6.0l 12-cyl. 4v Engine Mechanical, Engine Code(s): Bsb Audi A8 D3 рестайлинг

Technical Data

Engine number and engine data

Engine number

Scheme 349

The engine number ("engine code" and "serial number") is located at the front on the cylinder block, below the left cylinder head.

In addition, a sticker with "engine code" and "serial number" is affixed to the right cylinder head cover.

The engine code is also located on the vehicle data plate.

Engine data

*Super unleaded RON 95 is permitted, although with reduced power.

Scheme 350

General Repair Information

> Clean Working Conditions

> Fuel Supply System, Checking for Leaks

Clean Working Conditions

Even minor contaminations can lead to malfunctions in the fuel injection system. Therefore, when working on the fuel supply/injection system, pay careful attention to 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. Plug open lines and connections immediately with appropriate protective caps.
3. Place parts that have been removed on a clean surface and cover them. Do not use fluffy 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. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.

Fuel Supply System, Checking for Leaks

1. Let engine run a few minutes at average RPM.
2. Switch off ignition.
3. Check entire fuel supply system for leaks.
4. If there are leaks in spite of correct tightening torque, corresponding component must be replaced.

1. Afterward, perform test drive, fully depressing accelerator pedal at least once.
2. Check high pressure areas for leaks again.

Contact Corrosion

1. Contact corrosion can occur if appropriate connecting elements (bolts, nuts, washers) are not used.
2. For this reason, only install connecting elements that are treated with a special coating. These elements are distinguished by their greenish color.
3. Furthermore, all rubber, plastic parts and adhesives are made of non-conductive material.
4. If you have doubts about the reusability of parts, generally install new parts.

Engine, Removing and Installing

> General Information

> Engine, Removing

> Engine and Transmission, Separating

> Engine, Securing to Assembly Stand

> Engine, Installing

> Engine Wiring, Routing on Engine

General Information

Note. With the lock carrier installed, the engine is removed downward with the transmission and subframe. Before beginning work, make sure that the support element VAS 6131/10-12 for the scissor lift table VAS 6131 is also readily equipped with the support set VAS 6131/10. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. Drained coolant must be stored in a clean container for disposal or reuse.

Special tools, testers and auxiliary items required

Scheme 351

1. Pry Lever - Rmv Outside Mirror 80-200
2. Hose clamps up to 25 mm dia. 3094
3. Drip tray V.A.G 1306 or Drip tray for workshop crane VAS 6208
4. Hose clamp pliers V.A.G 1921

1. Spark plug connector pliers V.A.G 1922
2. Step ladder VAS 5085

Special tools, testers and auxiliary items required

Scheme 352

1. Scissor lift table VAS 6131 with Support set VAS 6131/10 and added Support element VAS 6131/10-12 as well as Supplementary set VAS 6131/11

Engine, Removing

1. Discharge refrigerant circuit --> «87 - AIR CONDITIONING»(/audi/a8/d3-2005-2007/remont/ac-compressor/#heating-air-conditioning) .
2. Activate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Switch ignition off.

Note. So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with the ignition key inserted.

Scheme 353

1. Remove cover of right luggage compartment side trim - arrows -.

Scheme 354

1. Remove cover - 1 - above battery.

Note. Ignore - 2 - in the illustration.

Scheme 355

1. Disconnect Ground (GND) strap - arrow - at battery.

Scheme 356

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

Scheme 357

1. Remove cover above coolant reservoir - arrows -.

1. Open cap of coolant expansion tank.
2. Remove both front wheels.

Note. Secure the brake discs with wheel bolts.

Scheme 358

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of auxiliary heater on sound insulation.

Scheme 359

1. Loosen quick-release fasteners - 1 - and - 2 - and remove sound insulation.
2. Remove front and rear parts of left and right front wheelhouse liners --> «66 - EXTERIOR EQUIPMENT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Place drip tray V.A.G 1306 or drip tray for workshop crane VAS 6208 under engine.

Scheme 360

1. Disconnect coolant hose - arrow - from left coolant pipe and drain coolant.

Scheme 361

1. Disconnect coolant hose next to left axle shaft from coolant pipe - arrow - and drain coolant.

Scheme 362

1. Disconnect coolant hoses - 1 - and - 2 - at radiator and drain coolant.

Scheme 363

1. Disconnect coolant hoses - arrows - and drain remaining coolant.

Scheme 364

1. Disconnect electrical connector - arrow - at Oil pressure switch F1.

Note. Illustration is shown with the lock carrier removed.

Scheme 365

1. Clamp off return hose for power steering pump with hose clamp 3094.
2. Disconnect return hose - 1 - from power steering pump.

Note. Ignore - 2 - in the illustration.

Scheme 366

1. Disconnect air duct hoses - 1 - and - 2 - at Secondary Air Injection (AIR) pump by pressing release buttons.

Scheme 367

1. Pull off both air duct hoses - arrows - at bottom of lower part of left air filter housing by pressing release buttons.

Scheme 368

1. Separate electrical connector - 3 - for Mass Air Flow (MAF) sensor 2 G246.
2. Disconnect hose - 2 - from air duct hose.
3. Disconnect air duct hose - 1 - at intake manifold.
4. Remove bolts - arrows -.

1. Remove upper part of left air filter housing.

Scheme 369

1. Remove air duct- 1 -.
2. Remove - arrows -.
3. Remove lower part of left air filter housing.

Scheme 370

1. Disconnect coolant hose - 2 -.
2. Disconnect air duct hoses - 1 - and - 3 - from combination valves.
3. Pull air duct hoses upward and out of engine compartment.

Note. Place a rag under hydraulic line to catch escaping hydraulic fluid.

1. Disconnect hydraulic pressure line - 2 - at power steering pump and set it aside on top of longitudinal member.

Note. Ignore - 1 - in the illustration. To prevent damage to the A/C compressor and to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Scheme 371

1. Disconnect refrigerant lines from A/C compressor - arrows -.
2. Plug openings of A/C compressor.

Scheme 372

1. Disconnect coolant hose - 1 -.
2. Disconnect vacuum hose - 2 - to brake booster.

Scheme 373

1. Disconnect Leak Detection Pump (LDP) V144 - arrow - to Leak Detection Pump (LDP) V144 from intake manifold.

Scheme 374

1. Separate electrical connector - 1 - for Mass Air Flow (MAF) sensor G70.
2. Disconnect air duct hose - 4 - at intake manifold.
3. Unhook retainer for connections - 2 - and - 3 - at upper part of air filter housing.
4. Remove bolts - arrows -.

1. Remove upper part of right air filter housing.

Scheme 375

1. Remove air duct - 1 -.
2. Remove bolts - arrows -.
3. Remove lower part of right air filter housing.

Scheme 376

Note. Place a rag under separating point to catch escaping coolant.

1. Disconnect coolant hose - arrow - at right on engine.

Scheme 377

1. Remove bolts - arrows - and remove right combination valve for secondary air injection.

Note. Ignore - 1 - in the illustration.

Scheme 378

1. Remove bolt - arrow - at torque support mount.

Scheme 379

1. Disconnect vacuum line to intake manifold - arrow -.

Scheme 380

1. Mark fuel return line - 1 - and fuel supply line - 2 -.

Scheme 381

1. Separate electrical connectors - 1 - and - 3 -.
2. Move electrical wiring clear.
3. Pull off vacuum hoses - 2 - and - 4 - at Evaporative Emission (EVAP) canister purge regulator valve N80 and at Evaporative Emission (EVAP) canister purge regulator valve 2 -N333-.
4. Move vacuum hoses clear.

Scheme 382

1. Disconnect electrical connection - 6 - at Throttle valve control module J338.
2. Disconnect vacuum hose - 1 -.
3. Pull off hoses - 4 - and - 5 - for crankcase breather.
4. Remove bolts - 2 - and - 3 -.

1. Remove right intake manifold side part.

Scheme 383

1. Remove rubber seal - 1 - for plenum chamber covers.
2. Remove plenum chamber covers - 2 - and - 3 -.

Scheme 384

1. Pry off caps on wiper arms with a screwdriver.
2. Loosen nuts - arrows - by several turns.
3. Loosen wiper arms by gently rocking them. Remove nuts and remove wiper arms.
4. Remove dust and pollen filter by opening 4 quick-release fasteners.

Note. Cover the air duct at air conditioning housing with a clean rag so that nothing can fall in.

Scheme 385

1. Remove bolts - arrows - at left and right for cowl grille - 1 -.
2. Carefully pull cowl grille off of retainers at windshield.

Scheme 386

1. Unfasten strut tower brace - arrow -.

Scheme 387

1. Remove bolts - 1 - and - 2 - and remove retaining bracket.
2. Release retaining tabs - arrows - and remove both engine control modules.

Note. The ECM electrical harnesses remain connected.

Scheme 388

1. Turn Air quality sensor G238 approx. 90° counter-clockwise - arrow - and remove from retainer.
2. Release retaining clips - 1 to 4 -.
3. Fold cover for electronics box in plenum chamber open slightly and pull off toward front.

Scheme 389

1. Disconnect multi-pin harness connectors - arrows - using spark plug connector pliers V.A.G 1922.
2. Disengage engine wiring harness at electronics box and at bulkhead.
3. Place wiring harness aside on engine with engine control modules connected.

Note. Protect the engine control modules from falling off.

Scheme 390

1. Disconnect coolant hose at bulkhead - arrow -.

Scheme 391

1. Remove right trim for A-pillar --> «70 - INTERIOR TRIM»(/audi/a8/d3-2005-2007/remont/gauges-instrument-panels/#body-interior) .
2. Fold floor covering back.
3. Remove protective cover from above main fuse holder.
4. Fold cover - 2 - aside.

1. Remove nut - 4 -.
2. Disconnect terminal 30 wiring to starter.

Note. Ignore - 1 - and - 3 - in the illustration.

Scheme 392

1. Unfasten harness clamp - 1 - in right front wheelhousing.
2. Pull wiring harness out from interior - arrow -.

Scheme 393

1. Separate electrical connectors - 1 - and - 3 -.
2. Unscrew Ground wire - 2 - on longitudinal member.
3. Unfasten bracket for wiring harness on longitudinal member - arrows - and place wiring harness aside.

Scheme 394

1. Loosen clamping sleeves - 1 - and - 2 -.

Scheme 395

1. Remove nuts - arrows - at retaining tabs for left and right front mufflers.

Scheme 396

Note. Decoupling elements at front mufflers must not be bent more than 10 danger of damage.

1. Remove nuts - arrows -.
2. Remove left front muffler with decoupling elements.

Scheme 397

1. Remove nuts - arrows -.
2. Remove right front muffler with decoupling elements.

Scheme 398

1. Remove heat shield for driveshaft - A - - arrows -.
2. Remove bolts at transmission/driveshaft flange.
3. Push driveshaft toward rear final drive. Constant velocity (CV) joints can move axially.
4. Tie up driveshaft to body.

Scheme 399

1. Remove bolts - arrows - at tunnel crossmember.

Scheme 400

1. Have a second mechanic press brake pedal.

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

Scheme 401

1. Loosen and remove bolts - arrows - uniformly at left and right.
2. Remove stabilizer.

Scheme 402

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

Scheme 403

1. Remove bolt from air spring damper at control arm - arrow -.

Scheme 404

1. Unbolt guide control arm - 1 - and control arm - 2 - on subframe.

Scheme 405

1. Pivot guide control arm - 1 - and control arm - 2 - outward.

1. Repeat work procedure on opposite side of vehicle.

Scheme 406

1. Remove heat shield above driveshaft from transmission - arrows -.
2. Unbolt driveshaft from transmission flange.

1. Pivot wheel bearing housing outward and remove drive axle.
2. Repeat work procedure on opposite side of vehicle.

Scheme 407

Preparing scissor lift platform

1. Equip scissor lift platform VAS 6131 with support set VAS 6131/10 and VAS 6131/11 as follows

*A washer must also be placed on the support element.

1. Screw support elements first tightly by hand on scissor lift platform.
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 or VAS 6131/11 on front of engine as shown in illustration.

Note. Place a washer - arrows - between the support elements VAS 6131/11-1 and the oil pan.

Scheme 409

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

Scheme 410

1. Position support elements from VAS 6131/10 at rear 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 411

1. Mark installation position of subframe and engine carrier to longitudinal members using a felt-tip marker.
2. Remove bolts - 1 - and - 4 -.
3. Remove bolts - 2 - and - 3 - in diagonal sequence and in stages.

Note. Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected. While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.

Scheme 412

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

1. Dimension - a - = 80 mm

Scheme 413

1. Unbolt heat shield for selector lever cable on left of transmission - arrows -.

Scheme 414

1. Press ball socket - 1 - of selector lever cable from selector shaft lever using pry lever 80-200.
2. Unclip locking plate - 2 - from selector lever cable bracket.
3. Move selector lever cable clear.

Note. While lowering, carefully guide engine/transmission assembly with subframe out of engine compartment in order to prevent damage.

1. Slowly lower engine/transmission subassembly downward.
2. Remove scissor lift table VAS 6131 from under vehicle.

Engine and Transmission, Separating

1. Engine/transmission unit removed and attached to scissor lift platform VAS 6131.

Scheme 415

1. Remove bolts - arrows - for front left and right transmission mounts.

Scheme 416

1. Remove bolt - arrow -.
2. Disconnect right bottom coolant pipe from coolant hose - 1 -.

Note. Ignore - 2 - in the illustration.

Scheme 417

1. Rotate spindles of support elements - 2 - at left and right of subframe completely downward.
2. Remove support pins from spindles.
3. Remove subframe - 3 - to side.

Note. A second technician is required to remove subframe.

1. Rotate spindles of support elements - 1 - at left and right of engine carrier - 4 - completely downward.

Scheme 418

1. Remove bolts - arrows - for engine mount at left and right.
2. Remove engine carrier.
3. Remove 4 base plates of support elements for engine carrier and subframe on scissor lift table VAS 6131.

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

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

*Support elements remain unchanged.

*Two washers (3 mm thick) must also be placed on support element.

Scheme 419

1. Remove bolt - 1 - from bottom left of engine/transmission flange.
2. Place two washers - arrows - (3 mm total thickness) on mounting pins of support elements VAS 6131/10-11 at rear of engine.

Scheme 420

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

Scheme 421

1. Position support elements from VAS 6131/10 at right on engine/transmission as shown in illustration.
2. Twist 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 422

Note. Place a rag under separating point to catch escaping coolant.

1. Disconnect coolant hoses - arrows - from the left coolant pipes.

Scheme 423

1. Remove bolts - 1 -.
2. Pull the oil dipstick guide tube upward and off - arrow -.

Scheme 424

1. Disconnect electrical harness connectors - 1 to 8 - for oxygen sensors.

Note. To disconnect electrical connectors - 3 - and - 6 - , unclip bracket for connectors from air filter housing and turn over (shown in close-up).

Scheme 425

1. Remove bolts - arrows - and pivot bracket for left exhaust manifolds with catalytic converters downward.

Scheme 426

1. Remove nuts - 1 to 4 - and remove both left exhaust manifolds with catalytic converters.

Scheme 427

1. Disconnect electrical harness connector at left on transmission, by pivoting twist lock counterclockwise - arrow -.

Scheme 428

1. Disconnect electrical harness connector - arrow - at Sensor for transmission RPM G182.

Scheme 429

1. Remove both bolts - 1 - and - 2 - for upper right coolant pipe.

Note. Ignore - arrows - in the illustration. The coolant pipe remains in the installed position.

Scheme 430

1. Disconnect coolant hoses - arrows -.
2. Remove bolts - 1 -.
3. Disconnect coolant connections at engine oil cooler.

Scheme 431

1. Remove bolts - arrows - and pivot the bracket for right exhaust manifolds with catalytic converters downward.

Scheme 432

1. Remove nuts - 1 to 4 - and remove both right exhaust manifolds with catalytic converters.

Scheme 433

1. Disconnect electrical harness connector - arrow - at right engine mount.
2. Remove bolts - 1 to 6 -.
3. Remove engine support with engine mount.

Scheme 434

1. Remove Ground wire - 4 - on starter.
2. Disconnect electrical wires - 2 - and - 3 - on starter.
3. Unscrew bolts - 1 - and - 5 - and remove starter.

Scheme 435

1. Unfasten 6 bolts - arrows - of torque converter in opening of removed starter (turn crankshaft 1 / 3 rotation in each case).

Note. To loosen the torque converter bolts, counterhold on the central bolt of the crankshaft.

1. Remove engine/transmission connecting bolts.

Scheme 436

1. Loosen side clamping screws - 1 - on scissor lift platform VAS 6131 and pull rear platform top with transmission toward rear - arrow - , simultaneously pushing torque converter through opening of drive plate.
2. Secure torque converter in transmission to prevent it from falling out.

Note. After removing the engine from the scissor lift table VAS 6131 , do not set it down on the oil pan. For performing work, lift engine using workshop crane VAS 6100 and secure to engine and transmission holder VAS 6095 --> Engine, Securing to Assembly Stand .

Engine, Securing to Assembly Stand

Special tools, testers and auxiliary items required

Scheme 437

1. Engine sling 2024 A/2
2. Lifting tackle 3033
3. Engine and transmission holder VAS 6095 with adapter set VAS 6095/2
4. Shop crane VAS 6100

1. Lift arm extension for workshop crane VAS 6101
2. Bolt M8x20

Scheme 438

Work sequence

1. Engine separated from transmission --> «Engine and Transmission, Separating»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-and-transmission-separating) .

1. Remove bolt - arrow -.
2. Disconnect oil filler tube at cylinder head cover.

Scheme 439

1. Disconnect electrical connection - 7 - at Throttle valve control module 2 J544.
2. Separate vacuum lines - 3 - and - 5 -.
3. Pull off hoses - 2 - and - 6 - for crankcase breather.
4. Remove bolts - 1 - and - 4 -.

1. Remove left intake manifold side part.

Scheme 440

1. Fasten strap 2024 A/2 with bolt M8x20 - arrow - tightened to 20 Nm at right on engine.

Scheme 441

1. Attach lift arm extension VAS 6101 to workshop crane VAS 6100.
2. Hook engine sling 3033 onto workshop crane VAS 6100 with lift arm extension for workshop crane VAS 6101 as shown in illustration.
3. Lift engine from support elements of scissor lift platform VAS 6131.
4. Remove left engine support from cylinder block.

Scheme 442

1. Secure engine on engine/transmission holder VAS 6095 with adapter set VAS 6095/2 and bracket VAS 6095/1-1 as shown in illustration.

Engine, Installing

Note. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be reinstalled at the same location. Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary. Install intermediate plate between engine and transmission onto alignment bushings.

Installation dimension for torque converter, checking

Scheme 443

When torque converter is installed correctly, the distance - a - between the contact surface of threaded holes at the torque converter and contact surface of the bell housing on Automatic Transmission 09E is at least 6 mm.

1. Before guiding engine and transmission together, rotate torque converter and engine drive plate so that fastening locations are positioned at height of opening of removed starter.

1. Bolt transmission to engine.

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%.

Engine/transmission, fastening

Scheme 444

*Bolt class 10.9.

1. Use new ribbed bolts to secure torque converter to drive plate.
2. Hand-tighten 6 bolts - arrows - of torque converter in opening of removed starter (turn crankshaft 1 / 3 rotation in each case).
3. Then tighten bolts of torque converter to specified torque (Turn crankshaft 1 / 3 rotation in each case).

Installation is in reverse order of removal. Note the following.

1. Install exhaust manifolds with catalytic converters: Left --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb) , right --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb) .
2. Check routing of wiring on engine --> «Engine Wiring, Routing on Engine»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb) .
3. Before installation, use a tap to clean threaded bores in transmission flanged shaft for crankshaft of locking fluid residue.

1. Rotate spindles of support elements VAS 6131/10-11 and VAS 6131/10-12 downward at left of engine/transmission assembly.
2. Unscrew both base plates for left support element on scissor lift platform VAS 6131.

1. Rotate spindles of support elements VAS 6131/10-11 and VAS 6131/10-13 downward at right of engine/transmission assembly.
2. Unscrew both base plates for right support element on scissor lift platform VAS 6131.

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

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

*Support elements remain unchanged.

*Only install support elements after installing subframe.

1. Position engine carrier on both support elements VAS 6131/10-7.
2. Rotate spindles of the support elements VAS 6131/10-7 upward on both sides.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

1. Fasten bolts - arrows - for engine carrier on both sides.

Note. A second technician is required to install the subframe onto the support elements.

1. Position subframe on both support elements VAS 6131/10-8.
2. Rotate spindles of support elements VAS 6131/10-8 upward on both sides.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

1. Fasten bolts - arrows - of left and right transmission mounts.
2. Using scissor lift platform VAS 6131 , slowly guide engine/transmission assembly with subframe and engine carrier into body from below.

1. Raise engine/transmission slightly so that distance between subframe and body achieves dimension - a -.

1. Dimension - a - = 80 mm

1. Attach selector lever cable to transmission --> «37 - CONTROLS, HOUSING»(/audi/a8/d3-2005-2007/remont/automatic-trans/#6-speed-automatic-transmission-09e-awd) for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-289215-S16746576102008062700000) for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .

1. Align subframe according to markings on longitudinal members.
2. Tighten bolts for subframe only to specified initial torque. Do not turn further (tighten bolts only after wheel alignment).

1. 50 Nm
2. 150 Nm
3. 150 Nm

1. Fasten bolts - 4 - for engine carrier.

1. Fasten bolts - arrows - at tunnel crossmember.
2. Install driveshaft --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a8/d3-2005-2007/remont/differentials-drive-axles/#rear-final-drive-0ar) .
3. Align exhaust system free of tension --> «Exhaust system, installing free of tension»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__exhaust-system-installing-free-of-tension) .
4. Install guide links, control arms and stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Install refrigerant lines --> «87 - AIR CONDITIONING»(/audi/a8/d3-2005-2007/remont/ac-compressor/#heating-air-conditioning) .
3. Install intake manifold side part: --> «Intake Manifold Left Side, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-left-side-removing-and) and --> «Intake Manifold Right Side, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-right-side-removing-and) .
4. Install strut tower brace --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 445

1. Adjust mount of torque support before fastening it. To adjust, rotate adjustment ring - 1 - until it rests against bracket of torque support.
2. Check harness connectors and routing: --> Electrical Wiring Diagrams, Troubleshooting Component Locations.
3. Observe safety precautions after connecting battery --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .

1. Check oil level --> «Engine Oil Level, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-level-checking) .
2. Fill with coolant. --> Filling under «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling)

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

1. Fill with fluid for power steering system and bleed steering system --> «48 - STEERING»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Fill refrigerant circuit --> «87 - AIR CONDITIONING»(/audi/a8/d3-2005-2007/remont/ac-compressor/#heating-air-conditioning) .
3. Install and adjust wiper arms --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .
4. Check adjustment of selector lever cable --> «37 - CONTROLS, HOUSING»(/audi/a8/d3-2005-2007/remont/automatic-trans/#6-speed-automatic-transmission-09e-awd) for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-289215-S16746576102008062700000) for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE.

1. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Perform wheel alignment --> «44 - WHEELS, TIRES AND WHEEL ALIGNMENT»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Inspect fuel system for leaks --> «Fuel Supply System, Checking for Leaks»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__fuel-supply-system-checking-for-leaks) .

Tightening torques

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%.

*Replace bolts.

Scheme 446

1 - Heat insulation sleeve

1. Attach to Camshaft Position (CMP) sensor 4 G301

2 - Electrical harnesses for camshaft adjusters

1. Clip into retainers

3 - Cable tie with clip

1. Clip into hole of bracket

4 - Retaining clip

1. Tighten to 9 Nm

5 - Ground (GND) wire

1. Tighten to 9 Nm

6 - Cable tie for oxygen sensor harnesses

1. Fasten to wiring to ignition coils cyl. 1 to 3 and cyl. 4 to 6

7 - Cable tie for oxygen sensor harnesses

1. Clip into hole of bracket

8 - Retaining clip

1. Tighten to 9 Nm

9 - Electrical harnesses for camshaft adjusters

1. Clip into retainers

10 - Heat insulation sleeve

1. Attach to Camshaft Position (CMP) sensor 3 G300

11 - Harness clip

1. Clip into holes

12 - Ground (GND) wire

1. Tighten to 9 Nm

Engine, Disassembling and Assembling

> Lock Carrier, Moving into Service Position

> Subframe, Lowering for Repair

Lock Carrier, Moving into Service Position

Special tools, testers and auxiliary items required

Scheme 447

1. Support tool 3369

Work sequence

1. Activate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Remove both front wheels.

Note. Secure the brake discs with wheel bolts.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of auxiliary heater on sound insulation.

1. Loosen quick-release fasteners - 1 - and remove front sound insulation.
2. Remove front part of left and right front wheelhouse liners --> «66 - EXTERIOR EQUIPMENT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove front bumper cover --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 448

1. Disconnect harness connector - 2 - and move wiring clear.
2. Remove bolts - 1 -.
3. Disconnect air ducting for auxiliary cooler.

Note. To prevent damage to the A/C compressor and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Scheme 449

1. Unclip refrigerant line at lock carrier - arrow -.
2. Free up hood release cable at left front of lock carrier.

Scheme 450

1. In left and right wheelhousing, unfasten nut - 1 - and bolt - 2 - for lock carrier.

Scheme 451

1. On both sides, remove bolts - 1 to 5 -.

Note. First, remove one bolt from left and right sides and mark the installed position of the lock carrier in the bolt hole using a felt tip marker.

Scheme 452

1. Remove bolts from sleeves of special tool support tool 3369.
2. Thread bolts from support tool 3369 at left and right into upper holes of impact absorber.
3. Pull off hood seal on both fenders.

Scheme 453

1. Remove one bolt - arrow - at top of lock carrier on left and right.
2. Carefully pull lock carrier toward front.

Installing

Installation is in reverse order of removal. Note the following

1. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install front bumper cover --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
4. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a8/d3-2005-2007/remont/procedures/#maintenance-procedures) .

Belt Pulley Side, Servicing

> Power Steering Pump Ribbed Belt Drive, Generator and Air Conditioning, Assembly Overview

> Ribbed Belt, Removing and Installing

> Power Steering Pump Belt Pulley and Air Conditioning Compressor Belt Pulley, Checking Alignment

> Vibration Damper, Removing and Installing

> Crankshaft Seal, Ribbed Belt Side, Replacing

Scheme 454

1 - Ribbed belt

1. Before removing, mark direction of rotation using chalk or felt-tip marker. Reversing direction of rotation of a run-in belt can damage belt
2. Removing and installing --> «Ribbed Belt, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__ribbed-belt-removing-and-installing)
3. Check for wear

2 - 23 Nm

3 - Generator

1. Removing and installing --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment)

4 - Cap for right idler roller

5 - Right idler roller for ribbed belt

1. Tighten to 32 Nm

6 - 23 Nm

7 - Tensioning spring for tensioning roller

1. With hydraulic damper
2. Installed location: lettering "TOP" faces up

8 - 8 Nm

9 - Belt pulley for coolant pump

10 - 10 Nm

11 - Coolant pump

1. Removing and installing --> «Coolant Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-pump-removing-and-installing)

12 - Cap for left idler roller

13 - Left idler roller for ribbed belt

1. Tighten to 32 Nm

14 - Tensioning roller with relay lever

15 - Alignment bushing

1. 2 pieces

16 - Bracket for air conditioning compressor

1. After replacing, check alignment of power steering pump pulley and air conditioning compressor pulley --> «Power Steering Pump Belt Pulley and Air Conditioning Compressor Belt Pulley, Checking Alignment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__power-steering-pump-belt-pulley-and)

17 - 23 Nm

18 - Fitting sleeves

1. 2 pieces

19 - Air conditioner compressor

1. Removing and installing --> «87 - AIR CONDITIONING»(/audi/a8/d3-2005-2007/remont/ac-compressor/#heating-air-conditioning)

20 - Alignment bushing

1. 2 pieces

21 - Bracket for power steering pump

1. After replacing, check alignment of power steering pump pulley and air conditioning compressor pulley --> «Power Steering Pump Belt Pulley and Air Conditioning Compressor Belt Pulley, Checking Alignment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__power-steering-pump-belt-pulley-and)

22 - 23 Nm

23 - 32 Nm

24 - Power steering pump

1. Removing and installing --> «48 - STEERING»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering)
2. After replacing, check alignment of power steering pump pulley and air conditioning compressor pulley --> «Power Steering Pump Belt Pulley and Air Conditioning Compressor Belt Pulley, Checking Alignment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__power-steering-pump-belt-pulley-and)

25 - Shim

1. Various thicknesses
2. After changing power steering pump, air conditioning compressor, power steering pump bracket, air conditioning compressor bracket or upper part of oil pan, check alignment of power steering pump and air conditioning compressor pulleys --> «Power Steering Pump Belt Pulley and Air Conditioning Compressor Belt Pulley, Checking Alignment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__power-steering-pump-belt-pulley-and)

26 - Belt pulley for power steering pump

27 - 23 Nm

28 - 23 Nm

29 - 25 Nm

30 - 32 Nm plus 1 / 4 turn (90)

1. Replace

31 - Vibration damper

1. With belt pulley for ribbed belt
2. Removing and installing --> «Vibration Damper, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__vibration-damper-removing-and-installing)

32 - 100 Nm plus 1 / 4 turn (90)

1. Replace
2. Use counter-holder T10069 to loosen and tighten

Ribbed Belt, Removing and Installing

Removing

1. Bring lock carrier into service position --> «Lock Carrier, Moving into Service Position»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__lock-carrier-moving-into-service-position) .
2. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
3. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

Scheme 455

Note. Before removing the ribbed belt, mark the turning direction of the belt with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

1. To relieve tension on ribbed belt, pivot tensioner in direction of - arrow - using a box-end 30 mm wrench.
2. Remove ribbed belt and release tensioning device.

Installing

Installation is in reverse order of removal. Note the following

Scheme 456

1. Place ribbed belt onto vibration damper belt pulley, then onto remaining belt pulleys, and finally onto tensioning roller.

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

1. Check alignment of power steering pump and air conditioning compressor belt pulleys after changing any of following components --> «Power Steering Pump Belt Pulley and Air Conditioning Compressor Belt Pulley, Checking Alignment»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__power-steering-pump-belt-pulley-and) .

1. Power steering pump
2. Bracket for power steering pump
3. Air conditioner compressor
4. Bracket for air conditioning compressor

1. Oil pan (upper section)

1. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Install front bumper cover --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
4. Start engine and check belt running.

1. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a8/d3-2005-2007/remont/procedures/#maintenance-procedures) .

Power Steering Pump Belt Pulley and Air Conditioning Compressor Belt Pulley, Checking Alignment

Note. To prevent damage to the ribbed belt, the alignment of the air conditioning compressor and power steering pump belt pulleys must be checked.

1. Check alignment of power steering pump and air conditioning compressor belt pulleys after changing any of following components

1. Power-steering pump
2. Bracket for power steering pump
3. Air conditioner compressor
4. Bracket for air conditioning compressor

1. Oil pan (upper section)

Special tools, testers and auxiliary items required

Scheme 457

1. Alignment gauge 3201

Requirement

1. Ribbed belt removed.

Work sequence

Scheme 458

1. Set alignment gauge 3201 onto ribbed belt pulley of air conditioning compressor.
2. Determine center point of power steering pump shaft by axially moving pump shaft back and forth.

1. Ribbed belt pulley for power steering pump must be aligned at center point with that of belt pulley for air conditioning compressor.

If both ribbed belt pulleys do not align

Scheme 459

1. Remove bolts - arrows - for power steering pump belt pulley.

1. Installed location: Protrusion - 1 - on ribbed belt pulley faces in direction of travel.

Scheme 460

1. Align offset of power steering pump belt pulley - 2 - to air conditioning compressor belt pulley using shims - 3 - of various thicknesses.
2. Fasten bolt - 1 -.
3. To finish, verify alignment of ribbed belt pulleys using alignment gauge 3201. If necessary, repeat adjustment.

Tightening torque

Vibration Damper, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 461

1. Counter-holder tool T10069

Removing

1. Bring lock carrier into service position --> «Lock Carrier, Moving into Service Position»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__lock-carrier-moving-into-service-position) .

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

Note. Before removing the ribbed belt, mark the turning direction on the belt with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

1. To relieve tension on ribbed belt, pivot tensioner in direction of - arrow - , using a box-end 30 mm wrench.
2. Remove ribbed belt and release tensioning device.

Scheme 462

1. Loosen center bolt - 1 - of vibration damper by holding vibration damper with counter-holder T10069.
2. Remove vibration damper.

Installing

Installation is in reverse order of removal. Note the following

Note. Always use a new center bolt to fasten the vibration damper. There must be no oil on the contact surfaces between the vibration damper and crankshaft. Also, do not oil the center bolt for the vibration damper.

1. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__ribbed-belt-removing-and-installing) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Install front bumper cover --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a8/d3-2005-2007/remont/procedures/#maintenance-procedures) .

Tightening torque

*Replace bolt.

* 90 corresponds to one quarter rotation.

Timing Chain Side, Servicing

> Drive Plate, Assembly Overview

> Drive Plate, Removing and Installing

> Timing Chain Covers, Assembly overview

> Crankshaft Seal, Timing Chain Side, Replacing

> Seals for Threaded Studs, Replacing

> Timing Chain Covers, Removing and Installing

> Timing Chains for Camshaft Drive, Removing and Installing

> Timing Chains for Camshaft Drive, Assembly Overview

> Camshaft Timing Chain, Removing and Installing

> Drive Chain, Assembly Overview

> Drive Chain, Removing and Installing

Scheme 463

1 - Drive plate

1. Removing and installing --> «Drive Plate, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__drive-plate-removing-and-installing)
2. Mark for reinstallation

2 - Washer

1. Mark for reinstallation

3 - 60 Nm plus 1 / 4 turn (90)

1. Replace

4 - Crankshaft

Drive Plate, Removing and Installing

Special tools, testers and auxiliary items required

1. Counter-holder tool T10069

Removing

1. Engine removed.
2. Engine separated from transmission.

1. Counter-hold crankshaft using counter-holder T10069 placed on vibration damper.

Note. Ignore - 1 - in the illustration.

Scheme 464

1. Mark installation position on drive plate to crankshaft using a felt-tip marker.
2. Unbolt drive plate - arrow -.

Installing

Installation is in reverse order of removal. Note the following

Always use new bolts when securing the drive plate.

Tightening torque

*Replace bolts.

* 90 corresponds to one quarter rotation.

Scheme 465

1 - Sealing ring for crankshaft - timing chain side

1. Replace
2. Removing and installing --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__crankshaft-seal-timing-chain-side-replacing)

2 - Seals for threaded studs

1. Replace
2. Removing and installing --> «Seals for Threaded Studs, Replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__seals-for-threaded-studs-replacing)

3 - 20 Nm

4 - 10 Nm

1. Observe tightening sequence --> see scheme 162

5 - 9 Nm

1. Insert using locking compound .

6 - Camshaft Position (CMP) sensor 4 G301

1. For exhaust camshaft cylinder bank 2 (left)

7 - O-ring

1. Replace

8 - 9 Nm

1. Insert using locking compound .

9 - Camshaft Position (CMP) sensor 2 G163

1. For intake camshaft cylinder bank 2 (left)

10 - O-ring

1. Replace

11 - 10 Nm

1. Observe tightening sequence --> see scheme 162

12 - Left cover for timing chain

1. After removal, replace cover with threaded fitting using newer version without threaded fitting

13 - 9 Nm

1. Insert using locking compound .

14 - Camshaft Position (CMP) sensor G40

1. For intake camshaft cylinder bank 1 (right)

15 - O-ring

1. Replace

16 - 10 Nm

1. Observe tightening sequence --> see scheme 163

17 - Right cover for timing chain

18 - 10 Nm

1. Observe tightening sequence --> see scheme 163

19 - O-ring

1. Replace
2. Insert into timing chain cover

20 - O-ring

1. Replace

21 - Oil seal

22 - Chain tensioner for right timing chain

1. Fasten to 60 Nm

23 - Camshaft Position (CMP) sensor 3 G300

1. For exhaust camshaft cylinder bank 1 (right)

24 - 9 Nm

1. Insert using locking compound .

25 - 10 Nm

26 - Lower timing chain cover

Crankshaft Seal, Timing Chain Side, Replacing

Special tools, testers and auxiliary items required

Scheme 466

1. Seal installer 2003
2. Counter-holder tool T10069
3. Pulling hook T20143/2

Work sequence

1. Engine removed
2. Engine separated from transmission

1. Counter-hold crankshaft using counter-holder T10069 placed on vibration damper.

Note. Ignore - 1 - in the illustration.

1. Mark installation position on drive plate to crankshaft using a felt-tip marker.

1. Remove bolts and drive plate - arrow -.

Scheme 467

1. Pry out seal using pulling hook T20143/2 - arrow -.
2. Clean operating and sealing surfaces.

Scheme 468

1. Push new seal onto crankshaft using press sleeve 2003/2 A.

Scheme 469

1. Press new seal into drive plate up to stop using seal installer 2003/3 and bolts - 1 - and - 2 -.
2. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__drive-plate-removing-and-installing) .

Seals for Threaded Studs, Replacing

Work sequence

1. Engine removed
2. Engine separated from transmission

Scheme 470

1. Pry out seals - 1 - using a screwdriver.
2. Clean sealing surfaces to ensure they are free of grease.
3. Carefully press in new seal up to stop using a 24 mm socket.

Timing Chain Covers, Removing and Installing

Special tools, testers and auxiliary items required

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

Removing

1. Engine removed
2. Engine separated from transmission

Note. During installation, reinstall all heat insulation sleeves at the same locations. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__drive-plate-removing-and-installing) .
2. Remove upper part of intake manifold: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .
3. Remove intake manifold lower part: --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and) .
4. Remove cylinder head covers --> «Cylinder Head Cover, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-head-cover-removing-and-installing) .

Scheme 471

1. Button heat insulation sleeve over camshaft position sensors for exhaust camshaft on both cylinder banks.
2. Disconnect electrical connections on camshaft position sensors for exhaust camshaft - arrow - and intake camshaft on both cylinder banks.

Scheme 472

1. Separate electrical connection - 2 - at Map controlled engine cooling thermostat F265.
2. Disconnect Ground wire - 3 - on cylinder head.
3. Loosen harness clamp - 1 - and free harness from upper coolant pipe.

Scheme 473

1. Remove bolts - 1 to 3 -.
2. Disconnect coolant hoses at upper coolant pipe - arrows -.
3. Remove upper coolant pipe.

Scheme 474

1. Disconnect coolant hoses - arrows - at upper left coolant pipe.
2. Remove bolts - 1 - and - 2 - and nut - 3 -.
3. Remove upper left coolant pipe.

Scheme 475

1. Disconnect electrical harness connector - 3 - at Engine Coolant Temperature (ECT) sensor G62.
2. Remove bolt - 4 - and remove guide tube - 1 - for wiring harness from engine.
3. Pull pipe connections - 2 - off of cylinder block.

Scheme 476

1. Disconnect coolant hoses - arrows - at lower right coolant pipe.
2. Remove bolts - 1 - and - 2 -.
3. Pull lower right coolant pipe rearward and off of cylinder head.

Scheme 477

1. Remove bolts - 1 -.
2. Pull middle right coolant pipe off of coolant hoses at positions indicated by - arrows -.

Scheme 478

1. Remove bolts - 1 to 3 - and remove left timing chain cover.

Scheme 479

1. Remove chain tensioner for camshaft timing chain - arrow -.
2. Remove bolts - 1 to 4 - and remove right timing chain cover.

Scheme 480

1. Remove bolts - 1 to 6 - and remove lower timing chain cover.
2. Press crankshaft seal - timing chain side - out of lower timing chain cover.

1. Pry out seals - 1 - for threaded studs using a screwdriver.

Installing

Installation is performed in reverse order of removal. Note the following

Note. Replace gaskets, seals and O-rings. During installation, protective heat sleeves must be reinstalled at the same location. During installation, all cable ties must be reinstalled at the same location.

Scheme 481

1. Using a rotating plastic brush, remove sealant residue on timing chain covers and on cylinder block and cylinder head.

1. Clean sealing surfaces to ensure they are free of oil and grease.

Note. Timing chain covers must be installed within 15 minutes after applying sealant.

Scheme 482

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

Scheme 483

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

1. Thickness of sealant bead: 1.5 to 2.0 mm

1. Set lower timing chain cover in place and fasten bolts - 1 to 6 - in a diagonal sequence.

Scheme 484

1. Apply a thin bead of sealant to edges between lower cover and left and right covers for timing chain - arrows -.

Scheme 485

1. Apply a sealant bead - arrow - on clean sealing surfaces of lower left and right timing chain covers, as shown in illustration.

1. Thickness of sealant bead: 1.5 to 2.0 mm.

1. Place O-ring - 1 - into right timing chain cover.

1. Set left timing chain cover in place and fasten bolts as follows: Tighten bolts to 1 and 3 to 5 Nm. Tighten bolts 2 to 10 Nm. Tighten bolts to 1 and 3 to 10 Nm.

1. Set right timing chain cover in place and fasten bolts as follows: Tighten bolts 2 , 3 and 4 to 5 Nm. Tighten bolts 1 to 10 Nm. Tighten bolts 2 , 3 and 4 to 10 Nm.

1. Fasten chain tensioner for camshaft timing chain - arrow - with a new seal.
2. Install crankshaft seal - timing belt side - --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__crankshaft-seal-timing-chain-side-replacing) .
3. Install seals for threaded studs --> «Seals for Threaded Studs, Replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__seals-for-threaded-studs-replacing) .
4. Install middle right coolant pipe. --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

1. Install lower right coolant pipe. --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)
2. Install upper left coolant pipe --> «Upper left coolant pipe, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__upper-left-coolant-pipe-removing-and) .
3. Install upper coolant pipe. --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__installing)
4. Install cylinder head covers. --> Installing under «Cylinder Head Cover, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-head-cover-removing-and-installing)

1. Install intake manifold lower-part: --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and) .
2. Install intake manifold upper-part: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .
3. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__drive-plate-removing-and-installing) .

Tightening torques

Timing Chains for Camshaft Drive, Removing and Installing

Note. The crankshaft holder 3242 serves exclusively to lock the crankshaft at TDC. To counterhold, the counter-holder tool T10069 must be used. The camshaft bar T10068 serves exclusively to lock the camshaft at TDC. To counterhold, an open-end 32 mm wrench must be set on the hex of the camshaft.

Scheme 486

1 - Chain sprocket for camshaft drive

1. Removing and installing --> Drive Chain, Removing and Installing

2 - Pivot pin, 15 Nm

3 - Guide rail

4 - 60 Nm plus 1 / 4 turn (90)

1. Replace
2. There must be no oil on contact surfaces between camshaft adjuster and camshaft or between bolt head and camshaft adjuster
3. Counterhold camshaft using open-end 32 mm wrench when loosening and tightening

5 - Exhaust camshaft adjuster

1. For cylinder bank 2 (left)
2. Identification: B2/Front side made of plastic
3. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)

6 - Camshaft timing chain

1. For cylinder bank 2 (left)

7 - Intake camshaft adjuster

1. For cylinder bank 2 (left)
2. Identification: B2/A2
3. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)

8 - 9 Nm

9 - 20 Nm

10 - 9 Nm

1. Insert using locking compound .

11 - Housing for camshaft adjustment solenoid valves

1. For cylinder bank 2 (left)
2. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)

12 - Tensioning rail

1. For cylinder bank 2 (left)

13 - Pivot pin, 42 Nm

1. With external hex
2. Insert using locking compound .

14 - Guide piece

15 - Chain tensioner

1. Lock chain tensioner with drill (3.5 mm diameter)

16 - Guide rail

1. With external hex

17 - Pivot pin, 15 Nm

18 - Intake camshaft adjuster

1. For cylinder bank 1 (right)
2. Identification: B1/A2
3. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)

19 - Housing for camshaft adjustment solenoid valves

1. For cylinder bank 1 (right)
2. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)

20 - 9 Nm

1. Insert using locking compound .

21 - Exhaust camshaft adjuster

1. For cylinder bank 1 (right)
2. Identification: B1/Front side made of plastic
3. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)

22 - 60 Nm plus 1 / 4 turn (90)

1. Replace
2. There must be no oil on contact surfaces between camshaft adjuster and camshaft or between bolt head and camshaft adjuster
3. Counterhold camshaft using open-end 32 mm wrench when loosening and tightening

23 - Camshaft timing chain

1. For cylinder bank 1 (right)

24 - Pivot pin, 25 Nm

1. With collar
2. Insert using locking compound .

25 - Chain tensioner

1. Fasten to 60 Nm

26 - Oil seal

1. Replace

27 - Tensioning rail

Camshaft Timing Chain, Removing and Installing

Note. The camshaft bar T10068 serves exclusively to lock the camshaft at TDC. To counterhold, an open-end 32 mm wrench must be set on the hex of the camshaft.

Special tools, testers and auxiliary items required

Scheme 487

1. Crankshaft holder 3242

Scheme 488

1. Camshaft bar T10068
2. Drill bit, 3.5 mm diameter

Removing

1. Engine removed
2. Engine separated from transmission

1. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__drive-plate-removing-and-installing) .
2. Remove upper part of intake manifold: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .
3. Remove intake manifold lower part: --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and) .
4. Remove cylinder head covers --> «Cylinder Head Cover, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-head-cover-removing-and-installing) .

1. Rotate crankshaft at center bolt in direction of engine rotation to TDC of ignition timing.

Scheme 489

1. Marking - 2 - on vibration damper must align with housing separation point - 1 -.

Scheme 490

1. At same time, camshaft bar T10068 must engage in both shaft grooves.

1. If necessary, turn crankshaft one rotation further.

Scheme 491

Note. If necessary, turn camshafts back and forth slightly using an open-end 32 mm wrench. Camshaft bar T10068 must not be installed during this process.

Scheme 492

1. Remove sealing plug from left side of cylinder block.
2. Thread crankshaft holder 3242 into hole (20 Nm).

Scheme 493

1. Remove all covers for timing chains --> «Timing Chain Covers, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__timing-chain-covers-removing-and-installing) .
2. If reusing current timing chains, mark direction of rotation and location of both left and right chains on chains with a paint marker.

Scheme 494

1. Push chain tensioner for camshaft timing chain on cylinder bank 2 (left) downward and lock in position with a 3.5 mm drill - 1 -.
2. Remove bolts - 6 - and remove chain tensioner - 5 -.
3. Remove bolt - 3 - and remove guide piece - 2 -.
4. Pull tensioning rail - 4 - from pivot pins.

Scheme 495

1. Pull guide rail - 1 - from pivot pins.

Scheme 496

1. Remove pivot pins - 1 -.
2. Remove timing chain for cylinder bank 2 (left), beginning at intake camshaft adjuster - 2 -.

Note. To ease the removal of the timing chain, rotate the camshaft adjuster back and forth slightly.

Scheme 497

1. Pull tensioning rail - 1 - and guide rail - 2 - for cylinder bank 1 (right) from pivot pins.

Note. To ease the removal of the guide rail, rotate the intake camshaft slightly to the left at the hex.

Scheme 498

1. Remove pivot pins - 1 -.
2. Remove timing chain for cylinder bank 1 (right), beginning at intake camshaft adjuster - 2 -.

Note. To ease the removal of the timing chain, rotate the camshaft adjuster back and forth slightly.

Installing

1. Secure camshaft in TDC position using camshaft bar T10068.
2. Secure crankshaft in TDC position using crankshaft holder 3242.
3. Drive chain installed --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__installing) .

Scheme 499

1. Place camshaft timing chain for cylinder bank 1 (right) onto chain sprocket for camshaft drive and onto camshaft adjuster.

1. The copper-colored chain links face the transmission.
2. The copper-colored chain links - arrows - must be positioned to the chain sprockets as shown in the illustration.
3. The exact positions are shown in the following illustrations.

Chain sprocket for camshaft drive

Scheme 500

1. The copper-colored chain link - 1 - must be positioned centrally to threaded hole - 2 - when camshaft timing chain - 3 - is tensioned.

Note. The copper-colored chain link that is located behind on the drive chain is only positioned as shown the first time it is laid in place. If the drive chain was not removed, the placement of the copper-colored chain link is of no significance.

Camshaft adjuster for exhaust camshaft

Scheme 501

1. The copper-colored chain link - arrow - must align with marking - 1 - on the exhaust camshaft adjuster.

Camshaft adjuster for intake camshaft

Scheme 502

1. The copper-colored chain link - arrow - must align with marking - 1 - on the intake camshaft adjuster.

1. Install pivot pin using locking compound .

1. Push guide rail - 2 - onto pivot pins.
2. Install tensioning rail - 1 -.

Note. If the guide rail cannot be pressed on, rotate the intake camshaft slightly to the left.

1. Place camshaft timing chain for cylinder bank 2 (left) onto chain sprocket for camshaft drive and onto camshaft adjuster.

1. The copper-colored chain link faces the engine.

Scheme 503

1. The copper-colored chain link - arrow - must be positioned to the chain sprockets as shown in the illustration.
2. The exact position is shown in the following illustrations.

1. Install guide rail - 1 - before checking position of chain.

Chain sprocket for camshaft drive

Scheme 504

1. The copper-colored chain link - 1 - must be positioned centrally to the threaded hole - 3 - when the camshaft timing chain - 2 - is tensioned.

Note. In the illustration, the copper-colored chain link - 4 - faces toward the viewer for improved clarity. When installed correctly, it faces in direction of the engine.

Verification

1. The copper-colored chain links - 1 - and - 4 - of the camshaft timing chain for the left and right cylinder banks must be positioned directly behind one another and be centrally aligned to the threaded hole - 3 - when installed properly.

Camshaft adjuster for exhaust camshaft

Scheme 505

1. The copper-colored chain link - arrow - must align with marking - 1 - on exhaust camshaft adjuster.

Camshaft adjuster for intake camshaft

Scheme 506

1. The copper-colored chain link - arrow - must align with marking - 1 - on intake camshaft adjuster.

1. Install pivot pins and tensioning rail - 4 -.
2. Fasten guide piece - 2 - with bolt - 3 -.
3. Fasten chain tensioner - 5 - with bolts - 6 -.
4. Pull 3.5 mm drill - 1 - out of alignment hole, thereby releasing chain tensioner.

Note. Before continuing the assembly, verify the correct positioning of the chain links to the markings.

1. Install timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__timing-chain-covers-removing-and-installing) .
2. Remove crankshaft holder 3242.

1. Turn crankshaft 2 rotations in engine direction of rotation, until marking - 2 - on vibration damper is aligned with housing separation point - 1 -.

1. Thread crankshaft holder 3242 into the hole (20 Nm).

1. Camshaft bar T10068 must engage in both shaft grooves.

1. If necessary, turn camshafts back and forth slightly using open-end 32 mm wrench. Camshaft bar T10068 must not be installed during this process.
2. Remove camshaft bar T10068.
3. Remove crankshaft holder 3242.
4. Screw sealing plug of TDC marking with new seal into bearing bracket.

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

1. Install cylinder head covers. --> Installing under «Cylinder Head Cover, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-head-cover-removing-and-installing)
2. Install intake manifold lower-part: --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and) .
3. Install intake manifold upper-part: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .
4. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__drive-plate-removing-and-installing) .

Tightening torques

* Insert using locking compound .

Scheme 507

1 - Pivot pin, 15 Nm

1. Without collar

2 - Guide rail

3 - 60 Nm plus 1 / 4 turn (90)

1. Replace
2. Use counter-holder T10069 on vibration damper to loosen and tighten

4 - Mounting pin

5 - Chain sprocket for camshaft drive

1. With needle bearings
2. Replace chain sprocket if needle bearings are faulty
3. Removing and installing --> Drive Chain, Removing and Installing

6 - Countersunk screw, 10 Nm

1. Replace
2. Insert using locking compound .

7 - Intermediate shaft

8 - Gasket

1. Replace

9 - Chain tensioner with tensioning rail

1. For drive chain
2. Lock chain tensioner with drill (3.5 mm diameter)

10 - 9 Nm

11 - Timing chain

1. Crankshaft/Intermediate shaft

12 - Drive gear

1. Integral part of crankshaft

Cylinder Head, Removing and Installing

> Cylinder Head, Assembly Overview

> Cylinder Head Cover, Removing and Installing

> Cylinder head, removing and installing

Cylinder Head, Assembly Overview

Note. Cylinder head bank 1 (right) is displayed in illustration.

Scheme 508

1 - 23 Nm

2 - Lifting eye

3 - Cylinder head

1. Removing --> «Cylinder head, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-head-removing-and-installing)
2. Check for distortion --> «Checking cylinder head for distortion»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)
3. Installing --> «Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__installing)
4. Replace coolant after replacing cylinder head

4 - Pivot pin, 15 Nm

1. For guide rail
2. For right cylinder head

5 - Cylinder head bolt

1. Different lengths; long bolts are installed on outside
2. Replace
3. Observe sequence for loosening: Right --> «Cylinder bank 1 (right)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-bank-1-right) , Left --> «Cylinder bank 2 (left)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-bank-2-left)
4. Observe sequence for tightening: Right --> «Cylinder bank 1 (right)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-bank-1-right) , Left --> «Cylinder bank 2 (left)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-bank-2-left)

6 - Cylinder head cover

1. Removing and installing --> «Cylinder Head Cover, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-head-cover-removing-and-installing)

7 - Oil seals

1. Replace if damaged or leaking

8 - Ignition coil

1. Use ignition coil puller T10166 for removal --> «Removing ignition coils»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

9 - O-ring

1. Replace

10 - Crankcase ventilation pipe

11 - Special bolt, 8 Nm

1. Replace if damaged or leaking
2. Observe sequence for tightening --> (Scheme 521).

12 - Cylinder head cover gaskets

1. Replace if damaged or leaking

13 - Gasket

1. Replace

14 - Combination valve for Secondary Air Injection (AIR)

15 - 10 Nm

16 - Cylinder head gasket

1. Different versions for cylinder bank 1 (right) and 2 (left)
2. Replace --> «Cylinder head, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-head-removing-and-installing)
3. Installed location: Part number facing cylinder head
4. After replacing replace entire amount of coolant

Cylinder bank 1 (right)

Follow sequence - 1 to 20 - when loosening cylinder head bolts.

Note. Arrow points in direction of travel.

Scheme 509

Tightening sequence cylinder bank 1 (right)

Note. Arrow points in direction of travel.

Scheme 510

Cylinder bank 2 (left)

Follow sequence - 1 to 21 - when loosening cylinder head bolts.

Note. Arrow points in direction of travel.

Scheme 511

Tightening sequence cylinder bank 2 (left)

Note. Arrow points in direction of travel.

Scheme 512

Scheme 513

1. Remove ignition coils from spark plugs using ignition coil puller T10166.

Scheme 514

1. Check cylinder head at multiple points for distortion. Use a straight edge and feeler gauges.

1. Permissible distortion: max. 0.05 mm

Cylinder Head Cover, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 515

1. Ignition coil puller T10166
2. Sealant

Removing

Note. The following repair is described for cylinder head bank 2 (left) with the engine removed. For cylinder head bank 1 (right) the procedure is the same.

1. Remove upper part of intake manifold: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .

Scheme 516

1. Remove bolts - arrows -.

1. Remove ignition coils from spark plugs using ignition coil puller T10166.
2. Set wiring harness with ignition coils aside.

1. Disconnect vacuum hose - 2 - to brake booster.

Note. Ignore - 1 - in the illustration.

Scheme 517

1. Remove bracket for rear wiring harness at cylinder head cover.
2. Remove electrical harness connectors - 1 - and - 2 - for camshaft adjustment solenoid valves from bracket and disconnect.

Scheme 518

1. Loosen bolt - arrow - for left rear engine lifting eye by several turns.

Scheme 519

1. Remove bolts for left cylinder head cover in sequence - 1 to 12 -.
2. Remove cylinder head cover.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace cylinder head cover gaskets if damaged. Replace bolts if damaged or sealing improperly.

Scheme 520

1. Coat transitions - arrows - between timing chain cover and cylinder head with a drop of sealant.

Scheme 521

1. Tighten cylinder head cover in sequence - 1 to 12 -.
2. Install intake manifold upper-part: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .

Tightening torques

Intake Manifold, Removing and Installing

> Intake Manifold, Assembly Overview

> Intake Manifold Left Side, Removing and Installing

> Intake Manifold Right Side, Removing and Installing

> Intake Manifold Upper Section, Removing and Installing

> Intake Manifold Lower Section, Removing and Installing

> Compression, Checking

Scheme 522

1 - Intake manifold lower part

1. Removing and installing --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and)

2 - 9 Nm

3 - Gasket

1. Replace

4 - Fuel rail

1. Removing and installing --> «24 FUEL INJECTION SYSTEM»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-fuel-injection-and-ignition-engine-codes-bsb)

5 - 9 Nm

6 - Oil seal

1. Replace
2. Must be coated with engine oil "0W/30" when installing

7 - 22 Nm

8 - Intake manifold side-part

1. Left intake manifold side part, removing and installing --> «Intake Manifold Left Side, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-left-side-removing-and)
2. Right intake manifold side part, removing and installing --> «Intake Manifold Right Side, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-right-side-removing-and)
3. Minimal oil residue in intake manifold side part is acceptable

9 - Gasket

1. Replace if damaged

10 - 7 Nm plus 1 / 2 turn (180)

1. Replace
2. To install, coat with engine oil
3. Starting from middle, tighten in stages and in diagonal sequence

11 - Intake manifold upper part

1. Removing and installing --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and)

12 - Vacuum hose

1. To Evaporative Emission (EVAP) canister purge regulator valve 2 N333

13 - Vacuum hose

1. To suction jet pump for brake booster

14 - Gasket

1. Replace

15 - 9 Nm

16 - Throttle valve control module

1. Cylinder bank 1 (right): Throttle valve control module J338
2. Cylinder bank 2 (left): Throttle valve control module 2 -544

17 - Vacuum hose

1. To Leak Detection Pump (LDP) V144

18 - Pressure regulator valve for crankshaft housing ventilation

1. With oil separator

19 - 9 Nm

20 - O-ring

1. Replace
2. To install, moisten with fuel
3. Do not use lubricants containing silicone

21 - Gasket

1. Replace if damaged
2. Press nubs of gasket into cylinder head

Intake Manifold Left Side, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 523

1. Spring-type clip pliers VAS 5024 A

Removing

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

Scheme 524

1. Disconnect hose - 1 - from air duct.
2. Remove left air duct - arrows -.

1. Disconnect vacuum hose - arrow - to Leak Detection Pump (LDP) V144 from intake manifold.

1. Disconnect electrical connection - 7 - at Throttle valve control module 2 J544.
2. Disconnect vacuum lines - 3 - and - 5 -.
3. Pull off hoses - 2 - and - 6 - for crankcase breather.
4. Remove bolts - 1 - and - 4 -.

1. Remove left intake manifold side part.

Note. Minimal oil residue in the intake manifold side part is acceptable

Installing

Installation is in reverse order of removal. Note the following

Note. Replace O-rings. Replace gasket for intake manifold side part if damaged. Secure all hose connections using hose clamps appropriate for the model type .

Tightening torque

Intake Manifold Right Side, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 525

1. Hose clamp pliers V.A.G 1921

Removing

Note. During installation, reinstall all heat insulation sleeves at the same locations.

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

1. Disconnect electrical connector - 1 - for Mass Air Flow (MAF) sensor G70.
2. Disconnect air duct - 4 - at intake manifold.
3. Unhook retainer for connections - 2 - and - 3 - at upper part of air filter housing.
4. Remove bolts - arrows -.

1. Remove upper part of right air filter housing.

1. Pull off vacuum hose - 4 - from Evaporative Emission (EVAP) canister purge regulator valve N80.

Note. Ignore - 1 to 3 - in the illustration.

1. Disconnect electrical connection - 6 - at Throttle valve control module J338.
2. Disconnect vacuum hose - 1 -.
3. Pull off hoses - 4 - and - 5 - for crankcase breather.
4. Remove bolts - 2 - and - 3 -.

1. Remove right intake manifold side part.

Note. Minimal oil residue in the intake manifold side part is acceptable

Installing

Installation is in reverse order of removal. Note the following

Note. Replace O-rings. Replace gasket for intake manifold side part if damaged. During installation, protective heat sleeves must be re-installed at the same location. Secure all hose connections using hose clamps appropriate for the model type .

Tightening torque

Intake Manifold Upper Section, Removing and Installing

Special tools, testers and auxiliary items required

1. Spring-type clip pliers VAS 5024 A

Removing

Note. During installation, reinstall all heat insulation sleeves at the same locations. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

1. Disconnect hose - 1 - from air duct.
2. Remove left air duct - arrows -.

1. Disconnect vacuum hose - arrow - to Leak Detection Pump (LDP) V144 from intake manifold.

1. Disconnect electrical connection - 7 - at Throttle valve control module 2 J544.
2. Disconnect vacuum lines - 3 - and - 5 -.
3. Pull off hoses - 2 - and - 6 - for crankcase breather.

Note. Ignore - 1 - and - 4 - in the illustration.

1. Disconnect electrical connector - 1 - for Mass Air Flow (MAF) sensor G70.
2. Disconnect air duct - 4 - at intake manifold.
3. Unhook retainer for connections - 2 - and - 3 - at upper part of air filter housing.
4. Remove bolts - arrows -.

1. Remove upper part of right air filter housing.

1. Disconnect electrical connection - 6 - at Throttle valve control module J338.
2. Disconnect vacuum hose - 1 -.
3. Pull off hoses for crankcase breather - 4 - and - 5 -.

Note. Ignore - 2 - and - 3 - in the illustration.

1. Pull off vacuum hose - 4 - from Evaporative Emission (EVAP) canister purge regulator valve N80.

Note. Ignore - 1 to 3 - in the illustration.

Scheme 526

1. Remove bolts - arrows -.
2. Remove bolts - 1 - and - 2 - and remove intake manifold upper part.

Note. Plug the intake ports of the cylinder head with clean rags.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace gaskets and O-rings. During installation, protective heat sleeves must be reinstalled at the same location. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be reinstalled at the same location.

Tightening torques

*Observe different bolt lengths.

*Replace bolts.

* 180 corresponds to one half turn.

Intake Manifold Lower Section, Removing and Installing

Removing

Scheme 527

1. Remove upper part of intake manifold --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .
2. Disconnect electrical harness connector - arrow -.

Note. Illustration shows intake manifold lower part removed.

Scheme 528

1. Disconnect electrical connections at fuel injectors by pressing release tabs down and then inward - arrow -.

Scheme 529

1. Remove bolts for fuel rail - arrows -.
2. Pull fuel rail with fuel injectors upward and out.
3. Place fuel rail with connected fuel hose onto a clean cloth.

Scheme 530

1. Remove bolts - arrows -.
2. Remove intake manifold lower part.

Note. Plug the intake ports of the cylinder head with clean rags.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace O-rings. Replace gaskets for intake manifold lower-part if damaged.

1. Press nubs of gaskets for intake manifold lower part into holes on cylinder heads.
2. Install intake manifold upper part --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .

Tightening torques

*Fasten diagonally in steps.

Valve Gear, Servicing

> Camshafts, Assembly Overview

> Camshaft Timing Adjusters, Removing and Installing

> Control Housing for Camshaft Adjustment, Removing and Installing

> Camshafts, Removing and Installing

> Valve Stem Seals, Replacing

> Camshafts, Checking Axial Clearance

> Valve Guides, Checking

> Valves, Checking

> Valve Dimensions

> Valve Seats, Reworking

Note. Cylinder head bank 1 (right) is displayed in the following illustration. After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic lifter equalization elements must seat themselves (otherwise the valves will make contact with the pistons). After working on the valve gear and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.

Scheme 531

1 - Exhaust camshaft adjuster

1. For cylinder bank 1 (right) Identification: B1/Front side made of plastic
2. For cylinder bank 2 (left) Identification: B2/Front side made of plastic
3. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)

2 - 60 Nm plus 1 / 4 turn (90)

1. Replace
2. There must be no oil on contact surfaces between camshaft adjuster and camshaft or between bolt head and camshaft adjuster
3. Counterhold camshaft using open-end 32 mm wrench when loosening and tightening

3 - Intake camshaft adjuster

1. For cylinder bank 1 (right) Identification: B1/A1
2. For cylinder bank 2 (left) Identification: B2/A2
3. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)

4 - Strainer

1. 2 pieces
2. Clean

5 - Valve stem seal

1. Replace --> «Valve Stem Seals, Replacing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__valve-stem-seals-replacing)

6 - Valve spring

1. Installed location: Larger diameter faces cylinder head

7 - Valve spring plate

8 - Valve keys

9 - Piston rings for camshaft adjuster

1. Install with gaps offset by 120
2. Oil contact surfaces
3. When installing, only spread piston rings minimally

10 - 5 Nm plus 1 / 8 turn (45)

1. Observe tightening sequence: Right cylinder head --> «Cylinder bank 1 (right)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-bank-1-right) , Left cylinder head --> «Cylinder bank 2 (left)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-bank-2-left)

11 - Bearing cap

1. Mark bearing caps 6 and 9
2. Observe installed position and tightening sequence: Right cylinder head --> «Cylinder bank 1 (right)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-bank-1-right) , left cylinder head --> «Cylinder bank 2 (left)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cylinder-bank-2-left)
3. On bearing caps for axial bearing, lightly coat face surface with adhesive lubricating paste before installing --> «Coating face surface of bearing cap for axial bearing with adhesive lubricating paste»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

12 - Intake camshaft

1. Checking axial play --> «Camshafts, Checking Axial Clearance»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshafts-checking-axial-clearance)
2. Check radial clearance using Plastigage (roller rocker lever removed)
3. Radial clearance wear limit: 0.1 mm
4. Run-out: max. 0.01 mm

1. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)
2. Identification --> «Camshaft identification cylinder bank 1 (right)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb) and --> «Camshaft identification cylinder bank 2 (left)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

13 - Exhaust camshaft

1. Checking axial play --> «Camshafts, Checking Axial Clearance»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshafts-checking-axial-clearance)
2. Check radial clearance using Plastigage (roller rocker lever removed)
3. Radial clearance wear limit: 0.1 mm
4. Run-out: max. 0.01 mm

1. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)
2. Identification --> «Camshaft identification cylinder bank 1 (right)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb) and --> «Camshaft identification cylinder bank 2 (left)»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

14 - Roller rocker lever

1. Do not interchange
2. Check roller for easy movement
3. Lubricate contact surface

15 - Securing clip

1. Check for secure seat

16 - Support element

1. With hydraulic valve clearance compensation
2. Do not interchange
3. Lubricate contact surface

17 - Cylinder head

1. Checking valve guides --> «Valve Guides, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__valve-guides-checking)

18 - Exhaust valve

1. Mark installed position
2. Do not rework, only lapping is permitted
3. Valve dimensions --> «Valve Dimensions»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)
4. Checking valve guides --> «Valve Guides, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__valve-guides-checking)

1. Reworking valve seats --> «Valve Seats, Reworking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__valve-seats-reworking)

19 - Intake valve

1. Mark installed position
2. Do not rework, only lapping is permitted
3. Valve dimensions --> «Valve Dimensions»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)
4. Checking valve guides --> «Valve Guides, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__valve-guides-checking)

1. Reworking valve seats --> «Valve Seats, Reworking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__valve-seats-reworking)

20 - Control housing

1. Removing and installing --> «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)
2. Lightly lubricate contact surfaces of piston rings before installing

21 - 9 Nm

1. Insert using locking compound .

Scheme 532

A - Exhaust camshaft, Identification 07C - Index 104 J

B - Intake camshaft, Identification 07C - Index 102 L

Scheme 533

A - Intake camshaft, Identification 07C - Index 101 L

B - Exhaust camshaft, Identification 07C - Index 103 H

Scheme 534

Camshaft adjusters - arrows - are marked as follows

1. Intake camshaft timing adjuster for cylinder bank 1 (right): B1/A2
2. Exhaust camshaft timing adjuster for cylinder bank 1 (right): B1/Front side made of plastic
3. Intake camshaft timing adjuster for cylinder bank 2 (left): B2/A2
4. Exhaust camshaft timing adjuster for cylinder bank 2 (left): B2/Front side made of plastic

Scheme 535

1. Lightly coat face surface - shown as shaded area - of bearing caps 7, 8, 27 and 28 for axial bearing with adhesive lubricating paste G 052 723 A2 .

Camshaft Timing Adjusters, Removing and Installing

Removing

Note. Camshafts and crankshaft must not be rotated when the timing drive is disassembled. The camshaft bar T10068 serves exclusively to lock the camshaft at TDC. To counterhold, an open-end 32 mm wrench must be set on the hex of the camshaft. Engine removed Engine separated from transmission

1. Remove timing chains for camshafts --> «Camshaft Timing Chain, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-chain-removing-and-installing) .

Scheme 536

1. Loosen bolt for camshaft adjuster by counterholding at hex - arrow - of camshaft with an open-end 32 mm wrench.
2. Remove camshaft adjuster.

Installing

Note. There must be no oil on the contact surfaces between the camshaft adjuster and camshaft or between the bolt head and camshaft adjusters. Observe alignment pin in camshaft adjuster. Use new bolts when securing the camshaft adjuster.

1. When installing, observe identification of camshaft adjuster - arrows

1. Intake camshaft timing adjuster for cylinder bank 1 (right): B1/A2
2. Exhaust camshaft timing adjuster for cylinder bank 1 (right): B1/Front side made of plastic
3. Intake camshaft timing adjuster for cylinder bank 2 (left): B2/A2
4. Exhaust camshaft timing adjuster for cylinder bank 2 (left): B2/Front side made of plastic

Note. The camshaft bar T10068 serves exclusively to lock the camshaft at TDC. To counterhold, an open-end wrench 32 mm must be set on the hex of the camshaft. There must be no oil on the contact surfaces between the camshaft adjuster and camshaft or between the bolt head and camshaft adjuster

1. Counter-hold at hex - arrow - of camshaft with an open-end 32 mm wrench and tighten camshaft adjuster.
2. Install timing chains for camshafts --> «Camshaft Timing Chain, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-chain-removing-and-installing) .

Tightening torque

* 90° corresponds to one quarter rotation.

*Replace bolts.

Control Housing for Camshaft Adjustment, Removing and Installing

Removing

Note. Camshafts and crankshaft must not be rotated when the timing drive is disassembled. The camshaft bar T10068 serves exclusively to lock the camshaft at TDC. To counterhold, an open-end 32 mm wrench must be set on the hex of the camshaft. Engine removed Engine separated from transmission

1. Remove timing chains for camshafts --> «Timing Chains for Camshaft Drive, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__timing-chains-for-camshaft-drive-removing) .

1. Loosen bolt for camshaft adjuster by counterholding at hex - arrow - of camshaft with an open-end 32 mm wrench.
2. Remove camshaft adjuster.

Scheme 537

1. Remove bolts - arrows - and remove control housing for camshaft adjustment.

Installing

Scheme 538

Installation is in reverse order of removal. Note the following.

1. Clean strainer - arrows - on backside of control housing for camshaft adjustment.
2. Lightly oil contact surface for piston rings in control housing for camshaft adjustment.

Note. When installing control housing for camshaft adjustment, make sure that the piston rings are not damaged on the camshafts. The piston ring gaps must be offset by 120.

1. Place control housing for camshaft adjustment onto camshaft.

1. Fasten bolts - arrows - in a diagonal sequence.
2. Install camshaft adjusters. --> Installing under «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing)
3. Install timing chains for camshafts --> «Timing Chains for Camshaft Drive, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__timing-chains-for-camshaft-drive-removing) .

Tightening torque

* Insert using locking compound .

Camshafts, Removing and Installing

Removing

Note. Camshafts and crankshaft must not be rotated when the timing drive is disassembled. The camshaft bar T10068 serves exclusively to lock the camshaft at TDC. To counterhold, an open-end 32 mm wrench must be set on the hex of the camshaft. Engine removed Engine separated from transmission

1. Remove timing chains for camshafts --> «Timing Chains for Camshaft Drive, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__timing-chains-for-camshaft-drive-removing) .

1. Loosen bolts for camshaft adjuster by counterholding at hex - arrow - of camshaft with an open-end 32 mm wrench.
2. Remove camshaft adjuster.

1. Remove bolts - arrows - and remove control housing for camshaft adjustment.

Cylinder bank 1 (right)

Scheme 539

1. Remove intake camshaft - A - as follows

1. Remove bearing caps 1 and 13.
2. Remove bearing caps 5 and 9.
3. Remove bearing cap 7.
4. Loosen bearing caps 3 and 11 alternately and in diagonal sequence, and remove.

1. Remove exhaust camshaft - B - as follows

1. Remove bearing caps 2 and 14.
2. Remove bearing caps 6 and 10.
3. Remove bearing cap 8.
4. Loosen bearing caps 4 and 12 alternately and in diagonal sequence, and remove.

Cylinder bank 2 (left)

Scheme 540

1. Remove intake camshaft - A - as follows

1. Remove bearing caps 21 and 33.
2. Remove bearing caps 25 and 29.
3. Remove bearing cap 27.
4. Loosen bearing caps 23 and 31 alternately and in diagonal sequence, and remove.

1. Remove exhaust camshaft - B - as follows

1. Remove bearing caps 22 and 34.
2. Remove bearing caps 26 and 30.
3. Remove bearing cap 28.
4. Loosen bearing caps 24 and 32 alternately and in diagonal sequence, and remove.

Continuation for both cylinder banks

1. Carefully remove camshafts and place on a clean surface.

Note. Ensure that the roller rocker levers and the support elements are not interchanged. If necessary, remove roller rocker levers together with the support elements and place on a clean surface.

Installing

1. Secure crankshaft in TDC position using crankshaft holder 3242.

1. Place support elements together with roller rocker levers into cylinder head.
2. Install roller rocker levers so that they rest on ends of valve stems.
3. Oil journal surfaces of camshafts.
4. Place respective camshaft into camshaft bearings of cylinder head.

Camshaft identification cylinder bank 1 (right)

A - Exhaust camshaft, Identification 07C - Index 104 J

B - Intake camshaft, Identification 07C - Index 102 L

Camshaft identification cylinder bank 2 (left)

A - Intake camshaft, Identification 07C - Index 101 L

B - Exhaust camshaft, Identification 07C - Index 103 H

Scheme 541

1. Insert camshafts into cylinder head in such a way that they are set at TDC ignition timing.

1. Slits - arrows - in camshafts at front must stand parallel at same height with upper edge of cylinder head.

1. Lightly coat face surface - shown as shaded area - of bearing cap with axial bearing (bearing caps 7, 8, 27, 28) with adhesive lubricating paste G 052 723 A2 .

Cylinder bank 1 (right)

1. Set camshaft bearing caps in place according to their number identification

Scheme 542

1. Points - arrow A - of intake and exhaust camshaft bearing caps face outward.
2. Identification on bearing caps is legible when read from intake side.

1. Install intake camshaft - A - as follows

1. Fasten bearing caps 3 and 11 alternately and diagonally and then tighten to specified torque.
2. Fasten bearing cap 7.
3. Fasten bearing caps 5 and 9.
4. Fasten bearing caps 1 and 13.

1. Install exhaust camshaft - B - as follows

1. Fasten bearing caps 4 and 12 alternately and diagonally and then tighten to specified torque.
2. Fasten bearing cap 8.
3. Fasten bearing caps 6 and 10.
4. Fasten bearing caps 2 and 14.

Cylinder bank 2 (left)

1. Set camshaft bearing caps in place according to their number identification

Scheme 543

1. Points - arrow A - of intake and exhaust camshaft bearing caps face outward.
2. Identification on bearing caps is legible when read from intake side.

1. Install intake camshaft - A - as follows

1. Fasten bearing caps 23 and 31 alternately and diagonally and then tighten to specified torque.
2. Fasten bearing cap 27.
3. Fasten bearing caps 25 and 29.
4. Fasten bearing caps 21 and 33.

1. Install exhaust camshaft - B - as follows

1. Fasten bearing caps 24 and 32 alternately and diagonally and then tighten to specified torque.
2. Fasten bearing cap 28.
3. Fasten bearing caps 26 and 30.
4. Fasten bearing caps 22 and 34.

1. Install control housings for camshaft adjustment --> «Control Housing for Camshaft Adjustment, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__control-housing-for-camshaft-adjustment-removing) .
2. Install camshaft adjusters --> Installing under «Camshaft Timing Adjusters, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshaft-timing-adjusters-removing-and-installing) .

1. Before continuing assembly, verify TDC position of camshafts.

1. The camshaft bar T10068 must engage in both shaft grooves.

1. Install timing chains for camshafts --> «Timing Chains for Camshaft Drive, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__timing-chains-for-camshaft-drive-removing) .

Tightening torque

* 45 corresponds to one eighth rotation.

Valve Stem Seals, Replacing

Special tools, testers and auxiliary items required

Scheme 544

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Valve keeper disassembly and assembly device VAS 5161 with guide plate VAS 5161/25

1. Adapter T40012

Work sequence

1. Engine removed

1. Remove camshafts --> «Camshafts, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshafts-removing-and-installing) .
2. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 545

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

Scheme 546

1. Place guide plate VAS 5161/25 from valve keeper disassembly and assembly device VAS 5161 on cylinder head.
2. Secure guide plate with a nut.
3. Screw adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar positive pressure.

Procedure for outer rows of valves

Scheme 547

1. Screw engaging device VAS 5161/6 with installation fork VAS 5161/5 into guide plate.
2. Push installation cartridge VAS 5161/8 into guide plate.
3. Hook in pressure fork VAS 5161/2 at engaging device and press down installation cartridge.
4. At same time, turn knurled bolt of installation cartridge to 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 installation cartridge.
2. Release pressure fork.
3. Take out installation cartridge.
4. Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

1. Remove valve spring with valve plate.

Procedure for inner rows of valves

Scheme 548

1. Screw engaging device VAS 5161/6 with installation fork VAS 5161/5 onto cylinder head.
2. Push the knurled spacer ring VAS 5161/17 onto installation cartridge VAS 5161/8.
3. Push installation cartridge into guide plate.
4. Hook in pressure fork VAS 5161/2 at engaging device and press down installation cartridge.

1. At same time, turn knurled bolt of installation cartridge to right, until points engage in valve keepers.
2. Lightly move knurled bolt back and forth, causing valve keepers to be pressed apart and be captured in installation cartridge.
3. Release pressure fork.
4. Take out installation cartridge.

1. Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

1. Remove valve spring with valve plate.

Continued for all rows of valves

Scheme 549

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

Note. For pressing on green-colored valve stem seals, the valve stem seal driver 3365 must be drilled to a diameter of 10.5 mm. Mark the drilled driver for later reuse.

Scheme 550

1. A plastic sleeve - A - is supplied with new valve stem seals.

1. Place plastic sleeve - A - on valve stem to prevent damage to new valve stem seals - B -.
2. Lightly coat sealing lips of valve stem seal with oil.
3. Push valve stem seal onto plastic sleeve.
4. Carefully press valve stem oil seal onto valve guide using 3365.

1. Remove plastic sleeve again.

Scheme 551

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

1. Large diameter of valve keepers points upward.

Scheme 552

1. Install valve spring and valve plate.

Installed position of valve spring

1. Larger diameter - arrow - faces cylinder head.

Procedure for outer rows of valves

1. Fasten guide plate to cylinder head again as shown in illustration.
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.

Procedure for inner rows of valves

1. Insert installation cartridge with knurled spacer wheel into guide plate.
2. Press down pressure fork and pull knurled bolt upward turning to left and right - valve keepers are inserted in this manner.
3. Release pressure fork with the knurled bolt still pulled.
4. Install camshafts. --> Installing under «Camshafts, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__camshafts-removing-and-installing)

Note. After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic lifter equalization elements must seat themselves (otherwise the valves will make contact with the pistons). After working on the valve gear and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.

Tightening torque

Camshafts, Checking Axial Clearance

Special tools, testers and auxiliary items required

Scheme 553

1. Dial gauge holder VW 387

Scheme 554

1. Dial gauge VAS 6079

Work sequence

Perform measurement with roller rocker levers and support elements removed. Bearing cap of axial bearing for respective camshaft remains installed.

Scheme 555

1. Secure dial gauge holder VW 387 to dial gauge VAS 6079 on cylinder head.
2. Determine axial clearance.

1. Axial play wear limit: 0.10 mm.

Valve Guides, Checking

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387

1. Dial gauge VAS 6079

Work sequence

Scheme 556

1. Insert valve into valve guide.

1. Valve stem tip must seal with valve guide.

Note. Due to differences in valve stem diameter, make sure that only intake valves are used to check intake valve guides, and only exhaust valves are used to check exhaust valve guides.

1. Determine tilt clearance.

1. Tilt clearance wear limit: 0.8 mm.

Note. If wear limit is exceeded, re-measure using new valves. If wear limit is still exceeded, replace cylinder head. The valve guides cannot be replaced. If a valve is replaced during repair, use the new valve for measurement.

Valves, Checking

1. Perform a visual check for signs of wear at stem and at seating surface.
2. Replace valves with significant traces of wear.

Scheme 557

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

Valve Seats, Reworking

Note. If a perfect contact pattern is not achieved by lapping the valve seats, rework the valve seats.

Special tools, testers and auxiliary items required

1. Depth gauge
2. Valve seat refacing tool

Note. When repairing engines with leaking valves, it is not sufficient to rework or replace valve seats and valves. It is particularly important to check the valve guides for wear on engines with higher mileage --> Valve Guides, Checking Only rework valve seats until a perfect contact pattern is obtained. The maximum permissible reworking dimension must be calculated before work is performed. If the reworking dimension is exceeded, the function of the hydraulic lifters can no longer be guaranteed and therefore the cylinder head must be replaced.

Determining maximum allowable reworking dimension

1. Insert valve and press it firmly against valve seat.

Note. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

Scheme 558

1. Measure distance - a - between end of valve stem and upper cylinder head surface with a depth gauge.
2. Calculate maximum allowable reworking dimension from measured distance and minimum dimension.

Measured distance minus minimum dimension = max. permissible reworking dimension.

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

Scheme 559

a - diameter 32.6 mm

b - Max. permissible reworking dimension

c - 0.9 to 1.5 mm

d - max. diameter 35.0 mm

r2 - Radius 2.0 mm

Z - Cylinder head lower edge

α - 45 valve seat angle

β - 30 upper correction angle

gamma - 60 lower correction angle

Note. Calculating the maximum allowable reworking dimension, --> Determining maximum allowable reworking dimension .

Reworking exhaust valve seat

a - diameter 26.7 mm

b - Max. permissible reworking dimension

c - 1.2 to 1.7 mm

d - max. diameter 29.0 mm

r2 - Radius 2.0 mm

Z - Cylinder head lower edge

α - 45 valve seat angle

β - 30 upper correction angle

gamma - 60 lower correction angle

Note. Calculating the maximum allowable reworking dimension, --> Determining maximum allowable reworking dimension .

Lubrication System Components, Removing and Installing

> Oil Pan, Assembly Overview

> Oil Pan Lower Section, Removing and Installing

> Oil Pump, Removing and Installing

> Oil Pan Upper Section, Removing and Installing

> Oil Filter Bracket, Assembly Overview

> Oil Filter Housing, Removing and Installing

> Engine Oil Cooler, Removing and Installing

> Oil Pressure and Oil Pressure Switch, Checking

> Engine Oil

> Engine Oil Level, Checking

Note. If large quantities of metal shavings or abraded material are found in the engine oil while servicing the engine, the oil passages must be carefully cleaned to prevent resulting damage and the engine oil cooler must be replaced. The oil level must not be above the max. mark - danger of damage to catalytic converter!

Viscosity classes and oil specifications --> 01 - MAINTENANCE .

Oil filling quantities --> Fluid Capacity Chart.

Scheme 560

1 - 9 Nm

1. Fasten in diagonal sequence in steps

2 - Oil pan lower part

1. With Oil level thermal sensor G266 --> «Oil level thermal sensor G266»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

3 - 20 Nm

4 - Oil seal

1. Replace

5 - Oil line

6 - 20 Nm

7 - Oil pump

1. Do not disassemble
2. With relief valve
3. Removing and installing --> «Oil Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pump-removing-and-installing)

8 - Chain tensioner

1. Before removing, secure with locking pin T40011
2. Do not disassemble
3. Removing and installing --> «Oil Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pump-removing-and-installing)

9 - Oil pan upper part

1. Removing and installing --> «Oil Pan Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pan-upper-section-removing-and)

10 - Drive chain for oil pump

11 - Chain sprocket for oil pump

1. Component of crankshaft

12 - Bolt

1. Observe varying lengths
2. Tightening sequence and torque specification --> (Scheme 576)

13 - 45 Nm

14 - Sealing plugs

15 - M6 = 9 Nm; M8 = 20 Nm

16 - Pulsation damper

17 - Suction line

1. Clean strainer if soiled

18 - 9 Nm

19 - 9 Nm

20 - Oil drain plug, 30 Nm

21 - Oil seal

1. Replace

Scheme 561

1. Insert bolt (10 Nm) using locking compound .
2. Sealing ring; replace
3. Electrical harness connector
4. Oil level thermal sensor G266

Oil Pan Lower Section, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 562

1. Drip tray for workshop crane VAS 6208 or Drip tray V.A.G 1306
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

1. Activate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of auxiliary heater on sound insulation.

1. Loosen quick-release fasteners - 1 - and remove front sound insulation.
2. Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
3. Drain engine oil.

Scheme 563

1. Disconnect electrical connector from Oil Level Thermal Sensor G266 - 1 -.
2. Unfasten oil pan lower part - arrow -.

Installing

Installation is in reverse order of removal. Note the following.

Note. Replace seal.

1. Using rotating plastic brush, remove any remaining sealant from oil pan lower part and oil pan upper part.

1. Clean sealing surfaces and ensure they are free of oil and grease.

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

Scheme 564

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

1. Thickness of sealant bead: 2 mm.

Note. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer. The oil pan lower part must be installed within 5 minutes after application of sealant.

1. Set oil pan lower part in place and fasten all bolts in diagonal sequence to 5 Nm.
2. Fasten bolts for oil pan lower part in a diagonal sequence.
3. Add engine oil and check oil level --> «Engine Oil Level, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-level-checking) .
4. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

Tightening torques

Oil Pump, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 565

1. Securing pin T40011

Removing

1. Remove oil pan lower part --> «Oil Pan Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pan-lower-section-removing-and) .

Scheme 566

1. Remove bolts - 1 to 3 - and remove oil line.

Scheme 567

1. Press chain tensioner in direction of - arrow - and secure with locking pin T40011.
2. Remove bolts - 1 - and - 2 -.
3. Remove chain tensioner.

Scheme 568

1. Remove bolts - arrows -.
2. Remove oil pump and remove drive chain for oil pump from chain sprocket, pivoting the oil pump aside slightly.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace seals.

1. Pay attention to alignment bushings during installation.
2. Install oil pan lower part --> «Oil Pan Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pan-lower-section-removing-and) .
3. Add engine oil and check oil level --> «Engine Oil Level, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-level-checking) .

Tightening torques

Oil Pan Upper Section, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 569

1. Hose clamps up to 25 mm diameter 3094
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

1. Remove both front wheels.

Note. Secure the brake discs with wheel bolts.

1. Remove front part of left front wheelhouse liner --> «66 - EXTERIOR EQUIPMENT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of auxiliary heater on sound insulation.

1. Loosen quick-release fasteners - 1 - and - 2 - and remove sound insulation.

1. Clamp off return hose for power steering pump with Hose Clamps Up to 25 mm dia. 3094.
2. Disconnect return hose - 1 - from power steering pump.

Note. Ignore - 2 - in the illustration.

1. Pull off both air duct hoses - arrows - at bottom of lower part of left air filter housing by pressing release buttons.

1. Separate electrical connector - 3 - for Mass Air Flow (MAF) sensor 2 G246.
2. Disconnect hose - 2 - from air duct.
3. Disconnect air duct - 1 - at intake manifold.
4. Remove bolts - arrows -.

1. Remove upper part of left air filter housing.

1. Remove air duct - 1 -.
2. Remove bolts - arrows -.
3. Remove lower part of left air filter housing.

Note. Place a rag under the hydraulic line to catch escaping hydraulic fluid.

1. Disconnect hydraulic pressure line - 2 - at power steering pump and set it aside on top of longitudinal member.

Note. Ignore - 1 - in the illustration.

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

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

Note. The ribbed belt stays in position on the remaining belt pulleys.

1. Remove bolts - arrows - and remove belt pulley - 1 - from power steering pump.

Scheme 570

1. Remove bolts - arrows - and remove power steering pump.

Scheme 571

1. Remove bolts - arrows - and remove bracket for power steering pump.
2. Lower subframe --> Subframe, Lowering for Repair .
3. Remove oil pan lower part --> «Oil Pan Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pan-lower-section-removing-and) .
4. Remove oil pump --> «Oil Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pump-removing-and-installing) .

Scheme 572

1. Disconnect electrical connector - arrow - at left engine mount and move electrical wiring clear.

Scheme 573

1. Remove retainer for connections - 1 to 4 - from oil pan upper part.
2. Disconnect electrical harness connectors - 1 to 4 -.
3. Remove engine/transmission bolts in area of oil pan upper part.
4. Remove bolts for oil pan upper part.

1. Remove oil pan upper part.

Installing

1. Using rotating plastic brush, remove any remaining sealant from oil pan upper part and engine bearing bracket.

1. Clean sealing surfaces and ensure they are free of oil and grease.

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

Scheme 574

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

1. Thickness of sealant bead: 1.5 to 2 mm.

Note. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.

Scheme 575

1. The oil pan upper part must be installed within 5 minutes after application of sealant.
2. With the engine removed, make sure that the contact surfaces of the cylinder block and the oil pan upper part are aligned to the transmission - arrow -.

Scheme 576

1. Set oil pan upper part in place and pre-tighten all bolts to 5 Nm in sequence - 1 to 36 -.
2. Tighten bolts for oil pan upper part/transmission - dark shaded areas - to 45 Nm.
3. Tighten bolts - 1 to 36 - to 9 Nm.
4. Tighten bolts M8 - 1 to 20 - to 20 Nm.

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

1. Install oil pump --> «Oil Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pump-removing-and-installing) .
2. Install oil pan lower part --> «Oil Pan Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pan-lower-section-removing-and) .
3. Add engine oil and check oil level --> «Engine Oil Level, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-level-checking) .
4. Install subframe --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Install power steering pump --> «48 - STEERING»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

Note. After replacing the oil pan upper part, check the alignment of the power steering pump and air conditioning compressor belt pulleys. --> Power Steering Pump Belt Pulley and Air Conditioning Compressor Belt Pulley, Checking Alignment .

1. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__ribbed-belt-removing-and-installing) .

Tightening torques

Scheme 577

1 - Oil filter housing

1. To loosen and tighten, use 36 mm socket wrench
2. Fasten to 25 Nm

2 - O-ring

1. Replace

3 - Hose connections for coolant hose

1. Fasten to 10 Nm

4 - 10 Nm

5 - O-ring

1. Replace

6 - Hose connections for coolant hose

1. Fasten to 10 Nm

7 - 10 Nm

8 - Engine oil cooler

1. Integrated into oil filter housing
2. With bypass valve
3. Removing and installing --> «Engine Oil Cooler, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-cooler-removing-and-installing)
4. Replace coolant after replacing oil cooler

9 - 10 Nm

10 - Oil seals

1. Replace

11 - Oil filter bracket

1. With filter bypass valve
2. Removing and installing --> «Oil Filter Housing, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-filter-housing-removing-and-installing)

12 - Oil seal

1. Replace

13 - O-ring

1. Replace

14 - O-ring

1. Replace

15 - Front coolant line

1. Removing and installing --> «Front coolant pipe, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__front-coolant-pipe-removing-and-installing)

16 - 10 Nm

17 - Oil pressure switch F1 1.4 bar

1. Fasten to 25 Nm
2. Black insulation
3. Checking, removing and installing --> «Oil Pressure and Oil Pressure Switch, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-pressure-and-oil-pressure-switch)

18 - Oil seal

1. Replace

19 - Alignment bushing

1. 2 pieces

20 - 22 Nm

21 - Oil filter element

1. Observe change intervals --> Maintenance Service Circular

22 - O-ring

1. Replace

Oil Filter Housing, Removing and Installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop crane VAS 6208 or Drip tray V.A.G 1306

Removing

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling) .
2. Bring lock carrier into service position --> «Lock Carrier, Moving into Service Position»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__lock-carrier-moving-into-service-position) .

1. Separate electrical connector - 1 - for Mass Air Flow (MAF) sensor G70.
2. Disconnect air duct - 4 - at intake manifold.
3. Unhook retainer for connections - 2 - and - 3 - at upper part of air filter housing.
4. Remove bolts - arrows -.

1. Remove upper part of right air filter housing.

1. Remove air duct - 1 -.
2. Remove bolts - arrows -.
3. Remove lower part of right air filter housing.

Note. Place a rag under separating point to catch escaping coolant.

1. Disconnect coolant hose - arrow - at right on engine.

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

Note. Before removing the ribbed belt, mark the turning direction on the belt with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

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

Scheme 578

1. Remove front coolant hose from auxiliary radiator - arrow -.
2. Remove bolts - 1 - and - 2 -.

Scheme 579

1. Disconnect coolant hoses - arrows -.
2. Remove bolts - 1 - and - 2 -.
3. Remove auxiliary radiator.

Scheme 580

1. Disconnect electrical wiring - 1 - on Generator.
2. Disconnect electrical connector - 2 -.

Scheme 581

1. Remove bolts - arrows -.
2. Pivot Generator downward and slightly toward left side.

Note. To continue disconnecting and removing the Generator, a second technician is necessary.

Scheme 582

1. Disconnect coolant hose - 2 - from connection on Generator.
2. Mark installed position of connection on Generator
3. Unscrew bolt - 1 - and remove bracket.
4. Remove both connections from Generator.

1. Remove Generator.
2. Lower subframe --> Subframe, Lowering for Repair .

1. Disconnect coolant hoses - 1 - and - 2 - at lower right coolant pipe.
2. Remove front right coolant pipe.

Note. Disregard - arrow - in the illustration.

Scheme 583

1. Remove bolts - arrows - and remove heat shield above right axle shaft from transmission.

1. Disconnect electrical connector - 3 -.
2. Disconnect Ground wire - 2 - on longmember.
3. Unfasten bracket for wiring harness on longitudinal member - arrows - and lay wiring harness aside.

Note. Ignore - 1 - in the illustration.

Scheme 584

To loosen the upper rear bolt at the engine support, a special tool must first be crafted as follows

1. Cut a long 8 mm Allen key with ball head at point indicated with - arrow -.

1. Dimension - a - = 103 mm.

1. Insert cut end - 2 - into an 8 mm socket - 1 -.

1. Disconnect electrical harness connector - arrow - at right engine mount.
2. Remove bolts - 1 to 6 -.
3. Remove engine support with engine mount.

1. Disconnect electrical connector - arrow - at Oil pressure switch -F1-.

Scheme 585

1. Remove bolts - arrows -.
2. Remove front coolant pipe.

1. Disconnect coolant hose - left arrow -.

Note. Ignore - right arrow - in the illustration.

1. Remove bolts - 1 -.
2. Disconnect hose connection at engine oil cooler.

Scheme 586

1. Place drip tray V.A.G 1306 or drip tray for workshop crane VAS 6208 under engine.
2. Disconnect coolant hose - arrow -.
3. Remove bolts - 1 to 5 -.
4. Remove oil filter housing.

Installing

Installation is in reverse order of removal. Note the following

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

1. Install front coolant pipe --> «Front coolant pipe, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__front-coolant-pipe-removing-and-installing) .

1. Align subframe according to markings on longitudinal members.
2. Tighten bolts for subframe only to initial specified torque. Do not tighten further (tighten bolts fully only after wheel alignment).

1. 50 Nm
2. 150 Nm
3. 150 Nm

1. Install air spring dampers --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Install stabilizer --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
3. Install Generator --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .
4. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Add engine oil and check oil level --> «Engine Oil Level, Checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-level-checking) .
2. Fill with coolant. --> Filling under «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling)
3. Perform wheel alignment --> «44 - WHEELS, TIRES AND WHEEL ALIGNMENT»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a8/d3-2005-2007/remont/procedures/#maintenance-procedures) .

Tightening torques

Engine Oil Cooler, Removing and Installing

Removing

1. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-filter-housing-removing-and-installing) .

Note. Place a rag under the oil filter housing to catch escaping engine oil and coolant.

Scheme 587

1. Remove bolts - arrows -.
2. Remove engine oil cooler.

Installing

Installation is in reverse order of removal. Note the following

Note. Replace seals.

1. Install oil filter housing. --> «Oil Filter Housing, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__oil-filter-housing-removing-and-installing)

Tightening torque

Oil Pressure and Oil Pressure Switch, Checking

Special tools, testers and auxiliary items required

Scheme 588

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

Conditions

1. Oil level OK
2. Engine oil temperature approx. 80 C

Work sequence

1. Activate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of auxiliary heater on sound insulation.

1. Loosen quick-release fasteners - 1 - and remove front sound insulation.

1. Disconnect electrical connector - arrow - at Oil pressure switch -F1-.
2. Remove oil pressure switch.
3. Thread adapter V.A.G 1342/14 into hole for oil pressure switch.

Scheme 589

1. Connect oil pressure gauge V.A.G 1342 to adapter V.A.G 1342/14.
2. Screw oil pressure switch - 2 - into oil pressure gauge V.A.G 1342.
3. Place brown wire of oil pressure gauge to Ground (-).

Oil pressure switch, checking

1. Connect voltage tester V.A.G 1527 B - 1 - with adapter cables from connector test kit V.A.G 1594 C to oil pressure switch and battery positive (+).

1. LED must not light up.

If LED lights up

1. Replace oil pressure switch.
2. Start engine.

Note. While starting engine, watch pressure tester and LED as oil pressure switch may open during start. At 1.2 to 1.6 bar pressure, LED must light up.

If LED does not light up

1. Replace oil pressure switch.

Oil pressure, checking

1. Start engine.

1. Oil pressure at idle: min. 0.8 bar
2. Oil pressure at 2000 RPM: min. 3.0 bar
3. Oil pressure at increased engine speed: max. 7.0 bar

If specifications are not obtained the pressure relief valve or the oil pump is malfunctioning.

1. Replace oil pump.

Assembling

Assembly is in reverse order of removal. Note the following

Note. Replace seal.

1. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

Tightening torque

Engine Oil

Viscosity classes and oil specifications

> Fluid Capacity Chart.

Oil filling quantities --> Fluid Capacity Chart.

Engine Oil Level, Checking

Note. Oil level must not exceed the max. marking danger of catalytic converter damage!

Conditions

1. Engine oil temperature min. 60 C.
2. Vehicle in level position.
3. After stopping engine, wait a few minutes to allow oil to flow back into oil pan.

Work sequence

1. Pull out oil dipstick, wipe off with a clean cloth and reinsert dipstick again up to stop.
2. Withdraw dipstick again and read oil level.

Scheme 590

a - Oil must not be added.

b - Oil may be topped up. After topping up, oil may be in range - a -.

c - Oil must be added. After topping up, it is sufficient if oil level is somewhere in range - b - (shaded area).

Note. Oil level must not exceed max. marking - a - and must not fall short of min. marking - c -.

Cooling System Components, Removing and Installing

> Cooling System, Component Overview

> Cooling System, Draining and Filling

> Coolant Pump, Removing and Installing

> After-Run Coolant Pump, Removing and Installing

> Coolant thermostat, checking

> Coolant thermostat, removing and installing

> Upper coolant pipe, removing and installing

> Upper left coolant pipe, removing and installing

> Lower left coolant pipe, removing and installing

> Right front coolant pipe, removing and installing

> Upper right coolant pipe, removing and installing

> Middle right coolant pipe, removing and installing

> Lower right coolant pipe, removing and installing

> Front coolant pipe, removing and installing

> Radiator and coolant fan, assembly overview

> Radiator, removing and installing

> Fan shroud, removing and installing

> Coolant fan, removing and installing

> Auxiliary cooler, removing and installing

> Cooling System, Checking for Leaks

Scheme 591

1 - Generator

2 - Engine oil cooler

1. Removing and installing --> «Engine Oil Cooler, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-cooler-removing-and-installing)
2. Replace coolant after replacing oil cooler

3 - Bleeder screw

4 - Bleeder screw

5 - Heater core

1. Replace coolant after replacing

6 - ATF cooler

1. Replace coolant after replacing ATF cooler

7 - Coolant expansion tank

1. With cap
2. Pressure relief valve in cap, checking --> «Checking pressure relief valve in cap»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

8 - Coolant thermostat

1. For ATF cooler and transfer gear oil cooler

9 - Engine Coolant Temperature (ECT) sensor G62

10 - Gear oil cooler for transfer gear

1. Replace coolant after replacing gear oil cooler

11 - Coolant thermostat

1. Checking --> «Coolant thermostat, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-checking)
2. Removing and installing --> «Coolant thermostat, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-removing-and-installing)

12 - Coolant pump

1. Removing and installing --> «Coolant Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-pump-removing-and-installing)

13 - After-run coolant pump V51

1. Removing and installing --> After-Run Coolant Pump, Removing and Installing

14 - Radiator

1. Removing and installing --> «Radiator, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__radiator-removing-and-installing)
2. Replace coolant after replacing radiator

Scheme 592

1 - Auxiliary cooler

1. Removing and installing --> «Auxiliary cooler, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__auxiliary-cooler-removing-and-installing)
2. Replace coolant after replacing auxiliary cooler

2 - Coolant thermostat for auxiliary cooler

3 - Generator

4 - Engine oil cooler

1. Removing and installing --> «Engine Oil Cooler, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-cooler-removing-and-installing)
2. Replace coolant after replacing engine oil cooler

5 - Bleeder screw

6 - Bleeder screw

7 - Heater core

1. Replace coolant after replacing heater core

8 - ATF cooler

1. Replace coolant after replacing ATF cooler

9 - Coolant expansion tank

1. With pressure relief valve in cap, checking --> «Checking pressure relief valve in cap»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

10 - Coolant thermostat

1. For ATF cooler and gear oil cooler for transfer gear

11 - Engine Coolant Temperature (ECT) sensor G62

12 - Gear oil cooler for transfer gear

1. Replace coolant after replacing gear oil cooler

13 - Coolant thermostat

1. Checking --> «Coolant thermostat, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-checking)
2. Removing and installing --> «Coolant thermostat, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-removing-and-installing)

14 - Coolant pump

1. Removing and installing --> «Coolant Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-pump-removing-and-installing)

15 - After-run coolant pump V51

1. Removing and installing --> After-Run Coolant Pump, Removing and Installing

16 - Radiator

1. Removing and installing --> «Radiator, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__radiator-removing-and-installing)
2. Replace coolant after replacing

Scheme 593

1 - Auxiliary cooler

1. Removing and installing --> «Auxiliary cooler, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__auxiliary-cooler-removing-and-installing)
2. Replace coolant after replacing auxiliary cooler

2 - Coolant thermostat for auxiliary cooler

3 - Generator

4 - Engine oil cooler

1. Removing and installing --> «Engine Oil Cooler, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-cooler-removing-and-installing)
2. Replace coolant after replacing engine oil cooler

5 - Bleeder screw

6 - Bleeder screw

7 - Heater core

1. Replace coolant after replacing heater core

8 - ATF cooler

1. Replace coolant after replacing ATF cooler

9 - Coolant expansion tank

1. With pressure relief valve in cap, checking --> «Checking pressure relief valve in cap»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

10 - Coolant thermostat

1. For ATF cooler and gear oil cooler for transfer gear

11 - Engine Coolant Temperature (ECT) sensor G62

12 - Gear oil cooler for transfer gear

1. Replace coolant after replacing gear oil cooler

13 - Coolant thermostat

1. Checking --> «Coolant thermostat, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-checking)
2. Removing and installing --> «Coolant thermostat, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-removing-and-installing)

14 - Coolant pump

1. Removing and installing --> «Coolant Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-pump-removing-and-installing)

15 - After-run coolant pump V51

1. Removing and installing --> After-Run Coolant Pump, Removing and Installing

16 - Auxiliary cooler

1. Removing and installing --> «Auxiliary cooler, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__auxiliary-cooler-removing-and-installing)
2. Replace coolant after replacing auxiliary cooler

17 - Radiator

1. Removing and installing --> «Radiator, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__radiator-removing-and-installing)
2. Replace coolant after replacing radiator

Scheme 594

1 - Auxiliary cooler

1. Removing and installing --> «Auxiliary cooler, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__auxiliary-cooler-removing-and-installing)
2. Replace coolant after replacing auxiliary cooler

2 - Engine oil cooler

1. Removing and installing --> «Engine Oil Cooler, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-cooler-removing-and-installing)
2. Replace coolant after replacing engine oil cooler

3 - Generator

4 - Bleeder screw

5 - Bleeder screw

6 - Heater core

1. Replace coolant after replacing heater core

7 - ATF cooler

1. Replace coolant after replacing ATF cooler

8 - Coolant expansion tank

1. With pressure relief valve in cap, checking --> «Checking pressure relief valve in cap»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

9 - Coolant thermostat

1. For ATF cooler and gear oil cooler for transfer gear

10 - Engine Coolant Temperature (ECT) sensor G62

11 - Gear oil cooler for transfer gear

1. Replace coolant after replacing gear oil cooler

12 - Coolant thermostat

1. Checking --> «Coolant thermostat, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-checking)
2. Removing and installing --> «Coolant thermostat, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-removing-and-installing)

13 - Coolant pump

1. Removing and installing --> «Coolant Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-pump-removing-and-installing)

14 - After-run coolant pump V51

1. Removing and installing --> After-Run Coolant Pump, Removing and Installing

15 - Radiator

1. Removing and installing --> «Radiator, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__radiator-removing-and-installing)
2. Replace coolant after replacing radiator

Scheme 595

1 - Engine Coolant (EC) switch-off valve (heater) N279

2 - Auxiliary cooler

1. Removing and installing --> «Auxiliary cooler, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__auxiliary-cooler-removing-and-installing)
2. Replace coolant after replacing auxiliary cooler

3 - Auxiliary heater

4 - Coolant thermostat for auxiliary cooler

5 - Recirculation Pump V55 for auxiliary heater

6 - Generator

7 - Engine oil cooler

1. Removing and installing --> «Engine Oil Cooler, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-oil-cooler-removing-and-installing)
2. Replace coolant after replacing engine oil cooler

8 - Bleeder screw

9 - Bleeder screw

10 - Heater core

1. Replace coolant after replacing heater core

11 - ATF cooler

1. Replace coolant after replacing ATF cooler

12 - Coolant expansion tank

1. With pressure relief valve in cap, checking --> «Checking pressure relief valve in cap»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb)

13 - Coolant thermostat

1. For ATF cooler and gear oil cooler for transfer gear

14 - Non-return valve

15 - Engine Coolant Temperature (ECT) sensor G62

16 - Gear oil cooler for transfer gear

1. Replace coolant after replacing gear oil cooler

17 - Coolant thermostat

1. Checking --> «Coolant thermostat, checking»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-checking)
2. Removing and installing --> «Coolant thermostat, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-removing-and-installing)

18 - Coolant pump

1. Removing and installing --> «Coolant Pump, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-pump-removing-and-installing)

19 - After-run coolant pump V51

1. Removing and installing --> After-Run Coolant Pump, Removing and Installing

20 - Radiator

1. Removing and installing --> «Radiator, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__radiator-removing-and-installing)
2. Replace coolant after replacing radiator

Cooling System, Draining and Filling

Special tools, testers and auxiliary items required

Scheme 596

1. Adapter V.A.G 1274/8
2. Drip tray V.A.G 1306 or drip tray VAS 6208
3. Hose clamp pliers V.A.G 1921
4. Cooling system charge unit VAS 6096

1. Refractometer T10007

Draining

1. Activate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

Note. Drained coolant must be stored in a clean container for disposal or reuse.

1. Remove cover above coolant reservoir - arrows -.

1. Open cap of coolant expansion tank.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of auxiliary heater on sound insulation.

1. Loosen quick-release fasteners - 1 - and remove front sound insulation.

1. Place drip tray V.A.G 1306 or drip tray VAS 6208 under engine.
2. Disconnect coolant hose - arrow - from left coolant pipe and drain coolant.

Scheme 597

1. Remove lower right coolant hose from auxiliary cooler - arrow - and allow remaining coolant to drain.

Filling

Note. The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water. Only coolant additive Plus G 012 A8F A1 (short: G12+) "according to TL VW 774 F" may be used. Other coolant additives may reduce the corrosion protection effect significantly. The damage resulting from this may lead to loss of coolant and consequently to severe engine damage. Coolant additive G12+ can be combined with additives G11 and G12. G12+ and coolant additives with the designation "according to TL VW 774 F" reduce frost and corrosion damage as well as lime deposits. They also raise the boiling point. For this reason the system must be filled all year round with frost and corrosion protection additives. Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates. Protection against frost must be assured to about -25 C (in arctic climatic countries to about -35 C). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%. If greater frost protection is required for climatic reasons, the amount of G12+ can be increased, but only up to 60% (frost protection to about -40 C), otherwise frost protection and cooling effectiveness will be reduced. Only clean drinking water may be used for mixing coolant. If the radiator, heater core, cylinder head and cylinder head gasket, cylinder block or any of the auxiliary coolers is replaced, completely replace the engine coolant. Dirty coolant must not be reused. For coolant G12+ , use refractometer T10007 to test frost protection in cooling system.

Conditions

1. Ignition switched off.

Work sequence

1. Connect lower right coolant hose to auxiliary cooler - arrow -.

1. Connect lower coolant hose to coolant pipe - arrow -.

Scheme 598

1. Fill replacement reservoir VAS 6096/1 with at least 15 liters of coolant pre-mixed to correct mixture ratio

1. G12+ (40%) and water (60%) for frost protection down to -25 C.
2. G12+ (50%) and water (50%) for frost protection down to -35 C.
3. G12+ (60%) and water (40%) for frost protection down to -40 C.

1. Thread adapter V.A.G 1274/8 onto coolant expansion tank.
2. Assemble cooling system charge unit VAS 6096 on adapter V.A.G 1274/8.
3. Place air outlet hose - 1 - into a small container - 2 -. (A small amount of coolant will come out together with vented air. This drains into container.)
4. Close both valves - A - and - B - by turning lever perpendicular to direction of flow.

1. Connect hose - 3 - to pressurized air.

1. Pressure: 6 to 10 bar positive pressure.

Scheme 599

1. Open valve - B - by turning lever in direction of flow.

A vacuum is created in the cooling system by the suction jet pump.

1. Needle on instrument display must travel into green region.

1. Also briefly open valve - A - by turning lever in direction of flow so that hose of replacement reservoir VAS 6096/1 is filled with coolant.
2. Close valve - A - again.
3. Let valve - B - remain open another 2 minutes.

1. A further vacuum is created in cooling system by suction jet pump.
2. Needle on instrument display must still remain in green region.

1. Close valve - B -.

1. Needle in display instrument must remain in green region, then sufficient vacuum in cooling system is obtained for upcoming filling.

If needle stands below the green region, repeat procedure.

If vacuum decreases, cooling system is leaking.

1. Disconnect pressurized air hose.
2. Open valve - A -.

Vacuum in cooling system has effect of extracting coolant from coolant reservoir VAS 6096/1 ; cooling system is filled.

1. Disconnect cooling system charge unit VAS 6096 from coolant expansion tank.

1. Remove rubber seal - 1 - for plenum chamber covers.
2. Remove plenum chamber cover - 2 -.

Note. Ignore - 3 - in the illustration.

Scheme 600

1. Open bleeder screws - arrows -.
2. Fill up coolant until it escapes from bleeder holes in coolant hoses.
3. Close bleeder screws.
4. Twist cap for expansion tank closed.

1. Make sure that auxiliary heater is switched off.
2. Start engine.
3. Set heating air conditioning system to "HI" on both sides.
4. Let engine run at 2000 RPM for 3 minutes.

1. Let engine run at idle until both large coolant hoses on main cooler are warm.
2. Let engine run at 2000 RPM for 1 minute.
3. Turn off engine and allow it to cool off.

Scheme 601

1. Check coolant level.

1. Coolant level must be at MAX. marking with engine cold.
2. Coolant level may be above MAX. marking with engine at operating temperature.

1. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

Coolant Pump, Removing and Installing

Removing

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling) .
2. Bring lock carrier into service position --> «Lock Carrier, Moving into Service Position»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__lock-carrier-moving-into-service-position) .

1. Disconnect electrical connector - 1 - for Mass Air Flow (MAF) sensor G70.
2. Disconnect air duct - 4 - at intake manifold.
3. Unhook retainer for connections - 2 - and - 3 - at upper part of air filter housing.
4. Remove bolts - arrows -.

1. Remove upper part of right air filter housing.

1. Remove air duct - 1 -.
2. Remove bolts - arrows -.
3. Remove lower part of right air filter housing.

Note. Place a rag under separating point to catch escaping coolant.

1. Disconnect coolant hose - arrow - at right on engine.

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

Note. Before removing the ribbed belt, mark the turning direction on the belt with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

1. To relieve tension on ribbed belt, pivot tensioner in direction of - arrow - , using a box-end 30 mm wrench.
2. Remove ribbed belt and release tensioning device.

Scheme 602

1. Remove bolts - arrows - and remove coolant pump belt pulley.

Scheme 603

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

Installing

Installation is performed in reverse order of removal, noting the following

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

1. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__ribbed-belt-removing-and-installing) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Install front bumper cover --> «63 - BUMPERS»(/audi/a8/d3-2005-2007/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Fill with coolant. --> Filling under «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling)
2. Check headlight adjustment --> «01 - MAINTENANCE»(/audi/a8/d3-2005-2007/remont/procedures/#maintenance-procedures) .

Tightening torques

Coolant thermostat, checking

Special tools, testers and auxiliary items required

Scheme 604

1. Portable multimeter V.A.G 1526 A
2. Connector test set V.A.G 1594 A
3. Vehicle Diagnostic, Testing and Information System VAS 5051 A with diagnostic cable VAS 5051/5A

Conditions

1. Engine cold

Checking internal resistance of heating element

Note. The Map controlled engine cooling thermostat F265 and wiring connections are monitored by the Engine Control Module (ECM).

Scheme 605

1. Vehicle Diagnostic, Testing and Information System VAS 5051 A with diagnostic cable VAS 5051/5A connected, On Board Diagnostic (OBD) and vehicle system "01 Engine electronics" selected. Switch ignition on.

1. Read Diagnostic Trouble Code (DTC) memory of engine control module.

If a fault related to Map controlled engine cooling thermostat F265 is displayed

1. Carefully pull engine cover at rear and middle upward and off - arrows 1 -.
2. Then, pull engine cover forward and off of intake manifold - arrows 2 -.

1. Disconnect electrical 2-pin connector - arrow - at Map controlled engine cooling thermostat F265.

Note. To improve clarity, the electrical connector is shown with the intake manifold removed.

1. Connect multimeter to thermostat for resistance measurement.

1. Specification: 14 to 16 ohms at 25° C

If specification is not obtained

1. Replace Map controlled engine cooling thermostat F265 --> «Coolant thermostat, removing and installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__coolant-thermostat-removing-and-installing) .

If specification is obtained

1. Check wiring connections according to wiring diagram.

Coolant thermostat, removing and installing

Removing

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling) .

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. The coolant must be completely drained, otherwise there is a risk that coolant may leak into the intake channels.

1. Remove intake manifold upper part: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .
2. Remove intake manifold lower part: --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and) .

1. Disconnect electrical harness connector - arrow -.
2. Move electrical wiring clear.

Scheme 606

1. Remove coolant hoses - 2 - and - 3 -.
2. Remove bolt - 1 - and disconnect pipe connection at housing.
3. Remove bolts - arrows - and remove thermostat housing.

Installing

Installation is in reverse order of removal. Note the following

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

1. Install intake manifold lower part: --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and) .
2. Install intake manifold upper part: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .
3. Fill with coolant. --> Filling under «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling)

Tightening torques

Upper coolant pipe, removing and installing

Special tools, testers and auxiliary items required

Scheme 607

1. Spark plug connector pliers V.A.G 1922

1. Spring-type clip pliers VAS 5024 A

Removing

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

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling) .
2. Remove intake manifold upper part: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .
3. Remove intake manifold lower part: --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and) .

1. Remove rubber seal - 1 - for plenum chamber covers.
2. Remove plenum chamber covers - 2 - and - 3 -.

1. Pry off caps on wiper arms using a screwdriver.
2. Loosen nuts - arrows - by several turns.
3. Loosen wiper arms by gently rocking arm. Remove nuts and remove wiper arms.
4. Remove dust and pollen filter by opening 4 quick-release fasteners.

Note. Cover the air duct at air conditioning housing with a clean rag so that nothing can fall in.

1. Remove bolts - arrows - at left and right for cowl grille - 1 -.
2. Carefully pull cowl grille off of retainers at windshield.

1. Remove strut tower brace - arrow -.

1. Remove bolts - 1 - and - 2 - and remove retaining bracket.
2. Release retaining tabs - arrows - and remove both engine control modules.

Note. Electrical harnesses remains connected.

1. Turn Air quality sensor G238 approx. 90° counter-clockwise - arrow - and remove from retainer.
2. Release retaining clips - 1 to 4 -.
3. Fold cover for electronics box in plenum chamber open slightly and pull off toward front.

1. Disconnect multi-pin harness connectors - arrows - using spark plug connector pliers V.A.G 1922.
2. Disengage engine wiring harness at electronics box and at bulkhead.
3. Lay wiring harness aside on engine with engine control modules connected.

1. Disconnect electrical connector - 2 - for Map controlled engine cooling thermostat F265.
2. Move wiring clear.
3. Disconnect ground wire - 3 - on cylinder head.
4. Loosen harness clamp - 1 - and remove harness from coolant pipe.

Note. Shown from the rear to improve clarity.

1. Remove bolts - 1 to 3 -.
2. Disconnect coolant hoses at coolant pipe - arrows -.

Note. Shown from rear to improve clarity.

1. Remove coolant pipe.

Installing

Installation is in reverse order of removal. Note the following

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

1. Install strut tower brace --> «40 - FRONT SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .
2. Install and adjust wiper arms --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/a8/d3-2005-2007/remont/cruise-control-systems/#electrical-equipment) .
3. Install intake manifold lower part: --> «Intake Manifold Lower Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-lower-section-removing-and) .
4. Install intake manifold upper part: --> «Intake Manifold Upper Section, Removing and Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__intake-manifold-upper-section-removing-and) .

1. Fill with coolant --> Filling under «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling)

Tightening torques

Upper left coolant pipe, removing and installing

Special tools, testers and auxiliary items required

1. Hose clamp pliers V.A.G 1921

Removing

1. Engine/transmission unit removed and attached to scissor lift platform VAS 6131.

1. Remove bolt - 1 -.
2. Pull oil dipstick guide tube upward and off - arrow -.

1. Disconnect electrical connector - 2 - for Heated Oxygen Sensor (HO2S) 4 G286.

Note. Disregard the other items in the illustration.

1. Move electrical wiring to oxygen sensor clear.

Scheme 608

1. Remove Heated Oxygen Sensor (HO2S) 4 G286 - arrow 2 - using ring spanner set 3337.

Note. Ignore - arrow 1 - in the illustration.

1. Disconnect coolant hoses - arrows - at upper left coolant pipe.
2. Remove bolts - 1 - , - 2 - and nut - 3 -.
3. Remove upper left coolant pipe upward.

Note. To improve clarity, the exhaust manifold and catalytic converters are shown removed.

Installing

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 Heated Oxygen Sensor (HO2S) 4 G286 --> «24 FUEL INJECTION SYSTEM»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-fuel-injection-and-ignition-engine-codes-bsb)
2. Install engine/transmission assembly --> «Engine, Installing»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__engine-installing) .

Tightening torques

Lower left coolant pipe, removing and installing

Special tools, testers and auxiliary items required

1. Drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306

1. Hose clamp pliers V.A.G 1921

Removing

1. Activate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

1. Remove cover above coolant reservoir - arrows -.

1. Open cap of coolant expansion tank.

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of auxiliary heater on sound insulation.

1. Loosen quick-release fasteners - 1 - and remove front sound insulation.

Scheme 609

1. Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
2. Disconnect coolant hose - 2 - from lower left coolant pipe and drain coolant.
3. Remove bolt - 1 - and nut - 3 -.
4. Disconnect lower left coolant pipe from coolant hose - 4 -.

Installing

Installation is in reverse order of removal. Note the following

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

1. Fill with coolant --> Filling under «Cooling System, Draining and Filling»(/audi/a8/d3-2005-2007/remont/cooling-fan/#60l-12-cyl-4v-engine-mechanical-engine-codes-bsb__cooling-system-draining-and-filling)
2. Deactivate vehicle lifting mode --> «43 - SELF LEVELING SUSPENSION»(/audi/a8/d3-2005-2007/remont/axle-shafts/#suspension-wheels-and-steering) .

Tightening torques

Scheme 610

Special tools, testers and auxiliary items required

1. Engine support bridge 10-222 A
2. Brace 10-222 A/21
3. Drip tray V.A.G 1306 or drip tray for workshop crane VAS 6208
4. Engine/transmission jack V.A.G 1383 A

Special tools, testers and auxiliary items required

1. Hose clamp pliers V.A.G 1921