table VAS 6131 with Support Set VAS 6131/10 as well as Supplementary Set VAS 6131/11 and VAS 6131/12 as follows

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

1. Note bubble level (sight glass) on support platform.

1. Drive scissor lift platform VAS 6131 under engine/transmission subassembly.

Scheme 408

1. Position support elements from VAS 6131/10 at front on engine as shown in illustration.
2. Ensure right threaded spindle at front of engine is completely installed.

Scheme 409

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

Scheme 410

1. Position support elements from VAS 6131/10 and VAS 6131/12 at left on transmission and tunnel cross member as shown in illustration.

Scheme 411

1. Position support elements from VAS 6131/10 and VAS 6131/11 at right on transmission as shown in illustration.
2. Twist all spindles of support elements upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

Scheme 412

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

Scheme 413

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

Scheme 414

1. First lower engine/transmission assembly using scissor lift platform VAS 6131 only approx. by dimension - a -.

1. Dimension - a - = 100 mm maximum.

Scheme 415

1. On a vehicle with heat shield, remove bolts - arrows - and remove selector lever cable heat shield.

Scheme 416

1. Identify installation position of selector lever cable bracket with a felt-tip pen for re-installation.
2. Press ball socket - 1 - of selector lever cable from selector shaft lever using pry lever 80 - 200.
3. Remove mounting bracket - 2 - from transmission.
4. Move selector lever cable clear.

1. Remove torque support.
2. Lower engine/transmission subassembly downward.
3. Push scissor lift platform VAS 6131 with engine/transmission subassembly under vehicle.

Engine and transmission, separating

Special tools, testers and auxiliary items required

Scheme 417

1. Bracket 30 - 211 A
2. Adapter VAS 6131/10-12 qty. 2

Scheme 418

1. Adapter T40058

Work procedure

1. Engine/transmission assembly removed and placed on Scissor Lift Table VAS 6131.

1. Twist spindles of support elements at left and right at subframe completely downward.
2. Remove both base plates of subframe support elements from Scissor Lift Table VAS 6131.
3. Remove subframe to side.

Note. The support points for front of engine and transmission remain unchanged.

Scheme 419

1. Remove lower engine-transmission connecting bolts - arrows -.

1. Equip Scissor Lift Table VAS 6131 with Support Set VAS 6131/10 as well as Supplementary Set VAS 6131/11 and VAS 6131/12 as follows

Scheme 420

1. Position support elements from VAS 6131/10 and VAS 6131/12 at left on engine as shown in illustration.

Scheme 421

1. Position support elements from VAS 6131/10 and VAS 6131/12 at right on engine as shown in illustration.
2. Twist spindles of attachments upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

1. Remove bolt - 2 - at left catalytic converter bracket.

Note. Ignore - 1 and 3 -.

1. Remove bolt - 2 - at right catalytic converter bracket.

Note. Ignore - 1 -.

Scheme 422

1. Remove electrical harness connectors from bracket and disconnect it

1. For Heated Oxygen Sensor (HO2S) G39
2. For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130

1. Free up electrical wires to oxygen sensors.

Note. The illustration shows electrical connectors in installation positions.

Scheme 423

1. Remove bolts - 2 and 4 - and place secondary air injection air guide pipe upward.
2. Remove bolts - 1 and 3 - and remove right coolant pipe from coolant hoses - arrows -.

Scheme 424

1. Remove nuts - 6 through 1 - and remove right exhaust manifold with catalytic converter.

Scheme 425

1. Remove electrical harness connectors from bracket and disconnect it

1. For Heated Oxygen Sensor (HO2S) 2 G108
2. For Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

1. Free up electrical wires to oxygen sensors.

Note. The illustration shows electrical connectors in installation positions.

Scheme 426

1. Remove oil dipstick guide tube bolt - 1 - and remove guide tube upward.
2. Remove bolts - 2, 3, 4 - and remove left coolant pipe from coolant hoses - arrows -.

Scheme 427

1. Remove nuts - 6 through 1 - and remove left exhaust manifold with catalytic converter.

Scheme 428

1. Disconnect electrical connector - arrow - on Engine Speed (RPM) Sensor G28.

1. To discharge static electricity, touch transmission housing with hand (without wearing gloves).

Scheme 429

1. Disconnect electrical connector on transmission by turning twist lock counter-clockwise - arrow -.
2. Free up wiring harness.

Scheme 430

1. Remove nut - 1 - and bolt - 2 - for ATF lines.

Note. To prevent dirt and moisture from entering, seal off open lines and connections with clean plugs or protective caps.

Scheme 431

1. Disconnect electrical connector - 1 - and free up electrical wiring on engine mount plate.
2. Remove bolts - arrows - and remove engine support with engine mount.

Scheme 432

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

Scheme 433

1. Insert guide pin of adapter T40058 so that small diameter - arrow 2 - points to engine. Large diameter - arrow 1 - points to socket.

Scheme 434

1. To loosen torque converter bolts, counter-hold crankshaft using adapter T40058.

Note. Disregard - arrow -.

Scheme 435

1. Remove 3 torque converter bolts - arrow - in opening on removed starter (turn crankshaft 1 / 3 rotation in each case).

Scheme 436

1. Remove engine-transmission connecting bolts - 3 through 7 -.

Note. Ignore - A -.

Scheme 437

1. Loosen side clamping screws - 1 - on scissor lift platform VAS 6131 and pull rear platform top with transmission toward rear - arrow - , simultaneously push torque converter off drive plate through opening for removed starter.

Scheme 438

1. Secure torque converter in transmission with Bracket 30 - 211 A to prevent it from falling down.

Scheme 439

Special tools, testers and auxiliary items required

1. Lifting tackle 3033
2. Engine and transmission holder VAS 6095 with bracket VAS 6095/1-6A
3. Shop crane VAS 6100

Special tools, testers and auxiliary items required

Scheme 440

1. Lift arm extension for workshop crane VAS 6101

Work procedure

Scheme 441

1. Disconnect electrical harness connector - arrow - at left engine mount.
2. Remove bolts - 1, 2, 3 - and remove engine support from engine mount.

Scheme 442

1. Engage Lifting Tackle 3033 on engine lifting eyes and on Shop Crane VAS 6100 with Lift Arm Ext./Workshop Hoist VAS 6101 as shown in the illustration.
2. Lift engine from support elements of Scissor Lift Table VAS 6131.

Scheme 443

1. Secure engine using bracket VAS 6095/1-6A on Engine and Transmission Holder VAS 6095 as shown in illustration.

Engine, installing

Torque specifications

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

Tightening torques --> Assembly mount, overview , --> Crankshaft, assembly overview .

Securing engine to transmission

Work procedure

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque. Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings. Only replace torque converter bolts with original bolts . Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location.

1. Check whether alignment sleeves for centering engine and transmission in cylinder block are present, insert missing alignment sleeves.

Scheme 444

When torque converter is installed correctly, distance - a - between contact surface of threaded holes at torque converter and contact surface of bell housing on Automatic Transmission 09E is at least 19 mm.

1. Before guiding engine and transmission together, rotate torque converter and drive plate so that holes and threaded holes are same height as opening on removed starter - arrow -.

1. Install ATF lines --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .

Scheme 445

1. Before installing an exchanged engine, check whether O-ring - arrow - is inserted in power steering pump input shaft.
2. Install starter --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment) .
3. Install right engine support --> «Right engine mount, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-engine-mount-removing-and-installing) .
4. Install exhaust manifold: Left --> «Left exhaust manifold with catalytic converter, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-exhaust-manifold-with-catalytic-converter) , right --> «Right exhaust manifold with catalytic converter, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-exhaust-manifold-with-catalytic-converter) .

1. Install left coolant pipe --> «Left coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Place oil dipstick guide tube in hole on upper part of oil pan.
3. Install right coolant pipe --> «Right coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-coolant-pipe-removing-and-installing) .
4. Install secondary air injection air guide pipe --> «Secondary air injection (AIR) system, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

1. Always clean threaded driveshaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.

1. Turn spindle of left rear support element on engine downward.
2. Remove left rear support element base plate from Scissor Lift Table VAS 6131.

1. Turn spindle of right rear support element on engine downward.
2. Remove right rear support element base plate from Scissor Lift Table VAS 6131.

Note. The support points for front of engine and transmission remain unchanged.

1. Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 as follows

1. Position subframe on both attachments VAS 6131/10-8.
2. Twist spindles of support elements upward on both sides.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.
4. Using Scissor Lift Platform VAS 6131 , slowly guide engine/transmission unit with subframe into body from below.

1. Lift engine/transmission subassembly using scissor lift platform VAS 6131 until dimension - a - is reached.

1. Dimension - a - = at least 100 mm.

1. Install selector lever cable and check adjustment --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
2. Bring torque support into installation position.
3. Raise engine/transmission assembly with subframe further using Scissor Lift Table VAS 6131.

Scheme 446

1. Align subframe and engine mount plates according to markings applied on longmembers during removal.
2. Tighten subframe and engine mount plate bolts only to specified torque, do not tighten further (only tighten bolts after axle alignment) --> «40 - FRONT SUSPENSION»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

1. Tighten bolts - arrows - on tunnel cross member --> «40 - FRONT SUSPENSION»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

The rest of installation is in reverse order of removal, note the following

1. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
2. Install guide control arm, control arm, stabilizer bar, connecting link, suspension strut and subframe crossmember --> «40 - FRONT SUSPENSION»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering)
3. On a vehicle with auxiliary heater, install muffler with corrugated exhaust pipe --> «87 - AIR CONDITIONING»(/audi/a6/c6-2008-2011/remont/ac-compressor/#heating-air-conditioning) .
4. Install drive shaft --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(ref-281377-S22368671332008031100000) .

1. Install front muffler: left --> «Left front muffler, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-front-muffler-removing-and-installing) , right --> «Right front muffler, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-front-muffler-removing-and-installing) .
2. Align exhaust system free of tension --> «Exhaust system, installing free of tension»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__exhaust-system-installing-free-of-tension) .
3. Install refrigerant lines --> «87 - AIR CONDITIONING»(/audi/a6/c6-2008-2011/remont/ac-compressor/#heating-air-conditioning) .
4. Install ATF lines --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .

1. Install power steering pump hydraulic hose --> «48 - STEERING»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
2. Install torque support --> «Assembly mount, overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
3. Install air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
4. Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component Locations , tightening torques --> «97 - WIRES»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment) .

1. Observe safety precautions after connecting battery --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment) .

1. Install dome brace --> «40 - FRONT SUSPENSION»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
2. Install wiper arms and adjust --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment) .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .
4. Before starting engine for the first time, fill power steering vacuum reservoir with hydraulic oil --> «48 - STEERING»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

Note. Power-steering pump must not run dry.

1. Fill with coolant «Filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__filling) .

Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant must not be re-used.

1. Fill refrigerant circuit Refrigerant R134a - Servicing.
2. Align subframe and both engine mount plates --> «40 - FRONT SUSPENSION»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
3. Perform axle alignment --> «44 - WHEELS, TIRES, WHEEL ALIGNMENT»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

1. Check ATF level --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .

Scheme 447

1 - Torque support stop

1. Must contact torque support buffer at top and bottom without play

2 - Bolt

1. 40 Nm

3 - Torque bracket

1. Removing and installing --> «Torque support, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__torque-support-removing-and-installing)

4 - Nut

1. 40 Nm

5 - Bolt

1. 75 Nm

6 - Right engine mount plate

1. Removing and installing --> «Right engine mount, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-engine-mount-removing-and-installing)

7 - Engine mount, right

1. Removing and installing --> «Right engine mount, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-engine-mount-removing-and-installing)

8 - Bolt

1. 40 Nm

9 - Nut

1. 40 Nm

10 - Right engine support

1. Removing and installing --> «Right engine mount, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-engine-mount-removing-and-installing)

11 - Left engine support

1. Removing and installing --> «Left engine mount, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-engine-mount-removing-and-installing)

12 - Nut

1. 40 Nm

13 - Engine mount, left

1. Removing and installing --> «Left engine mount, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-engine-mount-removing-and-installing)

14 - Left engine mount console

1. Removing and installing --> «Left engine mount, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-engine-mount-removing-and-installing)

15 - Bolt

1. 75 Nm

16 - Nut

1. 40 Nm

17 - Bolt

1. 40 Nm

18 - Bolt

1. 40 Nm

Left engine mount, removing and installing

Special tools, testers and auxiliary items required

Scheme 448

1. Engine support bridge 10 - 222 A

Scheme 449

1. Engine Support Basic Set T40091

Scheme 450

1. Engine Support Supplement Set T40093

Removing

Note. During installation, all cable ties must be re-installed at the same location.

1. Pull rear engine cover - arrows - off.

1. Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.

Scheme 451

1. Secure Adapter 10 - 222 A/4 with connector T40091/3 and supports T40093/1 and T40093/2 to suspension strut towers.

1. Support for left and right side of vehicle is marked.

Scheme 452

1. Install additional Engine Support Bridge 10 - 222 A parts as shown in illustration. Position supports T40093/3 on long member notches.
2. Engage Hook 10 - 222 A/10 in left engine lifting eye.
3. Tension engine with spindle.

1. Remove sound insulation by loosening securing pieces - 1, 2, arrow -.

Vehicles with auxiliary heater

1. Remove left front wheel.
2. Remove left front wheelhousing liner --> «66 - EXTERIOR EQUIPMENT»(ref-281388-S35527536922008031100000) .

1. Remove bolt - arrow - for corrugated exhaust pipe.

1. Loosen nut - A - on clamp for corrugated exhaust pipe.
2. Remove bolt - B - and remove muffler with corrugated exhaust pipe.

All

Scheme 453

1. Remove bolts - 1 and 2 - for left and right stabilizer bar mount.
2. Slightly lower stabilizer bar.

Scheme 454

1. Remove nut - 3 -.
2. Remove bolts - 1 and 2 - and remove left engine mount plate.

1. Disconnect electrical harness connector - arrow - at left engine mount.
2. Remove bolts - 1, 2, 3 - and remove engine support from engine mount.

Scheme 455

1. Remove nut - arrow - and remove engine mount from engine support.

Installing

1. Tightening torques --> «Assembly mount, overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque. During installation, all cable ties must be re-installed at the same location.

1. Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .
2. On a vehicle with auxiliary heater, install muffler with corrugated exhaust pipe --> «87 - AIR CONDITIONING»(/audi/a6/c6-2008-2011/remont/ac-compressor/#heating-air-conditioning) .

Right engine mount, removing and installing

Special tools, testers and auxiliary items required

1. Engine support bridge 10 - 222 A

1. Engine Support Basic Set T40091

1. Engine Support Supplement Set T40093

Removing

Note. During installation, all cable ties must be re-installed at the same location.

1. Pull rear engine cover - arrows - off.

1. Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.

1. Remove bolts - arrows -.
2. Remove air duct - 1 and 2 -.

1. Free up fuel line and line to EVAP canister on air filter housing.
2. Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70.
3. Remove air guide pipe from air filter housing by loosening hose clamps - 5 - and opening clips - arrows -.

Note. Ignore items - 2, 3, 4 -.

1. Open clips - arrows - and remove upper part of air filter housing.

1. Disconnect vacuum line - 1 -.
2. Remove pin from spreader clips - 4 -.
3. Remove lower part of air filter housing and, on the backside, separate electrical connection - 2 - at intake air switch-over valve N335.
4. Remove secondary air injection air guide hose - 3 - by pressing release buttons.

1. Secure Adapter 10 - 222 A/4 with connector T40091/3 and supports T40093/1 and T40093/2 to suspension strut towers.

1. Support for left and right side of vehicle is marked.

Scheme 456

1. Install additional Engine Support Bridge 10 - 222 A parts as shown in illustration. Position supports T40093/3 on long member notches.
2. Engage Hook 10 - 222 A/10 in left engine lifting eye.
3. Tension engine with spindle.
4. Remove right front wheel.

1. Remove sound insulation by loosening securing pieces - 1, 2, arrow -.

1. Remove bolts - 1 and 2 - for left and right stabilizer bar mount.
2. Slightly lower stabilizer bar.

1. Free up electrical wires on right engine mount plate.
2. Remove nut - 3 -.
3. Remove bolts - 1 and 2 - and remove right engine mount plate.

1. Disconnect electrical harness connector - 1 - at right engine mount.
2. Remove bolts - arrows - and remove engine support with engine mount.

1. Remove nut - arrow - and remove engine mount from engine support.

Installing

1. Tightening torques --> «Assembly mount, overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque. During installation, all cable ties must be re-installed at the same location.

1. Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

Torque support, removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop crane VAS 6208

Removing

1. Drain coolant --> «Cooling system, draining and filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

1. Remove bolts - arrows - for torque support.

Scheme 457

1. Place drip tray for workshop crane VAS 6208 under engine.
2. Remove bolts - arrows -.
3. Remove front coolant pipe from engine and from coolant pump.
4. Remove torque support.

Installing

1. Tightening torques --> «Coolant pipes, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque. Replace O-rings.

1. Bring torque support into installation position.
2. Install front coolant pipe --> «Front coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__front-coolant-line-removing-and-installing) .

Scheme 458

1. Position torque support stop so that rubber buffer contacts top and bottom without play and tightening bolts - arrows -.
2. Fill with coolant «Filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__filling) .

Scheme 459

1 - Bolt

1. 22 Nm

2 - Bolt

1. 55 Nm

3 - Tensioning device for ribbed belt

1. Removing and installing --> «Ribbed belt tensioner, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__ribbed-belt-tensioner-removing-and-installing)

4 - Ribbed belt

1. Check for wear
2. Do not kink

1. Removing and installing --> «Ribbed belt, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__ribbed-belt-removing-and-installing)
2. When installing, make sure it is seated correctly on pulleys

5 - Cover cap

6 - Bolt

1. 22 Nm

7 - Generator

1. Removing and installing --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment)

8 - Bolt

1. M8: 22 Nm
2. M10: 46 Nm

9 - Alignment bushing

1. For generator bracket
2. 2 pieces

10 - Generator bracket

11 - Bolt

1. 9 Nm

12 - Bracket

1. For idler pulley

13 - Idler roller for ribbed belt

14 - Bolt

1. 22 Nm

15 - Vibration damper

1. Removing and installing --> «Vibration damper, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__vibration-damper-removing-and-installing)

16 - Bolt

1. Replace
2. Tightening order «Vibration damper tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

17 - Alignment bushing

1. 2 pieces

18 - Bracket

1. For ribbed belt tensioner

19 - Bolt

1. Different lengths
2. 9 Nm

Scheme 460

1. Tighten bolts - arrow - in diagonal sequence in 3 stages as follows
2. Tighten bolts to 15 Nm.
3. Tighten bolts to 22 Nm.
4. Tighten an additional 90° ( 1 / 4 turn).

Ribbed belt, removing and installing

Removing

1. Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.

Scheme 461

1. Remove electrical harness connector - 2 - from bracket and disconnect it.
2. Release retaining clip - arrow - and lay aside Coolant Fan Control (FC) Control Module J293 - 1 -.

Scheme 462

1. Pivot tensioning device in direction of - arrow - to relieve tension on ribbed belt.
2. Remove ribbed belt and release tensioning device.

Installing

Installation is in reverse order of removal, note the following

Scheme 463

1. Route ribbed belt - 2 - over belt pulley in specified sequence.

1 - Generator

3 - Idler roller

4 - Vibration damper

5 - Tensioning roller

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

1. Start engine and check running belt.

Ribbed belt tensioner, removing and installing

Removing

1. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__ribbed-belt-removing-and-installing)

Scheme 464

1. Remove bolts - arrows -.
2. Remove ribbed belt tensioner from upper part of oil pan.

Installing

1. Tightening torque --> «Ribbed belt drive, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal.

Vibration damper, removing and installing

Removing

1. Bring lock carrier into service position --> «50 - BODY - FRONT»(ref-281388-S12064564912008031100000) .

1. Loosen 8 vibration damper bolts - arrow - several turns while counter holding at generator ribbed belt pulley center nut with an open-end wrench.
2. Remove ribbed belt --> «Ribbed belt, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__ribbed-belt-removing-and-installing)
3. Remove bolts - arrows - and remove vibration damper.

Installing

1. Tightening torque «Vibration damper tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque. Secure all hose connections using hose clamps appropriate for the model type . Installation of vibration damper is only possible in one position - note alignment bushing.

1. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__ribbed-belt-removing-and-installing) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(ref-281388-S12064564912008031100000) .

Crankshaft seal, ribbed belt side, replacing

Special tools, testers and auxiliary items required

Scheme 465

1. Seal remover T40019

Scheme 466

1. Assembly tool T40048

Work procedure

1. Bring lock carrier into service position --> «50 - BODY - FRONT»(ref-281388-S12064564912008031100000) .
2. Remove vibration damper --> «Vibration damper, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__vibration-damper-removing-and-installing) .

Scheme 467

1. Position inner part of Oil Seal Extractor T40019 flush with outer part and secure inner part with knurled thumb screw.
2. Lubricate threaded head of seal remover, place against seal, and with strong force install into seal as far as possible.
3. Loosen knurled screw and turn inner portion against crankshaft until oil seal is pulled out.
4. Clamp seal extractor at mounting points in a vise.

1. Remove seal using pliers.
2. Clean operating and sealing surfaces.

Scheme 468

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

Scheme 469

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

Note. Pull sleeve remains on crankshaft for pressing in.

Scheme 470

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

The rest of installation is in reverse order of removal, note the following

Note. Secure all hose connections using hose clamps appropriate for the model type .

1. Install vibration damper --> «Vibration damper, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__vibration-damper-removing-and-installing) .
2. Install ribbed belt --> «Ribbed belt, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__ribbed-belt-removing-and-installing) .
3. Install lock carrier with attachments --> «50 - BODY - FRONT»(ref-281388-S12064564912008031100000) .

Cylinder block, transmission side

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

Scheme 471

1 - Drive plate

1. Removing and installing --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing)
2. Mark for re-installation

2 - Bolt

1. Replace
2. 60 Nm plus an additional 90° ( 1 / 4 turn).

3 - Shim

1. Mark for re-installation

4 - Transmission-side crankshaft sealing ring

1. Replacing --> «Transmission-side crankshaft sealing ring, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__transmission-side-crankshaft-sealing-ring-replacing) .

5 - Crankshaft

Drive plate, removing and installing

Special tools, testers and auxiliary items required

Scheme 472

1. Counter-holder tool 10 - 201

Removing

1. Engine or transmission removed.

Scheme 473

1. Insert counter-hold tool 10 - 201 to loosen bolts.
2. Identify position of drive plate to crankshaft with a felt-tip pen for reinstallation.
3. Remove drive plate.
4. Remove shim from behind it.

Installing

1. Tightening torque --> «Drive plate, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

1. Install drive plate with shim.
2. Turn over counter-hold tool 10 - 201 to tighten bolts.

Transmission-side crankshaft sealing ring, replacing

Special tools, testers and auxiliary items required

Scheme 474

1. Pulling fixture T10122

Scheme 475

1. Extractor hook T20143

Work procedure

1. Engine or transmission removed.

1. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

Scheme 476

1. Pry out sealing ring using pulling hook T20143/2.
2. Clean operating and sealing surfaces.

Scheme 477

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

Scheme 478

1. Install pull sleeve T10122/2 with seal - 1 - on crankshaft.

Scheme 479

1. Press seal evenly and flush all around with thrust piece T10122/3.

The rest of installation is in reverse order of removal, note the following

1. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

Crankshaft

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

Scheme 480

1 - Cylinder block

1. Paired to - 12
2. Sealant applied on cylinder block (for guide frame) «Sealant applied on cylinder block (for guide frame)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

2 - Seals

1. Replace

3 - Crankshaft seal, ribbed belt side

1. Replacing --> «Crankshaft seal, ribbed belt side, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__crankshaft-seal-ribbed-belt-side-replacing) .

4 - Alignment bushing

1. 2 pieces
2. Insert into guide frame
3. Installed location «Sealant applied on cylinder block (for guide frame)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

5 - Bolt

1. 9 Nm

6 - Guide tube for oil dipstick

7 - O-ring

1. Replace

8 - Bolts

1. For guide frame
2. Replace
3. Various bolt sizes
4. Tightening order «Guide frame tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

9 - Baffle plate

10 - Bolt

1. Tightening order «Baffle plate tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

11 - Bolt

1. For guide frame to cylinder block sealing surfaces
2. Different bolt lengths
3. Tightening order «Guide frame tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

12 - Bearing bracket

1. Paired to - 1
2. Sealant applied on cylinder block (for guide frame) «Sealant applied on cylinder block (for guide frame)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
3. Bolt tightening sequence «Guide frame tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

13 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Note locating point in guide frame
4. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__axial-clearance-measuring)

14 - Bearing shell

1. For guide frame without lubricating groove
2. Mark used bearing shells
3. Insert new bearing shells for guide frame with proper color marking: New crankshafts --> «Allocation of main bearing shells for new crankshafts»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) , used and reworked crankshafts --> «Allocation of main bearing shells for used and reworked crankshafts»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__allocation-of-main-bearing-shells-for)

15 - Crankshaft

1. Measuring axial play --> «Axial clearance, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__axial-clearance-measuring)
2. Radial clearance, measuring --> «Radial clearance, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__radial-clearance-measuring)
3. Do not turn crankshaft when measuring radial play
4. Crankshaft dimensions --> «Crankshaft dimensions»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__crankshaft-dimensions)

16 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Measuring crankshaft axial clearance --> «Axial clearance, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__axial-clearance-measuring)

17 - Bearing shell

1. For cylinder block with oil groove
2. Mark used bearing shells
3. Insert new bearing shells for cylinder block with proper color marking: New crankshafts --> «Allocation of main bearing shells for new crankshafts»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) , used and reworked crankshafts --> «Allocation of main bearing shells for used and reworked crankshafts»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__allocation-of-main-bearing-shells-for)

18 - Seals

1. Replace

Scheme 481

1. Tighten bolts - 1 to 16 - in sequence.

1. 9 Nm

Scheme 482

1. Clean sealing surfaces so they are completely free of any oil or grease.
2. Apply sealant beads - arrows - to clean sealing surfaces as shown in illustration.

1. Thickness of sealant beads: 2.0 mm.

1. Install seals - 1 to 4 -.

Scheme 483

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

Scheme 484

1. Replace bolts - 1 to 20 -.
2. Tighten bolts in 7 stages as follows
3. Tighten bolts - 1 to 10 - to 30 Nm.
4. Tighten bolts - 11 to 20 - to 20 Nm.

1. Tighten bolts - 1 to 10 - to 50 Nm.
2. Tighten bolts - 11 to 20 - to 30 Nm.
3. Tighten bolts - 1 to 10 - an additional 90° ( 1 / 4 turn).
4. Tighten bolts - 11 to 20 - an additional 90° ( 1 / 4 turn).

1. Tighten guide frame to cylinder block sealing surface bolts, - highlighted in illustration but not numbered - , in a diagonal sequence to 9 Nm.

Scheme 485

Allocation of crankshaft bearing shells for cylinder block

1. Bearing shells with correct thickness are allocated to cylinder block in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to cylinder block is marked by one letter each at left front on cylinder block (can be read from outside) as shown in the illustration.

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

Scheme 486

Allocation of crankshaft bearing shells for guide frame - Version I

1. Bearing shells with correct thickness are allocated to guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to guide frame is marked by one colored dot each on crankshaft counterweight as shown in the illustration.

Scheme 487

Allocation of crankshaft bearing shells for guide frame - Version II

1. Bearing shells with correct thickness are allocated to guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. The allocation of bearing shells to guide frame is identified by a letter on the front crankshaft counterweight, as shown in the illustration. The "X" marks the end of the letter sequence and is near bearing 1 color identification on belt pulley side.

Note. Ignore - A -.

Allocation of main bearing shells for used and reworked crankshafts

Allocation of crankshaft bearing shells for cylinder block

1. Bearing shells are allocated to cylinder block corresponding to color markings stamped into cylinder block.
2. For used and reworked crankshafts, the main crankshaft journals must be measured in order to allocate the matching bearing shells.
3. Crankshaft dimensions --> «Crankshaft dimensions»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__crankshaft-dimensions) .
4. Thicker over-sized bearing shells are available for reworked crankshafts. These have the same color markings as the original-size bearing shells.

Allocation of crankshaft bearing shells for guide frame

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

Crankshaft dimensions

Axial clearance, measuring

Special tools, testers and auxiliary items required

Scheme 488

1. Dial gauge holder VW 387

Scheme 489

1. Dial gauge VAS 6079

Work procedure

Scheme 490

1. Secure Dial Gauge VAS 6079 with Dial Gauge Holder VW 387 to cylinder block as shown in illustration.
2. Position dial gauge against crankshaft counterweight.
3. Press crankshaft by hand against gauge and set gauge to "0".
4. Press crankshaft off gauge and read value.

1. Axial clearance: 0.090 to 0.251 mm.

Radial clearance, measuring

Special tools, testers and auxiliary items required

1. Plastigage

Work procedure

Note. Identify used bearing for reinstallation. If the bearing shells are worn down to the nickel layer, they must be replaced.

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

1. Plastigage must rest in center of bearing shell.

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

Radial clearance

1. New: 0.017 to 0.044 mm.
2. Wear limit: 0.08 mm.

Piston and connecting rod, assembly overview

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

Scheme 491

1 - Bolt

1. Replace
2. Lubricate threads and contact surface
3. 60 Nm plus an additional 90° ( 1 / 4 turn).
4. Tighten to 60 Nm to measure radial play, do not turn further

2 - Connecting rod bearing cap

1. Mark for re-installation
2. Mark affiliation to cylinder with paint «Mark connecting rod»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
3. Installation position of connecting rod pairs «Connecting rod, installed location»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

3 - Bearing shells

1. Check that retaining tabs are secured
2. Mark used bearing shells for reinstallation but not on running surface
3. Radial clearance, measuring --> «Radial clearance of connecting rod, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__radial-clearance-of-connecting-rod-measuring)
4. Over-sized bearings are available for reworked crankshaft connecting rod journals

4 - Connecting rod

1. Only replace as set
2. Mark affiliation to cylinder with paint «Mark connecting rod»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
3. Installation position of connecting rod pairs «Connecting rod, installed location»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
4. Axial play for each new connecting rod pair: 0.20 to 0.27 mm

1. Axial play wear limit: 0.30 mm
2. Radial clearance, measuring --> «Radial clearance of connecting rod, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__radial-clearance-of-connecting-rod-measuring)

5 - Piston pin

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

6 - Circlip

7 - Piston

1. Installation position of pistons «Piston installation position»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
2. Piston and cylinder dimensions --> «Piston and cylinder dimensions»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__piston-and-cylinder-dimensions)
3. Checking «Checking piston»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
4. Install with piston ring compressor

1. Measuring cylinder bore «Measuring cylinder bore»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

8 - Piston rings

1. Offset gaps by 120°
2. Use piston ring pliers for removal and installation
3. "TOP" marking or inscribed side must point to piston head
4. Gap, measuring «Piston ring end gap, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

1. Measuring side clearance «Measuring piston ring side clearance»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Scheme 492

1. Slide piston ring down from above at a right angle to cylinder wall until it is approx. 15 mm from bottom edge of cylinder.
2. When sliding in, use a piston without piston rings.

Scheme 493

1. Clean ring groove of piston before checking.

Scheme 494

1. Measure approx. 15 mm from the lower edge, at a 90° angle to piston pin axis using an external micrometer 75 to 100 mm.

1. Maximum deviation from nominal dimension: 0.03 mm.

Nominal dimension --> Piston and cylinder dimensions .

Scheme 495

1. Using an internal dial gauge 50 to 100 mm, measure at 3 points in diagonal sequence horizontally - A - and vertically - B -.

1. Maximum deviation from nominal dimension: 0.08 mm.

Nominal dimension --> Piston and cylinder dimensions .

Scheme 496

1. Mark allocation to cylinder with pen on piston crown for reinstallation.

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

Installed location

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

Scheme 497

Note. Only replace connecting rod as a set.

1. Mark connecting rod and connecting rod bearing cap to each other and to cylinder - arrow - with pen for reinstallation.

Scheme 498

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

Scheme 499

1. Oil spray jet
2. Bolts, 9 Nm. Insert with locking compound

Note. Do not bend piston spray nozzles. Bend piston spray nozzles must be replaced.

Piston and cylinder dimensions

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

Radial clearance of connecting rod, measuring

Special tools, testers and auxiliary items required

1. Plastigage

Work procedure

1. Remove connecting rod bearing caps.
2. Clean bearing caps and journals.
3. Place Plastigage over entire width of bearing journal or into bearing shells.
4. Install connecting rod bearing cap and tighten to 60 Nm. Do not turn crankshaft.

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

Radial clearance

1. New: 0.020 to 0.069 mm.
2. Wear limit: 0.120 mm.

1. Replace connecting rod bolts.

Cylinder head, assembly overview

Note. Cylinder head for cylinder bank 2 (left) is shown in illustration.

Scheme 500

1 - Cylinder head gasket

1. Replacing --> «Cylinder head, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Installed location: Part Number, points to cylinder head
3. After replacing, change engine oil and coolant

2 - Cylinder head

1. Removing and installing --> «Cylinder head, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
2. Check for distortion «Checking cylinder head for distortion»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
3. Reworking dimension «Reworking dimension, cylinder head»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
4. After replacing, change engine oil and coolant

3 - Cylinder head cover gasket

1. Replace if damaged or leaking

4 - Cylinder head cover

1. Removing and installing: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and)

5 - Gasket

1. For cap
2. Replace if damaged or leaking

6 - Cap

7 - Ignition coil

1. Remove with Ignition Coil Puller T40039

8 - Bolt

1. Replace if seal is damaged
2. Left cylinder head cover tightening sequence «Left cylinder head cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
3. Right cylinder head cover tightening sequence «Right cylinder head cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

9 - Valve 2 for camshaft adjustment N208

10 - Bolt

1. 2.4 Nm

11 - O-ring

1. Replace

12 - Seal

1. Replace

13 - Locking bolt

1. 35 Nm

14 - Bolt

1. 2.4 Nm

15 - Camshaft Adjustment Valve 2 (exhaust) N319

16 - O-ring

1. Replace

17 - Bolt

1. Replace
2. Observe sequence for loosening --> (Scheme 515)
3. Tightening order «Cylinder head tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Scheme 501

1. Tighten bolts - 1 to 15 - in sequence.

1. 9 Nm

Scheme 502

1. Tighten bolts - 1 to 16 - in sequence.

1. 9 Nm

Scheme 503

1. Tighten bolts in 5 stages - 1 to 5 - in sequence as follows
2. Insert bolts by hand as far as stop.
3. Tighten bolts to 30 Nm.
4. Tighten bolts to 60 Nm.

1. Tighten an additional 90° ( 1 / 4 turn).
2. Tighten an additional 90° ( 1 / 4 turn).
3. Insert bolts - arrows - with locking compound and tighten to 8 Nm; Locking compound .
4. Tighten bolts - arrows - an additional 90° ( 1 / 4 turn).

Scheme 504

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

1. Maximum permissible warpage: 0.1 mm.

Scheme 505

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

1. Minimum dimension: - a - = 139.5 mm.

Left cylinder head cover, removing and installing

Special tools, testers and auxiliary items required

Scheme 506

1. Ignition Coil Puller T40039

Removing

1. Remove coolant hose - 2 - from coolant reservoir.
2. Remove coolant reservoir - arrow - and disconnect electrical connector on Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir.
3. Lay aside coolant reservoir with connected coolant hoses - 1 and 3 -.

Scheme 507

1. Remove oil dipstick - 10 - from guide tube.
2. Remove bolts - 2 and 5 -.
3. Disconnect electrical connectors - 1, 3, 4, 6, 8, 9 - and free up wiring harness.
4. Remove crankcase ventilation hose - 7 - by pressing release buttons.

Scheme 508

1. Remove ignition coils using ignition coil puller T40039.

1. Remove left cylinder head cover bolts - 15 to 1 - in sequence.
2. Remove cylinder head cover.

Installing

1. Tightening torque «Left cylinder head cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover gaskets if damaged. Replace bolts for cylinder head cover if gasket is damaged. Secure all hose connections using hose clamps appropriate for the model type .

1. Clean sealing surfaces so they are completely free of any oil or grease.
2. Tighten cylinder head cover bolts «Left cylinder head cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Right cylinder head cover, removing and installing

Special tools, testers and auxiliary items required

1. Ignition coil puller T40039

Removing

1. Remove bolts - arrows -.
2. Remove air duct - 1 and 2 -.

1. Free up fuel line and line to EVAP canister on air filter housing and air guide pipe.
2. Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70.
3. Remove vacuum line - 3 - to air guide hose.

1. Lay aside air guide hose with connected crankcase ventilation hose - 2 - by loosening hose clamp - 4 - and opening clips - arrows -.

Note. Ignore - 5 -.

1. Open clips - arrows - and remove upper part of air filter housing.

Scheme 509

1. Remove bolts - 3 and 6 - on right cylinder head.
2. Disconnect electrical connectors - 1, 2, 4, 5, 7, 8 -.

1. Remove ignition coils using ignition coil puller T40039.

1. Remove right cylinder head cover bolts - 16 to 1 - in sequence.
2. Remove cylinder head cover.

Installing

1. Tightening torque «Right cylinder head cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover gaskets if damaged. Replace bolts for cylinder head cover if gasket is damaged. Secure all hose connections using hose clamps appropriate for the model type .

1. Clean sealing surfaces so they are completely free of any oil or grease.
2. Tighten cylinder head cover bolts «Right cylinder head cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Scheme 510

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. SW 17 socket V.A.G 1331/6
3. SW 14 socket, open ring V.A.G 1331/8
4. Multi-point socket T10070

Removing

Note. The procedure is primarily shown for left cylinder head in the following illustration. During installation, all cable ties must be re-installed at the same location.

1. Drain coolant --> «Cooling system, draining and filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Scheme 511

1. Remove knock sensor electrical connectors - 1 and 2 - from bracket.
2. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
3. Remove left coolant pipe --> «Left coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
4. Remove right coolant pipe --> «Right coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-coolant-pipe-removing-and-installing) (for right cylinder head).

1. Remove left secondary air injection combi-valve --> «Left combination valve for Secondary Air Injection, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-combination-valve-for-secondary-air) (for left cylinder head).
2. Remove right secondary air injection combi-valve --> «Right combination valve for Secondary Air Injection, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-combination-valve-for-secondary-air) .
3. Remove rear coolant pipe --> «Rear coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__rear-coolant-line-removing-and-installing) .
4. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .

1. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
2. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
3. Remove front muffler: left --> «Left front muffler, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-front-muffler-removing-and-installing) , right --> «Right front muffler, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-front-muffler-removing-and-installing) .

Left cylinder head

1. Remove left exhaust manifold nuts - 6 through 1 -.

Note. To improve clarity, the engine is shown removed. Both lower securing strips remain installed.

1. Remove bolts - 2 and 3 - and remove tab.

Note. Ignore - 1 -.

1. Remove left exhaust manifold from cylinder head stud bolts and securing strips.
2. Lay aside left exhaust manifold with catalytic converter in engine compartment.

Right cylinder head

1. Remove right nuts - 6 through 1 -.

Note. To improve clarity, the engine is shown removed. Both lower securing strips remain installed.

1. Remove bolt - 2 -.

Note. Ignore - 1 -.

1. Remove right exhaust manifold from cylinder head stud bolts and securing strips.
2. Lay aside right exhaust manifold with catalytic converter in engine compartment.

Scheme 512

Continued for both sides

1. Remove bolts - 1 and 2 - and remove affected chain tensioner.

Scheme 513

1. Disconnect electrical connectors - arrows - at fuel injectors.
2. Remove high pressure line - 2 - from connector on fuel rail.
3. Remove high pressure line - 1 - from connector on fuel rail. To do this, counter-hold at hex head with and open-end wrench and loosen union nut.

Note. Do not change bent shape of high pressure lines.

Scheme 514

1. Remove locking bolt - arrow -.

Scheme 515

1. Remove bolts - arrows -.
2. Using Socket T10070 , remove cylinder head bolts in - 1 to 10 - sequence.
3. Remove bolts and carefully remove cylinder head.
4. Lay cylinder head on a soft surface (foam).

Installing

1. Tightening torques --> «Cylinder head, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__cylinder-head-assembly-overview) , «Cylinder head tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) , --> «Camshaft timing chain, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-assembly-overview) , --> «Secondary air injection (AIR) system, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Note. Replace bolts which have been tightened to torque. Replace self-locking nuts, sealing rings, seals and O-rings. If a replacement cylinder head is installed, contact surfaces between bearing elements, roller rocker levers and cam running surfaces must be lubricated before installing cylinder head cover. Secure all hose connections using hose clamps of series-production status During installation, all cable ties must be re-installed at the same location.

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

Scheme 516

1. Camshaft Clamp T40070 must be installed on both cylinder heads and tightened to 25 Nm.

Scheme 517

1. Crankshaft holder 3242 must be installed.

Scheme 518

1. Position cylinder head gasket.

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

1. Install cylinder head.

1. Tighten cylinder head bolts «Cylinder head tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Note. Bolts must not be tightened after repairs.

1. Tighten locking bolt - arrow -.

Scheme 519

1. Check whether camshaft timing chain tensioner guide rail is secured with Locking Pin T40071.

Note. If the tensioning element was removed from the chain tensioner, note installation position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail. Disregard - arrow -.

Scheme 520

1. Clean chain tensioner oil screen - 2 -.
2. Place a new gasket - 3 - onto rear of chain tensioner - 1 -.

1. Set chain tensioner in place and install camshaft timing chain, as shown in the illustration.
2. Tighten bolts - 1 and 2 -.

The rest of installation is in reverse order of removal, note the following

1. Install exhaust manifold: Left --> «Left exhaust manifold with catalytic converter, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-exhaust-manifold-with-catalytic-converter) , right --> «Right exhaust manifold with catalytic converter, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-exhaust-manifold-with-catalytic-converter) .
2. Install front muffler: left --> «Left front muffler, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-front-muffler-removing-and-installing) , right --> «Right front muffler, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-front-muffler-removing-and-installing) .
3. Install camshaft timing chains «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
4. Install left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .

1. Install combination valve for Secondary Air Injection (AIR) system: Left --> «Left combination valve for Secondary Air Injection, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-combination-valve-for-secondary-air) , right --> «Right combination valve for Secondary Air Injection, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-combination-valve-for-secondary-air) .
2. Install rear coolant pipe --> «Rear coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__rear-coolant-line-removing-and-installing) .
3. Install left coolant pipe --> «Left coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
4. Place oil dipstick guide tube in hole on upper part of oil pan.

1. Install right coolant pipe --> «Right coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-coolant-pipe-removing-and-installing) .
2. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .
3. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Scheme 521

1. To tighten SW 14 union nut at fuel rail, use Torque Wrench V.A.G 1331 with Socket Insert AF 14, open ring V.A.G 1331/8 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Scheme 522

1. To tighten SW 17 union nut at fuel rail, use Torque Wrench V.A.G 1331 with SW 17 socket V.A.G 1331/6 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
2. Align exhaust system free of tension --> «Exhaust system, installing free of tension»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__exhaust-system-installing-free-of-tension) .
3. Change engine oil 405.
4. Change coolant --> «Cooling system, draining and filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Scheme 523

Special tools, testers and auxiliary items required

1. Spark plug removal tool 3122 B
2. Compression tester V.A.G 1763
3. Ignition Coil Puller T40039

Work procedure

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

1. Switch off ignition.
2. Remove Engine Control Module (ECM) J623 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Scheme 524

1. Only remove smaller connector - 1 - from engine control module (ECM) by removing connector lock - arrow -.

Note. The larger connector - 2 - remains connected.

1. Remove bolts - arrows -.
2. Remove air duct - 1 and 2 -.

1. Free up fuel line and line to EVAP canister on air filter housing and air guide pipe.
2. Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70.
3. Remove vacuum line - 3 - to air guide hose.

1. Lay aside air guide hose with connected crankcase ventilation hose - 2 - by loosening hose clamp - 4 - and opening clips - arrows -.

Note. Ignore - 5 -.

1. Open clips - arrows - and remove upper part of air filter housing.

1. Remove coolant reservoir - arrow - and disconnect electrical connector on Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir.
2. Lay aside coolant reservoir with connected coolant hoses - 1, 2, 3 -.

Scheme 525

1. Remove oil dipstick - 1 - from guide tube.
2. Remove bolts - 2 and 3 -.
3. Disconnect electrical harness connectors at ignition coils.
4. Press electrical wiring harness to side.

Scheme 526

1. Remove bolts - 1 and 2 -.
2. Disconnect electrical harness connectors at ignition coils.
3. Press electrical wiring harness to side.

1. Remove all ignition coils using Ignition Coil Puller T40039.
2. Remove spark plugs using Spark Plug Removal Tool 3122 B.
3. Check compression using compression tester V.A.G 1763.

Note. Using tester operating instructions.

1. Have a second technician press accelerator pedal completely and at the same time operate starter long enough until pressure increase no longer appears on tester.

Assembly is in reverse order of removal, note the following

1. Install sparks plugs 405.
2. Install Engine Control Module (ECM) J623 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Faults are saved in ECM when electrical connectors are disconnected

1. Connect Vehicle Diagnosis, testing info. system VAS 5051.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

Scheme 527

1 - Bolt

1. Tightening order «Timing chain lower cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

2 - Transmission-side crankshaft sealing ring

1. Replacing --> «Transmission-side crankshaft sealing ring, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__transmission-side-crankshaft-sealing-ring-replacing) .

3 - Alignment bushing

1. 2 pieces

4 - Left cylinder head gasket

5 - Bolt

1. Tightening order «Left timing chain cover, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

6 - Left timing chain cover

1. Removing and installing --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers)
2. Tightening order «Left timing chain cover, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

7 - O-ring

1. Replace

8 - Left coolant intermediate pipe

1. Drive out with drift

9 - O-ring

1. Replace

10 - Bolt

1. Tightening order «Right timing chain cover, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

11 - Right timing chain cover

1. Removing and installing --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers)
2. Tightening order «Right timing chain cover, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

12 - O-ring

1. Replace

13 - Right coolant intermediate pipe

1. Drive out with drift

14 - O-ring

1. Replace

15 - Right cylinder head gasket

16 - Alignment bushing

1. 2 pieces

17 - Lower timing chain cover

1. Removing and installing --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and)
2. Tightening order «Timing chain lower cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Scheme 528

1. Tighten bolts in - 1 to 8 - sequence.

1. 9 Nm

Scheme 529

1. Tighten bolts in - 1 to 8 - sequence.

1. 9 Nm

Scheme 530

1. Replace M6 bolts - 1, 3, 5, 6, 7, 11, 12, 13 - and - arrows -.
2. Tighten bolts in 6 stages as follows
3. Insert bolts - arrows - with locking compound and pre-tighten to 5 Nm.
4. Tighten bolts - 1 to 13 - in diagonal sequence to 8 Nm.

1. Tighten bolts - arrows - to 8 Nm.
2. Tighten M8 bolts - 2, 4, 8, 9, 10 - in a diagonal sequence to 22 Nm.
3. Turn M6 bolts - 1, 3, 5, 6, 7, 11, 12, 13 - an additional 90° ( 1 / 4 turn) in a diagonal sequence.
4. Tighten bolts - arrows - an additional 90° ( 1 / 4 turn).

Left and right timing chain covers, removing and installing

Special tools, testers and auxiliary items required

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

Removing

Note. During installation, all cable ties must be re-installed at the same location.

1. Pull rear engine cover - arrows - off.
2. Drain coolant --> «Cooling system, draining and filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
3. Remove left coolant pipe --> «Left coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
4. Remove right coolant pipe --> «Right coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-coolant-pipe-removing-and-installing) .

1. Remove oxygen sensors G39 and G108 (in front of catalytic converter) --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
2. Remove secondary air injection combi-valve: left --> «Left combination valve for Secondary Air Injection, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-combination-valve-for-secondary-air) , right --> «Right combination valve for Secondary Air Injection, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-combination-valve-for-secondary-air) .
3. Remove rear coolant pipe --> «Rear coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__rear-coolant-line-removing-and-installing) .

1. Remove bolts - 1 to 8 - and remove left timing chain cover.

1. Remove bolts - 1 to 8 - and remove right timing chain cover.

Installing

1. Tightening torques «Left timing chain cover, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) , «Right timing chain cover, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Note. Replace M6 bolts and O-rings. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location.

Scheme 531

1. Remove sealant residue on timing chain covers and cylinder head, e.g. with a rotating plastic brush.
2. Clean sealing surfaces so they are completely free of any oil or grease.

Scheme 532

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Scheme 533

1. Drive left coolant intermediate pipe - 2 - out of timing chain cover with a drift.
2. Replace O-rings - 1 - at coolant intermediate pipe - 2 -.
3. Insert coolant intermediate pipe in left timing chain cover.
4. Apply sealant bead - arrows - on clean sealing surfaces of left timing chain cover, as shown in illustration.

1. Thickness of sealant bead: 2.5 mm.

Note. Timing chain covers must be installed within 5 minutes after applying sealant.

1. Position left timing chain cover and tighten bolts «Left timing chain cover, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

1. Drive right coolant intermediate pipe - 2 - out of right timing chain cover with a drift.
2. Replace O-rings - 1 - at coolant intermediate pipe - 2 -.
3. Insert coolant intermediate pipe in right timing chain cover.
4. Apply sealant bead - arrows - on clean sealing surfaces of right timing chain cover, as shown in illustration.

1. Thickness of sealant bead: 2.5 mm.

1. Position right timing chain cover and tighten bolts «Right timing chain cover, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

The rest of installation is in reverse order of removal, note the following

1. Install rear coolant pipe --> «Rear coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__rear-coolant-line-removing-and-installing) .
2. Install secondary air injection combination valve: Left --> «Left combination valve for Secondary Air Injection, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-combination-valve-for-secondary-air) , right --> «Right combination valve for Secondary Air Injection, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-combination-valve-for-secondary-air) .
3. Install Heated Oxygen Sensor (HO2S) G39 and Heated Oxygen Sensor (HO2S) 2 G108 --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
4. Install left coolant pipe --> «Left coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

1. Place oil dipstick guide tube in hole on upper part of oil pan.
2. Install right coolant pipe --> «Right coolant pipe, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-coolant-pipe-removing-and-installing) .
3. Fill with coolant «Filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__filling) .

Timing chain lower cover, removing and installing

Special tools, testers and auxiliary items required

Scheme 534

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

Removing

1. Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
4. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

1. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
2. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
3. Remove oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .

1. Remove bolts - arrows -.
2. Remove bolts - 1 through 13 - and remove lower timing chain cover.
3. Press transmission-side crankshaft sealing ring out of lower timing chain cover.

Installing

1. Tightening torques «Timing chain lower cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Installation is in reverse order of removal, note the following

1. Pull alignment bushing out of top right of cylinder block.

Scheme 535

1. Chamfer alignment bushing with a file, as shown in the illustration.

1. Dimension - x - = 6.5 mm.
2. Dimension - y - = 8 mm.

1. Install alignment bushing into cylinder block so that the chamfered side faces upward.

Note. Because of the chamfer, the lower timing chain cover can be positioned more easily when the cylinder head is installed.

1. Remove sealant residue on lower timing chain cover and on cylinder block and cylinder head, e.g. with a rotating plastic brush.
2. Clean sealing surfaces so they are completely free of any oil or grease.

Scheme 536

1. Clean old sealant from holes - arrow - in cylinder head gaskets.

Note. With the cylinder head installed only half of the holes in the cylinder head gasket are visible.

Note. A kinked cylinder head gasket must be replaced.

Scheme 537

1. Bend the ends of cylinder head gaskets very slightly downward - arrows - until upper sealing surface of gasket and cylinder head can be cleaned.
2. Clean both cylinder head gaskets, top and bottom, so they are completely free of any oil or grease.

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Note. A kinked cylinder head gasket must be replaced.

1. Coat sealing surfaces of cylinder head gaskets, top and bottom, with a thin layer of sealant, to do this slightly bending cylinder head gaskets downward again - arrows -.
2. To coat surface between cylinder head and gasket, use a flat object, e.g. a feeler gauge.

Scheme 538

1. Apply sealant beads - 1 to 9 - on clean sealing surfaces of lower timing chain cover, as shown in illustration.

1. Thickness of sealant beads: 2.5 mm.

Note. Lower timing chain cover must be installed within 5 minutes of applying sealant.

1. Set lower timing chain cover in place, guiding cover at an angle from below onto the sealing surface of the cylinder block and cylinder head.
2. When installing, make sure that the cylinder head gaskets do not become damaged.

Note. A damaged cylinder head seal must be replaced.

1. Tighten bolts «Timing chain lower cover tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

The rest of installation is in reverse order of removal, note the following

1. Install crankshaft seal, transmission side --> «Transmission-side crankshaft sealing ring, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__transmission-side-crankshaft-sealing-ring-replacing) .
2. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .
3. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
4. Install left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .

1. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .
2. Install automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
3. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .

Camshaft timing chain, assembly overview

Left camshaft timing chain

Scheme 539

1 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing)

2 - Bolt

1. Replace
2. 80 Nm plus an additional 90° ( 1 / 4 turn).

3 - Bolt

1. Replace
2. 80 Nm plus an additional 90° ( 1 / 4 turn).

4 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing)

5 - Left camshaft timing chain

1. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing)

6 - Bolt

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

7 - Guide piece

8 - Chain tensioner for left camshaft timing chain

1. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing)

9 - Oil strainer

1. Set into chain tensioner
2. Observe locating tabs on circumference

10 - Gasket

1. Replace
2. Clipped onto chain tensioner

11 - Mounting bracket for drive sprocket

12 - Bolt

1. 9 Nm

13 - Drive sprocket for left camshaft timing chain

14 - Thrust washer for drive sprocket

15 - Bolt

1. 22 Nm

Right camshaft timing chain

Scheme 540

1 - Mounting bracket for drive sprocket

1. For right camshaft timing chain
2. Asymmetrical version
3. Installed location «Right camshaft timing chain drive sprocket mounting bracket location»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-camshaft-timing-chain-drive-sprocket)

2 - Bolt

1. 42 Nm

3 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing)

4 - Bolt

1. Replace
2. 80 Nm plus an additional 90° ( 1 / 4 turn).

5 - Bolt

1. Replace
2. 80 Nm plus an additional 90° ( 1 / 4 turn).

6 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing)

7 - Right camshaft timing chain

1. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing)

8 - Chain tensioner for right camshaft timing chain

1. Removing and installing --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing)

9 - Guide piece

10 - Oil strainer

1. Set into chain tensioner
2. Installed location: Observe locating tabs on circumference

11 - Gasket

1. Replace
2. Clipped onto chain tensioner

12 - Bolt

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

13 - Thrust washer for drive sprocket

14 - Drive sprocket for right camshaft timing chain

Scheme 541

1. Alignment bushings in right camshaft timing chain drive sprocket mounting pins - 3 - must engage in holes in thrust washer - 1 - and cylinder block.

2 - Drive sprocket for right camshaft timing chain

4 - Bolt

Scheme 542

Special tools, testers and auxiliary items required

1. Locking pin 3242
2. Torque wrench V.A.G 1332
3. Assembly tool V.A.G 1332/9
4. Adapter T40058

1. Camshaft Clamp T40070 , qty. 2
2. Locking Pin T40071 , qty. 2

Special tools, testers and auxiliary items required

Scheme 543

1. Wrench T40079

Note. According to the following description, the timing chains for camshafts remain on engine. Even if work is performed only on one of the cylinder heads, the procedure described must be followed, since then the valve timing at both cylinder heads must be adjusted.

1. Remove cylinder head cover: left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .

1. Insert guide pin of adapter T40058 so that small diameter - arrow 2 - points to engine. Large diameter - arrow 1 - points to socket.

1. Using Socket T40058 , rotate crankshaft in direction of engine rotation - arrow - to "TDC".

Scheme 544

1. The threaded holes - arrows - in camshafts must face upward.

1. Mount camshaft locating tool T40070 to both cylinder heads and tighten bolts - arrows - to 25 Nm.

1. The Camshaft Locating Tool T40070 is correctly positioned when holes for cylinder head bolts remain free.

Scheme 545

1. Remove locking bolt - arrow - from upper part of oil pan.

Scheme 546

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

Scheme 547

1. Press left camshaft timing chain tensioner glide track inward with a screwdriver - 1 - as far as stop and secure chain tensioner with Locking Pin T40071.

Note. The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

Scheme 548

1. Press right camshaft timing chain tensioner glide track inward with a screwdriver - 1 - as far as stop and secure chain tensioner with Locking Pin T40071.

Note. The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

Scheme 549

1. For re-installation, identify installation location of camshaft adjuster with paint.
2. Remove bolts - 1 and 2 - on left cylinder head and remove both camshaft adjusters.

Scheme 550

1. For re-installation, identify installation location of camshaft adjuster with paint.
2. Remove bolts - 1 and 2 - on right cylinder head and remove both camshaft adjusters.

1. Tightening torques --> «Camshaft timing chain, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-assembly-overview) , --> «Upper part of oil pan, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Note. Replace bolts which have been tightened to torque. Replace locking bolt O-ring.

1. Drive chain for timing mechanism installed --> «Drive chain for timing mechanism, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-chain-for-timing-mechanism-removing) .
2. Secure crankshaft in "TDC" position using Crankshaft Holder 3242.

1. Camshaft Clamp T40070 mounted on both cylinder heads and fastened to 25 Nm - arrows -.

1. Re-install camshaft adjuster on left cylinder head according to mark applied during removal.
2. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 and 2 -.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

1. Remove Locking Pin T40071.

1. Re-install camshaft adjuster on right cylinder head according to mark applied during removal.
2. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 and 2 -.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

1. Remove Locking Pin T40071.

Scheme 551

1. Position Key T40079 on intake camshaft adjuster at left cylinder head.
2. Position Torque Wrench V.A.G 1332 with Open Ring Spanner Insert V.A.G 1332/9 on Key T40079.
3. Have a second technician pre-tension camshaft adjuster to 40 Nm in direction of - arrow -.
4. Tighten bolts as follows while camshaft adjuster is held under pre-tension

Scheme 552

1. Position Key T40079 on exhaust camshaft adjuster at right cylinder head.
2. Position Torque Wrench V.A.G 1332 with Open Ring Spanner Insert V.A.G 1332/9 on Key T40079.
3. Have a second technician pre-tension camshaft adjuster to 40 Nm in direction of - arrow -.
4. Tighten bolts as follows while camshaft adjuster is held under pre-tension

1. Remove Key T40079.
2. Remove Camshaft Clamps T40070 on both cylinder heads - arrows -.

Scheme 553

1. Tighten camshaft adjuster bolts on left cylinder head as follows

Scheme 554

1. Tighten camshaft adjuster bolts on right cylinder head as follows

1. Remove crankshaft holder 3242.

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

Note. If rotated unitentionally beyond "TDC" , crankshaft must be rotated back approx. 30° and set to "TDC" again. The threaded holes - arrows - in the camshafts must face upward.

1. Mount camshaft locating tool T40070 to both cylinder heads and tighten bolts - arrows - to 25 Nm.

1. The Camshaft Locating Tool T40070 is correctly positioned when holes for cylinder head bolts remain free.

1. Install Crankshaft Holder 3242 in bore and tighten to 20 Nm.

1. The crankshaft holder 3242 must engage in the locating hole of crankshaft - 1 - , otherwise repeat adjustment.

1. Remove camshaft locating tools on both cylinder heads.
2. Remove crankshaft holder 3242.
3. Tighten "TDC" marking locking bolt.

The rest of installation is in reverse order of removal, note the following

1. Install left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .
2. Install cylinder head covers: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .

Camshaft timing chain, removing and installing

Special tools, testers and auxiliary items required

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

Note. Even if work is performed only on one of the cylinder heads, the procedure described must be followed, since then the valve timing at both cylinder heads must be adjusted.

1. Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
4. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

1. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
3. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
4. Remove oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .

1. Remove lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .
2. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

1. Identify running direction of left camshaft timing chain with paint for reinstallation.
2. Remove bolts - 1 and 2 - and remove left chain tensioner and left camshaft timing chain.

Scheme 555

1. Identify running direction of right camshaft timing chain with paint for re-installation.
2. Remove bolts - 1 and 2 - and remove right chain tensioner and right camshaft timing chain.

1. Tightening torque --> «Camshaft timing chain, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-assembly-overview) .

Note. If the tensioning element was removed from the chain tensioner, note installation position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail. Replace bolts which have been tightened to torque. Replace gasket.

1. Press left and right camshaft timing chain guide rail inward - arrow - as far as stop and secure chain tensioner with Locking Pin T40071.

1. Clean oil strainer - 2 - in both chain tensioners if necessary.
2. Place seal - 3 - on rear of chain tensioner - 1 -.

1. Insert chain tensioner in left cylinder head and position camshaft timing chain according to mark applied during removal, as shown in illustration.
2. Tighten bolts - 1 and 2 -.

1. Insert chain tensioner in right cylinder head and position camshaft timing chain according to mark applied during removal, as shown in illustration.
2. Tighten bolts - 1 and 2 -.

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

1. Position camshaft timing chains on camshafts «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Install lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .
3. Install crankshaft seal, transmission side --> «Transmission-side crankshaft sealing ring, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__transmission-side-crankshaft-sealing-ring-replacing) .
4. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
2. Install left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .
3. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .
4. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

1. Install automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
2. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .

Scheme 556

1 - Guide rail

2 - Bolt

1. Replace
2. 10 Nm plus an additional 90° ( 1 / 4 turn).

3 - Bolt

1. 22 Nm

4 - Thrust washer for drive sprocket

5 - Drive sprocket for left timing chain

6 - Bolt

1. Replace
2. 10 Nm plus an additional 90° ( 1 / 4 turn).

7 - Drive chain for timing mechanism

1. Removing and installing --> «Drive chain for timing mechanism, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-chain-for-timing-mechanism-removing)

8 - Guide rail

9 - Bolt

1. Replace
2. 10 Nm plus an additional 90° ( 1 / 4 turn).

10 - Bolt

1. 9 Nm

11 - Mounting bracket for drive sprocket

1. For right camshaft timing chain
2. Asymmetrical version
3. Installed location «Right camshaft timing chain drive sprocket mounting bracket location»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

12 - Thrust washer

13 - Drive sprocket for right timing chain

14 - Pivot pin for drive sprocket

15 - Bolt

1. Tightening torque --> «Camshaft timing chain, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-assembly-overview)

16 - O-ring

1. Replace

17 - Chain tensioner

18 - Bolt

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

19 - Crankshaft

20 - Bolt

1. Replace
2. 10 Nm plus an additional 90° ( 1 / 4 turn).

Right camshaft timing chain drive sprocket mounting bracket location

1. Alignment bushings in right camshaft timing chain drive sprocket mounting pins - 3 - must engage in holes in thrust washer - 1 - and cylinder block.

2 - Drive sprocket for right camshaft timing chain

4 - Bolt

Drive chain for timing mechanism, removing and installing

Special tools, testers and auxiliary items required

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

Scheme 557

1. Securing pin T40071

Removing

1. Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
4. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

1. Remove cylinder head cover: left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .
2. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
3. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
4. Remove oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .

1. Remove lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .
2. Remove camshaft timing chains --> «Camshaft timing chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-timing-chain-removing-and-installing) .
3. Remove power take-off drive chain --> «Power take-off drive chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__power-take-off-drive-chain-removing-and) .

Scheme 558

1. Push drive chain tensioner guide rail in direction of - arrow - and secure chain tensioner using Locking Pin T40071.
2. Identify running direction of drive chain with paint for reinstallation.
3. Remove bolts - 1 - and remove guide rail.
4. Remove bolts - 2 to 4 - and remove chain tensioner.

1. Remove timing mechanism drive chain.

Installing

1. Tightening torques --> «Timing mechanism drive chain, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

1. Route timing mechanism drive chain according to marks applied to drive chain sprockets during removal.

1. Install guide rail and tighten bolts - 1 -.
2. Install chain tensioner and tighten bolts - 2 -.
3. Press drive chain tensioner guide rail in direction of - arrow - and remove Locking Pin T40071 from chain tensioner.
4. Install power take-off drive chain --> «Power take-off drive chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__power-take-off-drive-chain-removing-and) .

1. Install camshaft timing chains «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Install lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .
3. Install crankshaft seal, transmission side --> «Transmission-side crankshaft sealing ring, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__transmission-side-crankshaft-sealing-ring-replacing) .
4. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
2. Install left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .
3. Install cylinder head covers: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .
4. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

1. Install automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
2. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .

Scheme 559

1 - Bolt

1. 9 Nm

2 - Chain tensioner

1. With glide track

3 - Gasket

1. Replace

4 - Spring

5 - Bolt

1. 42 Nm

6 - Pivot pin for idler sprocket

7 - Idler sprocket for chain for power take-off

8 - Idler sprocket mounting bracket

9 - Bolt

1. 9 Nm

10 - Power take-off drive chain

1. Removing and installing --> «Power take-off drive chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__power-take-off-drive-chain-removing-and)

11 - Crankshaft

12 - Drive sprocket for power take-off

13 - Circlip

Power take-off drive chain, removing and installing

Special tools, testers and auxiliary items required

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

1. Securing pin T40071

Removing

1. Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
4. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

1. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
2. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
3. Remove oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .
4. Remove lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .

Scheme 560

1. Identify running direction of power take-off drive chain with paint for reinstallation.
2. Press tensioning rail in direction of - arrow - and secure chain tensioner with Locking Pin T40071.
3. Remove bolt - 1 - and remove idler sprocket.

Note. When removing, be careful of spring in drive spur gear shaft.

1. Remove bolts - 2, 3, 4 - and remove chain tensioner.
2. Remove power take-off drive chain.

Installing

1. Tightening torques --> «Power take-off drive chain, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace the gasket. Secure all hose connections using hose clamps appropriate for the model type .

1. Install lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .
2. Install crankshaft seal, transmission side --> «Transmission-side crankshaft sealing ring, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__transmission-side-crankshaft-sealing-ring-replacing) .
3. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .
4. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

1. Install left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
2. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .
3. Install automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
4. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .

Scheme 561

1 - Circlip

2 - Spur gear unit

1. Cannot be replaced separately
2. Removing and installing --> «Spur gear unit, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__spur-gear-unit-removing-and-installing)

3 - Bolt

1. 22 Nm

4 - Sealing ring for A/C compressor drive

1. Replacing --> «Seals for power take-off, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

5 - Dust seal cap for A/C compressor drive

6 - Clamp

7 - Drive shaft for A/C compressor

1. 60 Nm

8 - O-ring

1. Replace

9 - Power-steering pump

10 - O-ring

1. Replace

11 - Drive shaft for oil pump

12 - Sealing ring for power-steering pump drive

1. Replacing --> «Seals for power take-off, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

13 - Spring

Scheme 562

Special tools, testers and auxiliary items required

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

Work procedure

1. Remove air conditioning compressor --> «87 - AIR CONDITIONING»(/audi/a6/c6-2008-2011/remont/ac-compressor/#heating-air-conditioning) .
2. Remove power steering pump --> «48 - STEERING»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 563

1. Remove hose clamp at dust cap - arrow -.
2. Remove dust cap together with A/C compressor input shaft from shaft end of A/C compressor drive spur gear.

Scheme 564

1. Pry out A/C compressor drive seal using pulling hook T20143/1.

Scheme 565

1. Pry out power-steering pump drive seal using pulling hook T20143/1.

Scheme 566

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

Scheme 567

1. Drive in sealing ring for power-steering pump drive using thrust piece T40052.

The rest of installation is in reverse order of removal, note the following

1. Install the power steering pump --> «48 - STEERING»(/audi/a6/c6-2008-2011/remont/axle-shafts/#suspension-wheels-steering) .

Note. Secure dust cap with a hose clamp appropriate to model type .

1. Slide dust seal cap - arrow - with hose clamp already installed onto shaft end of A/C compressor drive spur gear.
2. Install A/C compressor --> «87 - AIR CONDITIONING»(/audi/a6/c6-2008-2011/remont/ac-compressor/#heating-air-conditioning) .

Spur gear unit, removing and installing

Special tools, testers and auxiliary items required

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

Special tools, testers and auxiliary items required

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

Removing

1. Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
4. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

1. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
2. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
3. Remove oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .
4. Remove lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .

1. Remove power-steering pump from cylinder block.

1. Remove hose clamp at A/C compressor dust cap - arrow -.
2. Remove power take-off drive chain --> «Power take-off drive chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__power-take-off-drive-chain-removing-and) .

Scheme 568

1. Remove bolts - 1 to 6 -.
2. Remove spur gear unit.

Scheme 569

1. Remove compression spring - 2 - between spur gear unit - 1 - and oil pump input shaft - 3 -.

Scheme 570

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

Installing

1. Tightening torque --> «Power take-off, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Note. Replace sealing rings and O-rings.

Scheme 571

1. Remove A/C compressor drive seal - 2 - and power steering pump drive seal - 3 - using pulling hook T20143/1.
2. Remove O-ring - 1 -.
3. Remove sealant residue on spur gear unit and cylinder block.
4. Clean sealing surfaces so they are completely free of any oil or grease.

Scheme 572

1. Drive in sealing ring for A/C compressor drive using thrust piece T40051.
2. Drive in sealing ring for power-steering pump drive using thrust piece T40052.

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

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

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 1.5 mm).

Scheme 573

1. Apply sealant beads - arrows - to clean sealing surfaces of spur gear unit as shown in illustration.

1. Thickness of sealant beads: 2.0 mm.

1. Position O-ring - 1 - and secure it with some grease.

Note. The spur gear unit must be installed within 5 minutes after application of sealant.

1. Position compress spring - 2 - for input shaft - 3 - in spur gear unit - 1 -.

Note. Secure dust cap with a hose clamp appropriate to model type .

1. Slide dust seal cap - arrow - with hose clamp already installed onto shaft end of A/C compressor drive spur gear.

1. Position spur gear unit and tighten bolts - 1 to 6 - in a diagonal sequence in stages.
2. Install power take-off drive chain --> «Power take-off drive chain, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__power-take-off-drive-chain-removing-and) .
3. Slide power steering pump with new O-ring onto spur gear for power-steering pump drive.

The rest of installation is in reverse order of removal, note the following

1. Install lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .
2. Install crankshaft seal, transmission side --> «Transmission-side crankshaft sealing ring, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__transmission-side-crankshaft-sealing-ring-replacing) .
3. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .
4. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

1. Install left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .
2. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .
3. Install automatic transmission --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-281381-S39996584562008031100000) .
4. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .

Valvetrain

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.

Valvetrain, assembly overview

Note. Cylinder head for cylinder bank 2 (left) is shown in illustration.

Scheme 574

1 - Sealing plug

2 - Valve stem seal

1. Replacing --> «Valve stem seals, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

3 - Valve spring

1. Installed location «Installed position of valve spring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

4 - Support element

1. With hydraulic valve clearance compensation
2. Clipped into roller rocker lever - 8
3. Checking --> «Support elements with hydraulic adjustment, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__support-elements-with-hydraulic-adjustment-checking)
4. Mark for re-installation

1. Lubricate contact surface

5 - Valve spring plate

6 - Valve keys

7 - Securing clip

1. Check for secure seat

8 - Roller rocker lever

1. Mark for re-installation
2. Check roller for easy movement
3. Lubricate contact surface
4. To assemble, clip onto support element - 4 - with securing clip - 7

9 - Intake camshaft

1. Removing and installing --> «Camshafts, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
2. Measuring axial play --> «Camshaft axial play, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-axial-play-measuring)
3. Measure radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-dia. 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-dia. 36 mm: 0.032 to 0.078 mm
2. Run-out: maximum 0.04 mm

10 - Gasket

1. Replace

11 - Bearing bracket

1. With integrated camshaft bearings
2. Removing and installing --> «Camshafts, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

12 - Bolt

1. Tightening order «Bearing frame tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

13 - Camshaft position (CMP) sensor 2 G163

14 - Bolt

1. 9 Nm

15 - O-ring

1. Replace

16 - Bolt

1. 9 Nm

17 - Camshaft position (CMP) sensor 4 G301

18 - O-ring

1. Replace

19 - Compression ring

1. For camshaft adjuster

20 - Exhaust camshaft

1. Removing and installing --> «Camshafts, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
2. Measuring axial play --> «Camshaft axial play, measuring»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__camshaft-axial-play-measuring)
3. Measure radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-dia. 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-dia. 36 mm: 0.032 to 0.078 mm
2. Run-out: maximum 0.04 mm

21 - Cylinder head

1. Check valve guides --> «Valve guides, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__valve-guides-checking)

22 - Intake valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve dimensions»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
4. Check valve guides --> «Valve guides, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__valve-guides-checking)

23 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve dimensions»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)
4. Check valve guides --> «Valve guides, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__valve-guides-checking)

Scheme 575

1. Tighten bolts in 2 stages - 1 to 24 - in sequence as follows.
2. Install bolts by hand as far as stop.
3. Tighten bolts to 8 Nm.

Scheme 576

1. The tight spring coils - arrow - face toward cylinder head.

Camshaft axial play, measuring

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387

1. Dial gauge VAS 6079

Work procedure

1. Perform measurement with guide frame removed.

Scheme 577

1. Secure Dial Gauge Holder VW 387 with Dial Gauge VAS 6079 on cylinder head as shown in illustration.
2. Determine axial clearance.

1. Axial clearance: 0.100 to 0.191 mm.

Scheme 578

Special tools, testers and auxiliary items required

1. Multi-point socket T10035
2. Tool set T10133
3. Adapter T40058
4. Securing pins 1 set = qty. 2 T40116

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

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

Removing

1. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .
2. Remove left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .
3. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Scheme 579

1. Disconnect electrical connector at intake camshaft position sensor - arrow -.
2. Remove high-pressure pump --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

1. Remove Crankshaft Holder 3242 from upper part of oil pan.

1. Insert guide pin of adapter T40058 so that large diameter - arrow 1 - points to adapter. Small diameter - arrow 2 - points to engine.

Scheme 580

1. Rotate crankshaft with Socket T40058 opposite engine rotation direction 40° out of "TDC" position - arrow -.

1. Remove Camshaft Clamp T40070 at cylinder head.

1. Loosen guide frame bolts in sequence - 24 to 1 -.

Note. Proceed in the same way with right guide frame.

1. Carefully remove guide frame.
2. Mark camshafts for reinstallation and remove them.

Scheme 581

Note. Because the special tool cannot be used during installation, the alignment pins - arrows - on an engine with alignment pins must be driven out with a cotter pin driver.

Installing

1. Tightening torque «Bearing frame tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Note. Replace seals and sealing rings.

1. Remove sealant residue on cylinder head and guide frame, e.g. with rotating plastic brush.
2. Clean sealing surfaces so they are completely free of any oil or grease.
3. Oil journal surfaces of camshafts.
4. Place camshafts in cylinder head, noting position of camshafts so that guide frame can be installed without tension.

Scheme 582

Left cylinder head

1. Intake camshaft
2. Exhaust camshaft

1. Groove on end of shaft must lie as shown in illustration.

Scheme 583

Right cylinder head

1. Exhaust camshaft
2. Intake camshaft

1. Groove on end of shaft must lie as shown in illustration.

Continued for both sides

1. Check location of compression ring ends.

Scheme 584

1. The compression ring ends - 1 and 2 - must face upward or downward, and must never face sideways.

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Scheme 585

1. Lay seal - 2 - in guide frame groove.
2. Apply sealant beads - 1, 3, 4 - on clean guide frame sealing surfaces as shown in illustration.

1. Thickness of sealant beads: 2.5 mm.

1. Place guide frame on cylinder head.

Note. Ensure camshafts can be inserted in guide frame axial bearing without force.

Scheme 586

1. Insert locating pins T40116 in guide frame and cylinder head.

Note. Because the sealant begins hardening immediately, guide frame must be promptly positioned and tightened. After the guide frame has been installed, sealant must dry approx. 30 minutes.

1. Tighten guide frame bolts «Bearing frame tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Scheme 587

1. Drive sealing plugs - arrows - in flush.

Scheme 588

1. Remove locating pins T40116 with impact puller T10133/3.

Scheme 589

1. Rotate intake camshaft to "TDC" and tighten camshaft adjuster screw - 2 - on camshaft with a socket SW 24 - 1 - inserted between.

Note. Use pliers to counter-hold socket when tightening bolt.

1. Position a lever or ratchet with Socket T10035 on screw and rotate camshaft until threaded holes for Camshaft Clamp T40070 face up.
2. Next, loosely fasten Camshaft Clamp T40070 to intake camshaft.

1. The Camshaft Locating Tool T40070 is correctly positioned when the holes for cylinder head bolts remain free.

Scheme 590

1. Adapt camshaft adjuster screw - 2 - and socket 24 - 1 - to exhaust camshaft.
2. Rotate exhaust camshaft until threaded hole for Camshaft Clamp T40070 faces up.
3. At the same time, position a counter-hold SW 24 on Camshaft Clamp T40070 and swing Camshaft Clamp T40070 against exhaust camshaft to install - arrow -.
4. Tighten Camshaft Clamp T40070 by hand onto exhaust camshaft to avoid damaging threads (2nd technician needed).

1. Tighten Camshaft Clamp T40070 bolts to 25 Nm.

1. Using Socket T40058 , rotate crankshaft in direction of engine rotation - arrow - to "TDC".

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

The rest of installation is in reverse order of removal, note the following

1. Install high pressure pump --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
2. Position camshaft timing chains on camshafts «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
3. Install left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .
4. Install cylinder head covers: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .

Support elements with hydraulic adjustment, checking

Note. The support elements with hydraulic adjustment cannot be serviced. Irregular valve noises are normal while starting the engine.

Special tools, testers and auxiliary items required

1. Adapter T40058
2. Feeler gauge

Work procedure

1. Start engine and allow it to run until coolant fan has switched on once.
2. Increase RPM to approx. 2500 for 2 minutes and perform road test if necessary.

Note. If irregular valve noises disappear but return during short drives, oil check valve must be replaced. Oil check valve location --> Oil check valve and spray nozzle valve, assembly overview .

1. If support elements with hydraulic adjustment are still loud, locate faulty support element as follows
2. Remove cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .

1. Insert guide pin of adapter T40058 so that large diameter - arrow 1 - points to engine. Small diameter - arrow 2 - points to adapter.

1. Rotate crankshaft until cam lobes on support element to be checked point upward.

Scheme 591

1. To determine play between cam lobes and roller rocker lever, press lever down - arrow -.
2. If a 0.20 mm feeler gauge can slide between cam lobes and roller rocker lever, replace support element --> «Camshafts, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Final procedures

1. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .

Scheme 592

Special tools, testers and auxiliary items required

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Valve cotter disassembly and assembly device VAS 5161

1. Adapter T40012

Removing

1. Remove camshaft timing chains from camshafts --> «Camshaft timing chains, removing from camshafts»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Remove camshafts --> «Camshafts, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
3. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 593

1. Place drift VAS 5161/3 on valve spring plate and loosen stuck valve cotters using a plastic hammer.

Scheme 594

1. Place guide plate VAS 5161/19A from Valve Cotters Asm/Dis-Asm Device VAS 5161 on cylinder head.
2. Secure Guide Plate VAS5161/19A with knurled screws VAS 5161/12.
3. Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar positive pressure.

Scheme 595

1. Secure engaging device VAS 5161/6 with installation fork VAS 5161/5 to guide plate.
2. Push installation cartridge VAS 5161/8 into guide plate.
3. Engage pressure fork VAS 5161/2 at engaging device and press down installation cartridge.
4. At the same time, turn knurled bolt of installation cartridge to the right, until points engage in valve keepers.

1. Lightly move knurled bolt back and forth, causing valve keepers to be pressed apart and be captured in the installation cartridge.
2. Release pressure fork.
3. Remove installation cartridge.
4. Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

1. Remove valve spring with valve spring plate.

Scheme 596

1. Remove valve stem seal with Valve Seal Removal Tool 3364.

If Valve Seal Removal Tool 3364 cannot be used on some valve stem seals due to restricted clearance, proceed as follows

Scheme 597

1. Using a drift, drive out roll pin - arrow - at puller with a drift and remove impact puller attachment.

Scheme 598

1. Place lower part of puller on valve stem seal.
2. Secure puller with a drift or cotter pin driver - 1 - , as shown in illustration.
3. Place lever on puller and pull off valve stem seal - arrow -.

Installing

1. Lightly coat sealing lips of valve stem seal with oil.
2. Push valve stem seal onto plastic sleeve.

Scheme 599

1. Carefully press valve stem oil seal onto valve guide using valve stem seal driver 3365.
2. Remove plastic sleeve again.

Scheme 600

If the valve keepers were removed from the installation cartridge, they must then be inserted into the insertion device VAS 5161/18.

1. The large diameter of the valve keepers point upward.

1. Install valve spring and valve spring plate.

1. The tight spring coils - arrow - face toward cylinder head.

1. Install guide plate onto cylinder head again.
2. Insert installation cartridge into guide plate.
3. Press down pressure fork and pull knurled bolt upward turning to left and right, valve keepers are inserted in this manner.
4. Release pressure fork with knurled bolt still pulled.

1. Ensure that all roller rocker levers seat properly on valve stem ends and are clipped onto respective support elements.
2. Install sparks plugs 405.
3. Install camshafts --> «Camshafts, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
4. Position camshaft timing chains on camshafts «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

1. Install left and right timing chain covers «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__installing) .
2. Install cylinder head cover: Left --> «Left cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-cylinder-head-cover-removing-and) , right --> «Right cylinder head cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__right-cylinder-head-cover-removing-and) .

Scheme 601

Note. Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.

Valve guides, checking

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387

1. Dial gauge VAS 6079

Work procedure

Note. If valve is replaced during repair, use new valve for measurement. Due to different stem diameters, only use an intake valve in the intake guide and an exhaust valve in the exhaust guide.

1. Insert valve into valve guide.

1. Valve stem tip must seal with valve guide.

Scheme 602

1. Determine tilt clearance.

1. Wear limit: 0.8 mm.

1. If wear limit is exceeded, re-measure using new valves.
2. If wear limit is still exceeded, replace cylinder head.

Note. The valve guides cannot be replaced.

Valves, checking

1. Check valves at stem and seating surface for traces of wear.
2. If there are clear traces of wear, replace valve.

Oil pump and lower part of oil pan

Note. If large quantities of metal particles or abraded material are detected during engine repairs, it may be an indication for a damaged crankshaft or rod bearings. To prevent subsequent damage, the following work must be performed after the repair: Oil channels must be cleaned carefully; replace oil spray jets, oil cooler and oil filter. Viscosity classes, oil specifications, oil capacities Maintenance tables.

Scheme 603

1 - Bolt

1. 9 Nm

2 - Oil pan (lower section)

1. Removing and installing --> «Lower part of oil pan, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__lower-part-of-oil-pan-removing)

3 - Bolt

1. 9 Nm

4 - Oil pipe

5 - Gasket

1. Replace

6 - O-ring

1. Replace

7 - Bolt

1. 9 Nm

8 - Bolt

1. 9 Nm

9 - Oil check valve housing

10 - Gasket

1. Replace

11 - Oil check valve

12 - O-ring

1. Replace

13 - Oil pipe

14 - Bolt

1. 9 Nm

15 - O-ring

1. Replace

16 - Drive shaft for coolant pump

17 - Fitting sleeves

1. 2 pieces

18 - Oil pump

1. Do not disassemble
2. With relief valve approx. 5.5 bar
3. Removing and installing --> «Oil pump, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-pump-removing-and-installing)

19 - Drive shaft for oil pump

20 - Bolt

1. Replace
2. 8 Nm plus an additional 90° ( 1 / 4 turn).

21 - Gasket

1. Replace

22 - Intake tube

1. For oil pump

23 - Bolt

1. 9 Nm

24 - Oil strainer

1. Clean

25 - Oil baffle

26 - Bolt

1. 9 Nm

27 - Seal

1. Replace

28 - Oil Level Thermal Sensor G266

29 - Bolt

1. 9 Nm

30 - Oil drain plug

1. 25 Nm

31 - Seal

1. Replace

Scheme 604

1. Tighten bolts in 3 stages as follows
2. Tight bolts by hand in a diagonal sequence.
3. Pre-tighten all bolts in a diagonal sequence to 5 Nm.
4. Tighten bolts diagonally to 9 Nm.

Lower part of oil pan, removing and installing

Special tools, testers and auxiliary items required

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

1. Drain coolant --> «Cooling system, draining and filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Remove front coolant pipe --> «Front coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__front-coolant-line-removing-and-installing) .

Scheme 605

1. Remove nuts - 1 - and lay aside bracket with electrical wiring.

Scheme 606

1. Remove nuts - 1 and 2 -.
2. Remove ATF line bracket.

1. Disconnect electrical connector - 1 - at Oil Level Thermal Sensor G266.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove oil pan (lower part) - 2 - and pry out carefully.

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

1. Tightening torque «Lower part of oil pan, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Note. Replace sealing rings.

Scheme 607

1. Remove sealant residue lower part and upper part of oil pan, e.g. with rotating plastic brush.
2. Clean sealing surfaces so they are completely free of any oil or grease.

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Scheme 608

1. Apply sealant bead - arrow - on clean sealing surface of lower part of oil pan as shown in illustration.

1. Thickness of sealant bead: 2.5 mm.

Note. The oil pan (lower part) must be installed within 5 minutes after application of sealant.

1. Position lower part of oil pan and tighten bolts «Lower part of oil pan, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

The rest of installation is in reverse order of removal, note the following

1. Install front coolant pipe --> «Front coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__front-coolant-line-removing-and-installing) .
2. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .
3. Fill with coolant «Filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__filling) .

Oil pump, removing and installing

Special tools, testers and auxiliary items required

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

Scheme 609

1. Long-nose gripping pliers VAS 6226

Removing

1. Drain coolant --> «Cooling system, draining and filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Remove front coolant pipe --> «Front coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__front-coolant-line-removing-and-installing) .
3. Remove coolant pump --> «Coolant pump, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__coolant-pump-removing-and-installing) .
4. Remove lower section of oil pan --> «Lower part of oil pan, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__lower-part-of-oil-pan-removing) .

Scheme 610

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

Scheme 611

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

Note. Oil escapes when removing oil pipes.

Scheme 612

1. Remove bolts - arrows - and remove intake tube.

Scheme 613

1. Remove oil pipe together with oil check valve housing.

Note. Oil escapes when removing oil pipes.

Scheme 614

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

Scheme 615

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

Installing

1. Tightening torques --> «Oil pump and lower part of oil pan, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Note. Replace sealing rings and O-rings.

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

1. Unlock Long-nose gripping pliers VAS 6226 and let drive shaft - 1 - glide into oil pump.

Scheme 616

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

1. Toothed gears must not be able to be rotated.

The rest of installation is in reverse order of removal, note the following

1. Install coolant pump --> «Coolant pump, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__coolant-pump-removing-and-installing) .
2. Install lower section of oil pan «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
3. Install front coolant pipe --> «Front coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__front-coolant-line-removing-and-installing) .
4. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .

1. Fill with coolant «Filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__filling) .

Scheme 617

1 - Seals

1. Replace

2 - O-ring

1. Replace

3 - Seals

1. Replace

4 - O-ring

1. Replace

5 - Oil pan (upper section)

1. Removing and installing --> «Upper part of oil pan, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__upper-part-of-oil-pan-removing)

6 - Bolt

1. Tightening order «Upper part of oil pan, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

7 - Seal

1. Replace

8 - Locking bolt

1. 35 Nm

Scheme 618

1. Tighten bolts - 1 through 7 - in 2 stages as follows
2. Pre-tighten all bolts in a diagonal sequence to 5 Nm.
3. Tighten bolts diagonally to 14 Nm.

Upper part of oil pan, removing and installing

Special tools, testers and auxiliary items required

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

Removing

1. Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, removing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__engine-removing) .
4. Separate engine and transmission --> «Engine and transmission, separating»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

1. Secure engine to assembly stand --> «Engine, securing to assembly stand»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Remove drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .
3. Remove left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
4. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

1. Remove oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .
2. Remove lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .
3. Remove ribbed belt tensioner --> «Ribbed belt tensioner, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__ribbed-belt-tensioner-removing-and-installing) .
4. Remove front coolant pipe --> «Front coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__front-coolant-line-removing-and-installing) .

1. Remove generator --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment) .

Scheme 619

1. Remove bolts - arrows - and remove air generator bracket.

1. Disconnect electrical connector - 1 - at Oil Level Thermal Sensor G266.
2. Place old oil collecting and extracting device V.A.G 1782 under engine.

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

1. Remove oil pan (lower part) - 2 - and pry out carefully.

1. Remove oil pump --> «Oil pump, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-pump-removing-and-installing) .
2. Remove bolts - 1 to 7 - for upper section of oil pan.
3. Press upper part of oil pan from alignment pins of cylinder block.

Installing

1. Tightening torques --> «Ribbed belt drive, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) , «Upper part of oil pan, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

Note. Replace sealing rings and O-rings.

Scheme 620

1. Using rotating plastic brush, remove any remaining sealant from oil pan (upper part) and at cylinder block.
2. Clean sealing surfaces so they are completely free of any oil or grease.

1. Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 1 mm).

Scheme 621

1. Insert new seals - 1 to 4 - into grooves on cylinder block.

Scheme 622

1. Apply sealant beads - 1 and 2 - on clean sealing surfaces of upper part of oil pan, as shown in illustration.

1. Thickness of sealant beads: 2.5 mm.

Note. The oil pan (upper part) must be installed within 5 minutes after application of sealant.

1. Position lower part of oil pan and tighten bolts «Upper part of oil pan, tightening sequence»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj)

The rest of installation is in reverse order of removal, note the following

1. Install oil pump --> «Oil pump, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-pump-removing-and-installing) .
2. Install coolant pump --> «Coolant pump, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__coolant-pump-removing-and-installing) .
3. Install lower section of oil pan «Installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
4. Install front coolant pipe --> «Front coolant line, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__front-coolant-line-removing-and-installing) .

1. Install ribbed belt tensioner --> «Ribbed belt tensioner, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__ribbed-belt-tensioner-removing-and-installing) .
2. Install generator --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment) .
3. Install lower timing chain cover --> «Timing chain lower cover, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__timing-chain-lower-cover-removing-and) .
4. Install crankshaft seal, transmission side --> «Transmission-side crankshaft sealing ring, replacing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__transmission-side-crankshaft-sealing-ring-replacing) .

1. Install oil filter housing --> «Oil filter housing, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-filter-housing-removing-and-installing) .
2. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
3. Install left and right timing chain covers --> «Left and right timing chain covers, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__left-and-right-timing-chain-covers) .
4. Install drive plate --> «Drive plate, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__drive-plate-removing-and-installing) .

1. Install engine --> «Engine, installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .
2. Add engine oil and check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .

Scheme 623

1 - O-ring

1. Replace

2 - Spray nozzle valve

1. Removing and installing --> «Oil check valve and spray nozzle valve, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-check-valve-and-spray-nozzle)

3 - Gasket

1. Replace

4 - Cover

5 - O-ring

1. Replace

6 - Hose

1. For crankcase ventilation

7 - Bolt

1. 9 Nm

8 - Bolt

1. 9 Nm

9 - Oil check valve

1. Removing and installing --> «Oil check valve and spray nozzle valve, removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-check-valve-and-spray-nozzle)

10 - O-ring

1. Replace

Oil check valve and spray nozzle valve, removing and installing

Note. If irregular valve noises disappear after a long drive but always return on short drives, oil check valve must be replaced.

Removing

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Scheme 624

1. Remove bolts - 1, 4, 5, 6, 7 - on high pressure line retaining clamps.
2. Disconnect electrical harness connectors at fuel injectors.
3. Remove high pressure lines - 2 and 9 - from connections on fuel rail.
4. Remove high pressure lines - 3 and 8 - from connections on fuel rail. To do this, counter-hold at hex head with and open-end wrench and loosen union nut.

1. Remove high pressure lines.

Scheme 625

1. Remove bolts - arrows -.
2. Remove cover - 2 - with crankcase ventilation hose - 1 -.
3. Remove seal.

Scheme 626

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

Installing

1. Tightening torques --> «Oil check valve and spray nozzle valve, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace gaskets and O-rings.

1. Install high pressure lines --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) as described under "Fuel injectors, removing and installing".
2. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Crankcase ventilation hose, removing and installing

Removing

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Scheme 627

1. Remove bolt - arrow - and remove crankcase ventilation hose - 1 - from cover - 2 -.

Installing

1. Tightening torque --> «Oil check valve and spray nozzle valve, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Scheme 628

1 - Gasket

1. Replace

2 - Bolt

1. 9 Nm

3 - Oil filter housing

1. With oil filter by-pass valve 1.3 bar

4 - Bolt

1. 22 Nm

5 - Oil filter element

1. Replace O-ring - 6 - when filter is changed
2. Observe change intervals 405

6 - O-ring

1. Replace

7 - Cap

1. 25 Nm

8 - Bolt

1. 9 Nm

9 - Bracket

1. For evaporative emission (EVAP) canister purge regulator valve N80

10 - Locking bolt

1. 50 Nm

11 - Locking bolt

1. 9 Nm

12 - Seal

1. Replace

13 - O-ring

1. Replace

Scheme 629

Bolts - arrows

1. 9 Nm

Scheme 630

Oil Pressure Switch F1 - 1

1. 20 Nm
2. Replace seal

Oil filter housing, removing and installing

Removing

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .

Note. To collect escaping engine oil, place a clean cloth around oil filter housing.

1. Remove cover and remove oil filter insert.

Scheme 631

1. Remove bolts - arrows - and remove oil filter housing.

Installing

1. Tightening torques --> «Oil filter housing, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace sealing rings and O-rings.

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-fuel-injection-and-ignition-engine-codes-bvj) .
2. Check oil level --> «Oil level, checking»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-level-checking) .

Oil cooler, removing and installing

Special tools, testers and auxiliary items required

Scheme 632

1. Hose clamps up to 25 mm dia. 3094

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

Removing

1. Remove generator --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment) .

1. Remove bolts - arrows - and remove air generator bracket.

1. Clamp off coolant hoses with hose clamps Hose clamps up to 25 mm dia. 3094 as shown in illustration.

Note. Lay a cloth below to catch escaping coolant.

1. Remove coolant hoses - 1 and 2 - from oil cooler.
2. Place old oil collecting and extracting device V.A.G 1782 under engine.
3. Remove bolts - arrows - and remove oil cooler.

Installing

1. Tightening torques --> «Ribbed belt drive, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) , --> «Oil filter housing, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

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

1. Install generator --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/a6/c6-2008-2011/remont/cruise-control-systems/#electrical-equipment) .
2. Check coolant level «Filling»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__filling) .

Oil Pressure Switch F1 , removing and installing

Removing

1. Bring lock carrier into service position --> «50 - BODY - FRONT»(ref-281388-S12064564912008031100000) .

1. Disconnect electrical connector - 2 - on Oil Pressure Switch F1 - 1 -.
2. Remove Oil Pressure Switch F1.

Installing

1. Tightening torque --> «Oil filter housing, assembly overview»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj) .

Installation is in reverse order of removal, note the following

Note. Replace sealing ring. Secure all hose connections using hose clamps appropriate for the model type .

1. Install lock carrier with attachments --> «50 - BODY - FRONT»(ref-281388-S12064564912008031100000) .

Scheme 633

Special tools, testers and auxiliary items required

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

Work procedure

1. Oil level OK
2. Engine oil temperature approximately 80° C.

1. Remove Oil Pressure Switch F1 --> «Oil Pressure Switch F1 , removing and installing»(/audi/a6/c6-2008-2011/remont/cooling-fan/#42l-v8-4v-engine-mechanical-engine-codes-bvj__oil-pressure-switch-f1-removing) .

Scheme 634

1. Connect oil pressure gauge V.A.G 1342 with adapter V.A.G 1342/14 to hole for oil pressure switch.
2. Install oil pressure switch - 2 - into oil pressure gauge V.A.G 1342.
3. Place brown wire of oil pressure gauge on Ground (GND) ("").

Oil pressure switch, checking