5.2l 10-cyl. 4v Engine Mechanical Engine Code(s): Bxa Audi S6 C6

Technical Data

> Engine Number

> Engine Data

Scheme 1

1. Remove front engine cover - 1 - - arrows -.

Note. Ignore - 2 -.

Scheme 2

Engine number ("engine code" and "serial number") is located at front on cylinder block at top - arrow -.

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

Engine Data

General Information

> Safety Precautions

> Before Opening High-Pressure Fuel Injection System

> Clean Working Conditions

> Contact Corrosion

> Lines, Routing and Securing

Safety Precautions

Note the following when working on the fuel system

1. Procedures before opening high pressure fuel injection system --> «Before Opening High-Pressure Fuel Injection System»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__before-opening-high-pressure-fuel-injection-system) .

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

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

1. Connect Vehicle Diagnosis, Testing and Information System VAS 5051B.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

1. Disconnect battery --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

Note the following when working on the cooling system

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

Before Opening High-Pressure Fuel Injection System

1. The fuel injection system is separated into a high-pressure section (max. approximately 120 bar) and a low-pressure section (approximately 6 bar).
2. Before opening high pressure area, fuel pressure must be reduced to a residual pressure of approximately 6 bar. The procedure for this is as follows.

Special tools, testers and auxiliary items required

Scheme 3

1. Vehicle diagnostic, testing, and information system VAS 5051 (VAS 5051 B version shown as example only)

Procedure

Proceed as follows

Scheme 4

1. Connect vehicle diagnosis, testing and information system VAS 5051B while the ignition is switched off.

Scheme 5

Display on VAS 5051B

1. Press Vehicle Self-Diagnosis button - 1 - in selection.

Scheme 6

Display on VAS 5051B

1. In selection - 1 - , press "01 - Engine electronics" vehicle system and continue by pressing button.

Scheme 7

Display on VAS 5051B

1. In selection - 1 - , press diagnostic function "006 - Basic setting" and continue by pressing the button.

Scheme 8

Display on VAS 5051B

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

Scheme 9

Display on VAS 5051B

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

Example

3 - 40.63 bar

Scheme 10

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

Scheme 11

1. Disconnect electrical connector - arrow - at Fuel Metering Valve 2 N290 on right high pressure pump.

Display on VAS 5051B

1. Check indication in display field - 3

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

1. Switch off ignition.

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

Now components or lines can be opened.

1. Lay clean cloths around connectors and catch escaping fuel.

Final procedures

1. Reconnect electrical harness connectors.
2. Start "Guided Functions" operating mode.
3. Generate readiness code in ECM.

Clean Working Conditions

Even a little contamination can lead to faults. Pay careful attention to the following rules for clean working conditions when working on the fuel supply and injection system

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. Use lint-free cloths.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (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.
2. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

Contact Corrosion

Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.

For this reason, only install connecting elements that are treated with a special coating.

Also, rubber or plastic parts and adhesive consist of non-conductive materials.

If there are doubts about the suitability of parts, generally use new parts .

Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. Audi accessories are recommended. Damage due to contact corrosion is not covered by warranty.

Lines, Routing and Securing

To prevent mistakes and ensure the original installation location is kept, mark the hydraulic lines, vacuum lines or electrical lines before removing them. If necessary, draw sketches or take pictures.

Engine, Removing and Installing

> Engine, Removing

> Engine and Transmission, Separating

> Engine, Securing to Assembly Stand

> Engine, Installing

Engine, Removing

Note. With lock carrier installed, engine is removed downward with transmission and subframe. Drained coolant must be stored in a clean container for disposal or reuse. During installation, reinstall all heat insulation sleeves and heat shields at the same locations. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Scheme 12

Special tools, testers and auxiliary items required

1. Pry Lever - Rmv Outside Mirror 80-200
2. Old oil collecting and extracting device V.A.G 1782
3. Hose clamp pliers V.A.G 1921
4. Hose clip pliers VAS 6340 (formerly: VAS 5024 A)

1. Step ladder VAS 5085
2. Scissor lift table VAS 6131 with support set VAS 6131/10 and adapters VAS 6131/10-12 (qty. 2)

Special tools, testers and auxiliary items required

Scheme 13

1. Drip tray for workshop crane VAS 6208

Scheme 14

1. Tensioning Strap T10038

Note. If the engine should be separated from transmission after removal, another Adapter VAS 6131/10-12 (qty. 2) set is needed.

Procedure

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

1. Remove luggage compartment floor trim.
2. Open battery retaining strap if present.

Scheme 15

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

Scheme 16

1. With ignition switched off, disconnect Battery Ground (GND) wire - arrow -.
2. Discharge refrigerant circuit --> Refrigerant R134a - Servicing.
3. Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device V.A.G 1782.

1. Remove front engine cover - 1 - and rear - 2 - - arrows -.

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

Scheme 17

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place drip tray for workshop crane VAS 6208 under engine.

Scheme 18

1. Remove drain plug - 2 - at coolant thermostat housing and drain coolant.
2. Remove coolant hoses - 1 - and - 3 -.

Scheme 19

1. Remove drain plug - arrow - at front coolant pipe and drain coolant.

Scheme 20

1. Disconnect coolant hoses at positions indicated by - arrows -.
2. Drain remaining coolant.

Scheme 21

1. Disconnect Ground (GND) cable - arrow - from right longitudinal member.

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

Scheme 22

1. Remove bolts - 1 - and - 2 -.
2. Disconnect refrigerant lines from A/C compressor.
3. Seal open connections on A/C compressor using clean plugs.

Note. Place a rag under separating point to catch escaping hydraulic fluid.

Scheme 23

1. Remove hydraulic hose - arrow - from line on left longmember.

Scheme 24

1. Disengage electrical connector - arrow - from bracket at left of lock carrier.

Note. Electrical connector is not disconnected.

Scheme 25

1. Disconnect electrical connector - 1 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and remove vacuum hose - 2 -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 from bracket and lay aside with hose connected.

Scheme 26

1. Remove bolts - arrows - and remove left air duct.

Scheme 27

1. Loosen hose clamp - 1 - and remove screws - 2, 3, 4 -.
2. Remove upper part of left air filter housing.

Scheme 28

1. Disconnect electrical connector - arrow - on Mass Air Flow (MAF) Sensor 2 G246.

Scheme 29

1. Remove lower part of air filter housing from side connection.
2. Tilt upper part of air filter housing up and out - arrow -.

Scheme 30

1. Disconnect secondary air injection electrical connector - arrow - below headlamp.
2. Free up electrical wiring.

Note. To improve clarity, the bumper cover is shown removed.

1. Remove hood seal from lock carrier and from fender edges.

Scheme 31

1. Disconnect vacuum hoses - 1 - and - 2 - and free them up.

Note. Place a rag under separating point to catch escaping hydraulic fluid.

Scheme 32

1. Disconnect power steering hydraulic pressure line - arrow - at left front on engine.

Scheme 33

1. Disconnect air guide hoses - arrows - to secondary air injection combi-valves.

Scheme 34

1. Remove bolts - arrows - and remove right air duct.

Scheme 35

1. Disconnect vacuum hose - 5 - from air guide hose.

1. Loosen hose clamp - 6 - and remove screws - 1,2, 3 -.
2. Remove upper part of right air filter housing.

Scheme 36

1. Disconnect electrical connector - arrow - on Mass Air Flow (MAF) Sensor G70.
2. Remove lower part of air filter housing from side connection.

Scheme 37

1. Tilt upper part of air filter housing up and out - arrow -.

Scheme 38

1. Remove coolant hoses - 4 - and - 5 - from coolant reservoir and coolant pipe.
2. Disconnect electrical connector - 1 - on Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.
3. Remove bolts - 2 - and - 3 - and remove coolant reservoir.

Scheme 39

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

Scheme 40

1. Remove coolant hoses - 1 - and - 2 - from right coolant pipe.

Scheme 41

1. Remove nut - arrow - and remove coolant pipe from right longmember.

Scheme 42

1. Remove vacuum hoses - 1 - and - 2 -.

Scheme 43

1. Disconnect fuel supply line - arrow - on distribution piece.

Scheme 44

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

Scheme 45

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

Scheme 46

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

Scheme 47

1. Remove bracket - 1 - from suspension strut transverse beam.
2. Remove bolts - 2 - and - 3 - and remove suspension strut transverse beam.

Scheme 48

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

Scheme 49

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

Scheme 50

1. Remove Ground (GND) cable - arrow - at left in plenum chamber.

Scheme 51

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

Scheme 52

1. Release retaining clips - arrows - and remove ECM - 1 - and - 2 -.

Note. The ECMs remain connected to the wiring harness.

Scheme 53

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

Scheme 54

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

Scheme 55

1. Remove bolts - 1 - and - 2 -.
2. Disconnect electrical connector - 3 - on Brake System Vacuum Pump V192.

Scheme 56

1. Free electrical wiring up to generator using Pry Lever - Rmv Outside Mirror 80-200.

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

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

Scheme 57

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

Scheme 58

1. Remove left and right bolts and nuts - 1 through 5 -.
2. Remove stabilizer bar with cross beam.

Scheme 59

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

Scheme 60

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

Scheme 61

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

Scheme 62

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

Scheme 63

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

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

Scheme 64

1. Remove electrical connectors - 1 - for Heated Oxygen Sensor (HO2S) G39 and - 2 - for Heated Oxygen Sensor (HO2S) 3 G285 from bracket.

Scheme 65

1. Remove subframe transverse beam - arrows -.

Scheme 66

1. Loosen clamping sleeves - 1 - and - 2 - and slide them back.

Scheme 67

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

Scheme 68

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

Prepare scissor lift platform

Scheme 69

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

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 70

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

Scheme 71

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

Scheme 72

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

Scheme 73

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

Scheme 74

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

Scheme 75

1. Remove bolts - 1 -.
2. Mark installation position of subframe and of both engine mount consoles to longmembers using a felt-tip marker.
3. Remove bolts - 2, 3, 4 - 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 76

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

1. Dimension - a - = max. 100 mm.

Scheme 77

1. Remove bolts - arrows - and remove selector lever cable heat shield.

Note. Mark the installation position of bracket for selector lever cable using a felt-tip marker.

Scheme 78

1. Press ball socket - 1 - of selector lever cable from selector shaft lever.
2. Remove mounting bracket - 2 - from transmission.
3. Move selector lever cable clear.
4. Lower engine/transmission subassembly downward.

1. Push scissor lift platform VAS 6131 with engine/transmission subassembly under vehicle.

Engine and Transmission, Separating

Special tools, testers and auxiliary items required

1. Support Element VAS 6131/10-12 (qty. 2)

Scheme 79

1. Adapter T40058

Procedure

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

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

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

Scheme 80

1. Remove coolant hose from coolant pipe at left of engine - arrow -.

Scheme 81

1. Remove coolant hose from ATF cooler on bottom of transmission - arrow -.

Scheme 82

1. Remove After-Run Coolant Pump V51 - arrows -.

Note. Coolant hoses and electrical connector remain attached.

Scheme 83

1. Remove bottom engine/transmission connecting bolts - arrows -.

1. Equip Scissor Lift Table VAS 6131 with Support Set VAS 6131/10 as well as 3 Support Elements VAS 6131/10-12 as follows

Scheme 84

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

Scheme 85

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

Scheme 86

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

1. Disconnect electrical connectors - 1 - for Heated Oxygen Sensor (HO2S) G39 and - 2 - for Heated Oxygen Sensor (HO2S) 3 G285.

Scheme 87

1. Disconnect electrical connector at left on transmission by turning twist lock counterclockwise - arrow -.
2. Free up electrical wiring.

Scheme 88

1. Remove right oxygen sensor connection heat shield from transmission - arrows -.

Scheme 89

1. Remove oxygen sensor electrical connectors - 1 through 6 - from bracket on transmission.
2. Disconnect electrical harness connectors.

Scheme 90

1. Remove bolts - 2 - and - 3 - and remove oil dipstick guide tube upward - arrow -.
2. Loosen hose clamps - 1 - and - 4 - and remove left coolant pipe from coolant hoses.

Scheme 91

1. Remove bolt - arrow - at left exhaust tract strap.

Scheme 92

1. Remove nuts - arrows -.

Scheme 93

1. Remove nuts in - 9 to 1 - sequence and remove left front exhaust manifold with catalytic converter.

Scheme 94

1. Remove nuts - 6 to 1 - in sequence and remove left rear exhaust manifold with catalytic converter.

Scheme 95

1. Remove left drive axle heat shield from transmission - arrows -.

Scheme 96

1. Remove bolts - 2 - and - 3 -.
2. Loosen hose clamps - 1 - and - 4 - and remove right coolant pipe from coolant hoses.

Scheme 97

1. Remove bolt - arrow - at right exhaust tract strap.

Scheme 98

1. Remove nuts - arrows -.

Scheme 99

1. Remove nuts - 9 to 1 - in sequence and remove right front exhaust manifold with catalytic converter.

Scheme 100

1. Remove nuts - 6 to 1 - in sequence and remove right rear exhaust manifold with catalytic converter.

Scheme 101

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

Scheme 102

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

Scheme 103

1. To loosen torque converter bolts, counterhold crankshaft using adapter T40058.

Note. Disregard - arrow -.

Scheme 104

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

Scheme 105

1. Remove engine/transmission connecting bolts - 3 to 7 -.

Note. Ignore - A -.

Scheme 106

1. Loosen side clamping screws - 1 - on scissor lift platform VAS 6131 and pull rear platform top with transmission toward rear - arrow - , simultaneously push torque converter through opening of drive plate while doing this.

Scheme 107

Special tools, testers and auxiliary items required

1. Lifting tackle 3033
2. Engine and Transmission Holder VAS 6095 with Bracket VAS 6095/1-7
3. Shop crane VAS 6100
4. Lift arm extension for workshop crane VAS 6101

Procedure

Scheme 108

1. Disconnect electrical harness connector - arrow - at left engine mount.
2. Remove bolts - 1 to 4 - and remove engine support from engine mount.

Scheme 109

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

Scheme 110

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

Scheme 111

1. Secure engine on the engine and transmission holder VAS 6095 using bracket VAS 6095/1-7 tightened to 40 Nm as shown in the 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, reinstall all heat insulation sleeves and heat shields at the same locations. During installation, all cable ties must be reinstalled at the same location.

1. Install left and right engine supports.
2. Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.

Bushing for torque converter

Scheme 112

1. On a vehicle with automatic transmission, check whether bearing bushing - arrow - is inserted at rear of crankshaft. Drive in bushing if necessary.

1. Before guiding engine and transmission together, rotate torque converter and drive plate so that holes or threaded holes are same height as opening on removed starter - arrows -.
2. To secure torque converter to drive plate, use new original ribbed bolts .
3. 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 113

1. Before installing an exchanged engine, check whether O-ring - arrow - is inserted in power steering pump input shaft.
2. Install starter --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
3. Install left exhaust system tract --> «Left Exhaust System Tract, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-exhaust-system-tract-removing-and) .
4. Install right exhaust system tract --> «Right Exhaust System Tract, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-exhaust-system-tract-removing-and) .

1. Install left coolant pipe --> «Left Coolant Pipe, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-coolant-pipe-removing-and-installing) .
2. Install right coolant pipe --> «Right Coolant Pipe, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-coolant-pipe-removing-and-installing) .
3. Always clean threaded bores in transmission flanged shaft for crankshaft of locking fluid residue using a tap before installation.

1. Turn spindle of left support element on engine/transmission assembly downward.
2. Remove left support element base plate from Scissor Lift Table VAS 6131.
3. Turn spindle of right support element on engine/transmission assembly downward.

1. Remove right support element base plate from Scissor Lift Table VAS 6131.

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

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

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

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

1. Dimension - a - = max. 100 mm.

1. Install selector lever cable and check adjustment if necessary --> «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09e-awd) for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE «37 CONTROLS, HOUSING»(ref-281379-S34729037192008031100000) for AUTOMATIC TRANSMISSION 09L, ALL WHEEL DRIVE .
2. Raise engine/transmission assembly with subframe further using Scissor Lift Table VAS 6131.

Scheme 114

1. Align subframe and engine mount consoles according to markings applied on longmembers during removal.
2. Tighten subframe and engine bearing plate bolts only to specified torque, do not tighten further (only tighten bolts after axle alignment).

1. 55 Nm
2. 110 Nm
3. 110 Nm
4. 75 Nm

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

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

1. Install drive axles --> «40 - FRONT SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Install guide control arm, control arm, stabilizer bar, connecting link, suspension strut and subframe crossmember --> «40 - FRONT SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
3. Install driveshaft --> «39 FINAL DRIVE, REAR DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#rear-final-drive-01r) .
4. Align exhaust system --> «Exhaust System, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__exhaust-system-installing) .

1. Install refrigerant lines --> «87 - AIR CONDITIONING»(/audi/s6/c6-2006-2008/remont/ac-compressor/#heating-air-conditioning) .
2. Install left and right air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
3. Electrical connections and routing --> Electrical Wiring Diagrams, Troubleshooting and Component Locations , tightening torques --> «97 - WIRES»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
4. Observe safety precautions after connecting battery --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

1. Install suspension strut cross member --> «40 - FRONT SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Mount wiper arms and adjust --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .
4. Before starting engine for the first time, fill power steering vacuum reservoir with hydraulic oil --> «48 - STEERING»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Note. Power-steering pump must not run dry.

1. Fill with coolant --> «Cooling System, Draining and Filling»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

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

1. Fill refrigerant circuit --> Refrigerant R134a - Servicing.
2. Align subframe and both engine mount consoles --> «40 - FRONT SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Perform axle alignment --> «44 - WHEELS, TIRES, WHEEL ALIGNMENT»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening Specifications

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

Belt Pulley Side, Servicing

> Ribbed Belt Drive, Component Overview

> Ribbed Belt, Removing and Installing

> Vibration Damper, Removing and Installing

> Crankshaft Seal, Ribbed Belt Side, Replacing

Scheme 115

1 - 22 Nm

2 - 22 Nm

3 - Tensioning device for ribbed belt

4 - 22 Nm

5 - Generator

1. Removing and installing --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment)

6 - M8, 22 Nm; M10, 46 Nm

7 - Alignment bushing

1. For generator bracket
2. 2 pieces

8 - Generator bracket

9 - 10 Nm

10 - Idler roller holder

11 - Vibration damper

1. Removing and installing --> «Vibration Damper, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__vibration-damper-removing-and-installing)

12 - Bolt

1. Replace
2. Only use original equipment bolts, Bolt class 12.9
3. Insert bolts that are not self-locking with locking compound; Locking compound .
4. Tightening order --> «Vibration Damper, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__vibration-damper-removing-and-installing)

13 - Idler roller for ribbed belt

14 - 22 Nm

15 - Cover cap

16 - Ribbed belt

1. Check for wear
2. Do not kink
3. Before removing, mark direction of rotation using chalk or felt-tip marker. A reversed in turning direction can cause damage to the ribbed belt under operating conditions.
4. Removing and installing --> «Ribbed Belt, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__ribbed-belt-removing-and-installing)

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

17 - Threaded bushing

Ribbed Belt, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 116

1. Torque wrench V.A.G 1332

Scheme 117

1. Socket AF 16 mm V.A.G 1332/14

Removing

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

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

Scheme 118

1. Loosen tensioning bolt - arrow - and remove ribbed belt.

Installing

Installation is in reverse order of removal, note the following

Scheme 119

1. Place ribbed belt over belt pulley in specified sequence.

1. Generator
2. Ribbed belt
3. Idler roller
4. Vibration damper
5. Tensioning roller

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

Scheme 120

1. Position torque wrench with Socket AF 16 mm V.A.G 1332/14 on tensioning roller hex head and tension ribbed belt to 70 Nm.
2. At the same time, tighten tensioning bolt - arrow - to 25 Nm.
3. Start engine and check running belt.

Vibration Damper, Removing and Installing

Removing

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Remove radiator --> «Radiator, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__radiator-removing-and-installing) .

Scheme 121

1. Loosen 8 bolts - arrow - on vibration damper several turns by counterholding on generator belt pulley central nut with open end wrench.

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

1. Loosen tensioning bolt - arrow - and remove ribbed belt.
2. Remove vibration damper.

Installing

Installation is in reverse order of removal, note the following

Note. Replace the vibration damper bolts with new original bolts . Insert bolts that are not self-locking with locking compound; Locking compound . The vibration damper can only be installed in one position - note the alignment bushing.

1. Tighten vibration damper bolts - arrow - diagonally in 3 stages.
2. Using torque wrench, tighten to 15 Nm.
3. Using torque wrench, tighten to 22 Nm.
4. With Torx key, 90 ( 1 / 4 turn) additional turn.
5. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__ribbed-belt-removing-and-installing) .
6. Install radiator --> «Radiator, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__radiator-removing-and-installing) .
7. Fill with coolant --> «Cooling System, Draining and Filling»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Crankshaft Seal, Ribbed Belt Side, Replacing

Special tools, testers and auxiliary items required

Scheme 122

1. Seal remover T40019

Scheme 123

1. Assembly tool T40048

Procedure

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Remove radiator --> «Radiator, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__radiator-removing-and-installing) .
3. Remove vibration damper --> «Vibration Damper, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__vibration-damper-removing-and-installing) .

Scheme 124

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

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

Scheme 125

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

Scheme 126

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

Note. Pull sleeve remains on crankshaft for pressing in.

Scheme 127

1. Position Pressure Sleeve T40048/3 with 2 bolts M8x55 mm - arrows - on crankshaft.
2. Install bolts by hand.
3. Tighten bolts each 1 / 2 turn by alternating sides to press in seal until it reaches stop.

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

1. Install vibration damper --> «Vibration Damper, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__vibration-damper-removing-and-installing) .
2. Install ribbed belt --> «Ribbed Belt, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__ribbed-belt-removing-and-installing) .
3. Install radiator --> «Radiator, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__radiator-removing-and-installing) .
4. Fill with coolant --> «Cooling System, Draining and Filling»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Timing Chain Side, Servicing

> Drive Plate, Component Overview

> Drive Plate, Removing and Installing

> Crankshaft Seal, Timing Chain Side, Replacing

> Timing Chain Covers, Component Overview

> Timing Chain Covers, Removing and Installing

> Lower Timing Chain Cover, Removing and Installing

> Camshaft Timing Chain, Component Overview

> Camshaft Timing Chains, Removing from Camshafts

> Camshaft Timing Chain, Removing and Installing

> Timing Mechanism Drive Chain, Component Overview

> Timing Mechanism Drive Chain, Removing and Installing

> Power Take-Off Drive Chain, Oil Pump and Balance Shaft, Component Overview

> Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing

> Power Take-Off, Component Overview

> Power Take-Off Seals, Replacing

> Spur Gear Unit, Removing and Installing

> Balancing Shaft, Component Overview

> Balancing Shaft, Removing and Installing

Scheme 128

1 - Drive plate

1. Removing and installing --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing)
2. Mark for re-installation

2 - Washer

1. 3.4 mm thick
2. Mark for re-installation

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

1. Replace

4 - Crankshaft

5 - Centering bushing

1. For torque converter
2. Check availability

6 - Crankshaft seal, timing chain side

1. Replacing --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-timing-chain-side-replacing) .

7 - Spacer washer

1. 1.5 mm thick
2. Mark for re-installation

Drive Plate, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 129

1. Counter-holder tool 10-201

Removing

1. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
2. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-and-transmission-separating) .
3. Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand --> «Engine, Securing to Assembly Stand»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Scheme 130

1. Insert counterhold tool 10-201 to loosen bolts.
2. Mark installation position on drive plate to crankshaft using a felt-tip marker.
3. Remove drive plate.
4. Remove spacer washer behind.

Installing

Installation is in reverse order of removal, note the following

1. Install drive plate with spacer washer.
2. Use new bolts when securing.
3. Turn over counterhold tool 10-201 to tighten bolts.
4. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .

Torque specifications

Crankshaft Seal, Timing Chain Side, Replacing

Special tools, testers and auxiliary items required

Scheme 131

1. Pulling fixture T10122

Scheme 132

1. Extractor hook T20143

Procedure

1. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
2. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-and-transmission-separating) .
3. Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand --> «Engine, Securing to Assembly Stand»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
4. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .

Scheme 133

1. Pry out sealing ring using Pulling Hook T20143/2.
2. Clean operating and sealing surfaces.

Scheme 134

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

Scheme 135

1. Install pull sleeve T10122/2 with sealing ring - 1 - onto crankshaft.

Scheme 136

1. Press seal evenly and flush all around using T10122/3.

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

1. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
2. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .

Scheme 137

1 - Bolt

1. M6 - 8 Nm plus an additional 90 ( 1 / 4 turn); replace
2. M8 - 22 Nm
3. Note tightening sequence --> (Scheme 151)

2 - Crankshaft seal, timing chain side

1. Replacing --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-timing-chain-side-replacing) .

3 - Alignment bushing

1. 2 pieces

4 - Left cylinder head gasket

5 - 9 Nm

1. Observe sequence when tightening: Left --> see scheme 163; right --> (Scheme 145)

6 - Left timing chain cover

1. Removing and installing --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing)

7 - O-ring

1. Replace

8 - Left coolant intermediate pipe

1. Drive out with suitable drift

9 - O-ring

1. Replace

10 - 9 Nm

1. Note tightening sequence --> (Scheme 145)

11 - Right timing chain cover

1. Removing and installing --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing)

12 - O-ring

1. Replace

13 - Right coolant intermediate pipe

1. Drive out with suitable drift

14 - O-ring

1. Replace

15 - Right cylinder head gasket

16 - Alignment bushing

1. 2 pieces

17 - Lower timing chain cover

1. Removing and installing --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and)

Timing Chain Covers, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 138

1. Hose clamp pliers V.A.G 1921
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Removing

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

1. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
2. Leave engine with transmission installed on scissor lift platform VAS 6131.

1. Remove bolts - 2 - and - 3 - and remove oil dipstick guide tube upward - arrow -.
2. Loosen hose clamps - 1 - and - 4 - and remove left coolant pipe from coolant hoses.

1. Remove bolts - 2 - and - 3 -.
2. Loosen hose clamps - 1 - and - 4 - and remove right coolant pipe from coolant hoses.

Scheme 139

1. Remove nuts - 2 - and - 4 - and remove connector bracket from rear coolant pipe.
2. Free up engine wiring harness on rear coolant pipe.
3. Disconnect electrical connector - 3 - on Engine Coolant Temperature (ECT) Sensor G62.
4. Remove coolant hose - 5 - from rear coolant pipe.

1. Remove bolts - 1 - and - 6 - and remove rear coolant pipe.

Scheme 140

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

Scheme 141

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

Installing

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

Scheme 142

1. Remove sealant residue on timing chain covers and cylinder head, e.g. with a rotating plastic brush.

1. Clean sealing surfaces, they must be free of oil and grease.

Scheme 143

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

Scheme 144

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

1. Thickness of sealant bead: 2.5 mm.

Note. Covers for timing chain must be installed within 5 minutes after applying sealant.

1. Position left timing chain cover and tighten bolts in sequence - 1 to 8 -.

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

1. Thickness of sealant bead: 2.5 mm.

1. Position right timing chain cover and tighten bolts in sequence - 1 to 8 -.

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

1. Install rear coolant pipe --> «Rear Coolant Line, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__rear-coolant-line-removing-and-installing) .
2. Install left coolant pipe --> «Left Coolant Pipe, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-coolant-pipe-removing-and-installing) .
3. Install right coolant pipe --> «Right Coolant Pipe, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-coolant-pipe-removing-and-installing) .
4. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .

Torque specifications

Lower Timing Chain Cover, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 145

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

Removing

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-and-transmission-separating) .

1. Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand --> «Engine, Securing to Assembly Stand»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
3. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
4. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

1. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .

Scheme 146

1. Remove bolts - arrows -.
2. Remove bolts - 1 to 13 - and remove lower timing chain cover.
3. Press crankshaft seal timing chain side out of lower timing chain cover.

Installing

Installation is in reverse order of removal, note the following

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

Scheme 147

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

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

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

Note. The chamfer simplifies installation of the lower timing chain cover with cylinder head installed.

1. Remove sealant residue in timing chain cover and cylinder block, e.g. with a rotating plastic brush.

1. Clean sealing surfaces so they are completely free of any oil or grease.

Scheme 148

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

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

Scheme 149

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

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

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

Scheme 150

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

1. Thickness of sealant beads: 2.5 mm.

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

1. Set lower timing chain cover in place, guiding cover at an angle from below onto cylinder block sealing surface and cylinder head.
2. When installing, make sure that the cylinder head gaskets do not become damaged. A damaged gasket must be replaced.
3. Tighten bolts in 5 stages as follows: Tighten the bolts arrows to 5 Nm using a torque wrench. Tighten bolts 1 to 13 in diagonal sequence to 8 Nm with torque wrench. Tighten bolts arrows to 9 Nm with torque wrench. Tighten bolts 1, 3, 5, 6, 7, 11, 12, 13 an additional 90° (1/4 turn) in a diagonal sequence using a rigid wrench. Tighten bolts 2, 4, 8, 9, 10 to 22 Nm with torque wrench. The rest of installation is in reverse order of removal, note the following
4. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-timing-chain-side-replacing) .
5. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
6. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
7. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
8. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
9. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .
10. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .

Torque specifications

Camshaft Timing Chain, Component Overview

Left camshaft timing chain

Scheme 151

1 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing)

2 - Camshaft bolt

1. Replace
2. Initial tightening specifications: 60 Nm
3. Final tightening specifications: 80 Nm plus an additional 90 ( 1 / 4 turn)

3 - Camshaft bolt

1. Replace
2. Initial tightening specifications: 60 Nm
3. Final tightening specifications: 80 Nm plus an additional 90 ( 1 / 4 turn)

4 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing)

5 - Left camshaft timing chain

1. Before removing, mark direction of rotation with paint. Reversing rotation direction of a used chain can destroy it
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing)

6 - 5 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

7 - Guide piece

8 - Chain tensioner for left camshaft timing chain

1. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing)

9 - Oil strainer

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

10 - Gasket

1. Replace
2. Clipped onto chain tensioner

11 - Mounting bracket for drive sprocket

12 - 9 Nm

13 - Drive sprocket for left camshaft timing chain

14 - Thrust washer for drive sprocket

15 - 22 Nm

Right camshaft timing chain

Scheme 152

1 - Mounting bracket for drive sprocket

1. For right camshaft timing chain
2. Asymmetrical version
3. Installed location --> «Location of the mounting pins for the camshaft timing chain drive sprocket»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

2 - 42 Nm

3 - Camshaft adjuster for exhaust camshaft

1. Identification "Exhaust"
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing)

4 - Camshaft bolt

1. Replace
2. Initial tightening specifications: 60 Nm
3. Final tightening specifications: 80 Nm plus an additional 90 ( 1 / 4 turn)

5 - Camshaft bolt

1. Replace
2. Initial tightening specifications: 60 Nm
3. Final tightening specifications: 80 Nm plus an additional 90 ( 1 / 4 turn)

6 - Camshaft adjuster for intake camshaft

1. Identification "Intake"
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing)

7 - Right camshaft timing chain

1. Before removing, mark direction of rotation with paint. Reversing rotation direction of a used chain can destroy it
2. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing)

8 - Chain tensioner for right camshaft timing chain

1. Removing and installing --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing)

9 - Guide piece

10 - Oil strainer

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

11 - Gasket

1. Replace
2. Clipped onto chain tensioner

12 - 5 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

13 - Thrust washer for drive sprocket

14 - Drive sprocket for right camshaft timing chain

Scheme 153

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

2 - Drive sprocket for right camshaft timing chain

4 - Bolt, 42 Nm

Scheme 154

Special tools, testers and auxiliary items required

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

1. Camshaft locator T40070 (2x)
2. Securing pin T40071 (2x)

Special tools, testers and auxiliary items required

Scheme 155

1. Adapter T40079

Removing

Note. According to the following description, the timing chains for camshafts remain on engine.

1. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
2. Leave engine with transmission installed on the scissor lift platform VAS 6131.
3. Remove cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .
4. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .

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

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

Scheme 156

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

Scheme 157

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

1. The camshaft locating tool T40070 is correctly positioned when holes for the cylinder head bolts remain free.

Scheme 158

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

Scheme 159

1. Install the crankshaft holder 3242 in the hole and tighten to 20 Nm. If necessary, rotate the crankshaft back and forth slightly to completely center the holder.

Scheme 160

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

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

Scheme 161

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

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

Scheme 162

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

Scheme 163

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

Installing

Note. Replace bolts which have been tightened to torque.

1. Drive chain for timing mechanism installed --> «Timing Mechanism Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-mechanism-drive-chain-removing-and) .

Scheme 164

1. Secure crankshaft in "TDC" position using Crankshaft Holder 3242.

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

Note. Reinstall left camshaft adjuster according to the mark applied during removal.

1. Replace camshaft bolts.

1. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 - and - 2 -.

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

1. Remove Locking Pin T40071.

Note. Reinstall right camshaft adjuster according to the mark applied during removal.

1. Replace camshaft bolts.
2. Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 - and - 2 -.

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

1. Remove Locking Pin T40071.

Note. A 2nd technician is needed for further work.

Scheme 165

1. Position Adapter T40079 on intake camshaft adjuster at left cylinder head.
2. Position Torque Wrench V.A.G 1332 with Open Ring Spanner Insert V.A.G 1332/9 on Adapter T40079.
3. Pre-tension camshaft adjuster to 40 Nm in direction of - arrow - and maintain tension.
4. Tighten bolts - 1 - on exhaust camshaft simultaneously to initial torque.

1. Torque specification: 60 Nm.

1. Continue holding pretension on exhaust camshaft and pre-torque bolt - 2 - on exhaust camshaft.

1. Torque specification: 60 Nm.

Scheme 166

1. Position Adapter T40079 on exhaust camshaft adjuster at right cylinder head.
2. Position Torque Wrench V.A.G 1332 with Open Ring Spanner Insert V.A.G 1332/9 on Adapter T40079.
3. Pre-tension camshaft adjuster to 40 Nm in direction of - arrow - and maintain tension.
4. Tighten bolts - 1 - on intake camshaft simultaneously to initial torque.

1. Tightening Specifications: 60 Nm.

1. Continue holding pretension on exhaust camshaft and pre-torque bolt - 2 - on exhaust camshaft.

1. Tightening Specifications: 60 Nm.

1. Remove Adapter T40079.

1. Remove Camshaft Clamp T40070 on both cylinder heads - arrows -.

Scheme 167

1. First tighten camshaft bolt - 1 - and then camshaft bolt - 2 - on left cylinder head to final torque.

1. Tightening Specifications: 80 Nm plus an additional 90 ( 1 / 4 turn).

Scheme 168

1. First tighten camshaft bolt - 1 - and then camshaft bolt - 2 - on right cylinder head to final torque.

1. Tightening Specifications: 80 Nm plus an additional 90 ( 1 / 4 turn).

1. Remove crankshaft holder 3242.

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

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

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

1. The camshaft locating tool T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

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

1. The crankshaft holder 3242 must engage in the locating hole or groove on the crankshaft - 1 -. Repeat adjustment if it does not.

1. Remove camshaft locating tools on both cylinder heads.
2. Remove crankshaft holder 3242.
3. Install "TDC" mark sealing plug with new seal in upper part of oil pan.

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

1. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
2. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .
3. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .

Tightening Specifications

Camshaft Timing Chain, Removing and Installing

Special tools, testers and auxiliary items required

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

Removing

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-and-transmission-separating) .

1. Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand --> «Engine, Securing to Assembly Stand»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
3. Remove cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .
4. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
3. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
4. Remove camshaft timing chains from camshafts --> «Camshaft Timing Chains, Removing from Camshafts»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

1. Mark running direction of left camshaft timing chain with paint.

Scheme 169

1. Remove bolts - 1 - and - 2 - and remove left chain tensioner and left camshaft timing chain.
2. Mark running direction of right camshaft timing chain with paint.

Scheme 170

1. Remove bolts - 1 - and - 2 - and remove right chain tensioner and right camshaft timing chain.

Installing

Note. If the tensioning element is to be removed from the chain tensioner, observe the installed position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail. Replace bolts which have been tightened to torque.

Scheme 171

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

Scheme 172

1. Clean oil strainer - 2 - in both chain tensioners if necessary.
2. Place a new gasket - 3 - onto rear of the chain tensioner - 1 -.

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

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

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

1. Position camshaft timing chains on camshafts --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing) .
2. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
3. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-timing-chain-side-replacing) .
4. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
3. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .
4. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .

1. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .
2. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .

Tightening specifications

Scheme 173

1 - Guide rail

2 - 10 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

3 - 24 Nm

4 - Thrust washer for drive sprocket

5 - Drive sprocket for left timing chain

6 - 10 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

7 - Timing Mechanism Drive Chain

1. Before removing, mark direction of rotation with paint. Reversing rotation direction of a used chain can destroy it.
2. Removing and installing --> «Timing Mechanism Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-mechanism-drive-chain-removing-and)

8 - Guide rail

9 - 10 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

10 - 9 Nm

11 - Mounting bracket for drive sprocket

1. For right camshaft timing chain
2. Asymmetrical version
3. Installed location --> «Location of the mounting pins for camshaft timing chain drive sprocket»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__location-of-the-mounting-pins-for)

12 - Thrust washer

13 - Drive sprocket for right timing chain

14 - Pivot pin for drive sprocket

15 - 42 Nm

16 - O-ring

1. Replace

17 - Chain tensioner

18 - 5 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

19 - Crankshaft

20 - 10 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

Location of the mounting pins for camshaft timing chain drive sprocket

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

2 - Drive sprocket for right camshaft timing chain

4 - Bolt, 42 Nm

Timing Mechanism Drive Chain, Removing and Installing

Special tools, testers and auxiliary items required

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

Scheme 174

1. Securing pin T40071

Removing

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-and-transmission-separating) .

1. Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand --> «Engine, Securing to Assembly Stand»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
3. Remove cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .
4. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
3. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
4. Remove camshaft timing chains --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing) .

1. Remove oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Scheme 175

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

1. Remove timing mechanism drive chain.

Installing

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

1. Route timing mechanism drive chain according to marks applied to drive chain sprockets during removal.
2. Install guide rail and tighten bolts - 1 -.
3. Install chain tensioner and tighten bolts - 2 -.
4. Press drive chain tensioner guide rail in direction of - arrow - and remove Locking Pin T40071 from chain tensioner.

1. Install oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Install camshaft timing chains --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing) .
3. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
4. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-timing-chain-side-replacing) .

1. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
2. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
3. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
4. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .

1. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
2. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .

Torque specifications

Scheme 176

1 - 9 Nm

2 - Chain tensioner

1. With glide track

3 - Gasket

1. Replace

4 - Spring

5 - 42 Nm

6 - Chain sprocket for balance shaft

7 - Bearing cap

8 - Differential shaft

1. Removing and installing --> «Balancing Shaft, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__balancing-shaft-removing-and-installing)

9 - 9 Nm

10 - Drive chain for power take-off, oil pump and balance shaft

1. Before removing, mark direction of rotation with paint. Reversing rotation direction of a used chain can destroy it.
2. Removing and installing --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

11 - Crankshaft

12 - Drive chain for power take-off and oil pump

13 - Circlip

Scheme 177

Special tools, testers and auxiliary items required

1. Locking pin 3242
2. Old oil collecting and extracting device V.A.G 1782
3. Adapter T40058
4. Securing pin T40071

1. Setting gauge T40128

Removing

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-and-transmission-separating) .

1. Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand --> «Engine, Securing to Assembly Stand»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

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

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

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

1. Install crankshaft holder 3242 into hole to 20 Nm. If necessary rotate crankshaft very slightly back and forth to completely center the holder.
2. Remove vibration damper --> «Vibration Damper, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__vibration-damper-removing-and-installing) .
3. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
4. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
3. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .

Scheme 178

1. Mark running direction of power take-off chain with paint.
2. Press tensioning rail in direction of - arrow - and secure chain tensioner with Locking Pin T40071.
3. Remove bolt - 1 - and remove balance shaft chain sprocket.
4. Remove bolts - 2 to 4 - and remove chain tensioner.

1. Remove drive chain for power take-off, oil pump and balance shaft.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets, seal and O-rings. Secure crankshaft - 1 - in "TDC" position using crankshaft holder 3242.

Scheme 179

1. Remove bolts - 2 - and - 4 -.
2. Remove balance shaft cover.
3. Remove bolts - 1 - and - 3 -.

Note. Balance shaft front bearing cap remains installed.

Scheme 180

1. Position Setting Gauge T40128 on balance shaft front bearing cap.

1. Rib on Setting Gauge T40128 must engage in groove on balance shaft.

1. Fasten Setting Gauge T40128 to cylinder block with 2 M6x30 bolts - arrows -.

1. Route drive chain for power-take off, oil pump and balance shaft according to marks made during removal.
2. Install chain tensioner and tighten bolts - 2 through 4 -.
3. Place drive chain on balance shaft chain sprocket and tighten bolt - 1 -.
4. Remove Setting Gauge T40128.

1. Tighten bolts - 1 - and - 3 -.
2. Replace balance shaft cover O-ring.
3. Tighten bolts - 2 - and - 4 - on balance shaft cover.

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

1. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
2. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-timing-chain-side-replacing) .
3. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
4. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

1. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
2. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
3. Install vibration damper --> «Vibration Damper, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__vibration-damper-removing-and-installing) .
4. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .

1. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .

Torque specifications

Scheme 181

1 - Circlip

2 - Spur gear unit

1. Cannot be replaced separately
2. Removing and installing --> «Spur Gear Unit, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__spur-gear-unit-removing-and-installing)

3 - 22 Nm

4 - Sealing ring for A/C compressor drive

1. Replacing --> «Power Take-Off Seals, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

5 - Dust seal cap for A/C compressor drive

6 - Clamp

7 - Drive shaft for A/C compressor

1. Tighten to 60 Nm

8 - O-ring

1. Replace

9 - Power-steering pump

10 - O-ring

1. Replace

11 - Drive shaft for oil pump

12 - Sealing ring for power-steering pump drive

1. Replacing --> «Power Take-Off Seals, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

13 - Spring

Scheme 182

Special tools, testers and auxiliary items required

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

Procedure

1. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
2. Remove air conditioning compressor --> «87 - AIR CONDITIONING»(/audi/s6/c6-2006-2008/remont/ac-compressor/#heating-air-conditioning) .
3. Remove power steering pump --> «48 - STEERING»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 183

1. Pry out sealing ring for A/C compressor drive using pulling hook T20143/1.

Scheme 184

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

Scheme 185

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

Scheme 186

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

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

1. Install power steering pump --> «48 - STEERING»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Install A/C compressor --> «87 - AIR CONDITIONING»(/audi/s6/c6-2006-2008/remont/ac-compressor/#heating-air-conditioning) .

Spur Gear Unit, Removing and Installing

Special tools, testers and auxiliary items required

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

Special tools, testers and auxiliary items required

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

Removing

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-and-transmission-separating) .

1. Leave engine on Scissor Lift Table VAS 6131 or secure engine to assembly stand --> «Engine, Securing to Assembly Stand»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
3. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
4. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

1. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
2. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
3. Remove power-steering pump from cylinder block.

Scheme 187

1. Remove hose clamp at A/C compressor dust cap - arrow -.
2. Remove power take-off drive chain --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Scheme 188

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

Scheme 189

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

Scheme 190

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

Installing

Note. Replace seals and O-rings.

Scheme 191

1. Remove A/C compressor drive seal - 2 - and power steering pump drive seal - 3 - using Pulling Hook T20143/1.
2. Remove O-ring - 1 -.
3. Remove sealant residue on front bearing cap and on cylinder block.
4. Clean sealing surfaces, they must be free of oil and grease.

Scheme 192

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

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

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

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

Scheme 193

1. Apply sealant beads - arrows - on clean sealing surfaces of front bearing cap as shown in illustration.

1. Thickness of sealant beads: 2.0 mm.

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

Note. The bearing cap must be installed within 5 minutes after application of sealant.

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

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

1. Position spur gear unit and tighten bolts - 1 to 6 - in a diagonal sequence in stages.
2. Install oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
3. Slide power steering pump with new O-ring onto spur gear for power-steering pump drive.

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

1. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
2. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-timing-chain-side-replacing) .
3. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
4. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

1. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
2. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
3. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .
4. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .

Torque specifications

Scheme 194

1 - Differential shaft

1. Removing and installing --> «Balancing Shaft, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__balancing-shaft-removing-and-installing)

2 - 9 Nm

3 - Rear bearing cap

1. For balance shaft

4 - Seals

1. For balance shaft rear bearing cap
2. Replace

5 - O-rings

1. Replace

6 - Front bearing cap

1. For balance shaft

7 - 9 Nm

8 - Cover

1. For balance shaft

9 - 5 Nm

10 - O-ring

1. Replace

Balancing Shaft, Removing and Installing

Removing

1. Remove oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Scheme 195

1. Remove bolts - arrows -.
2. Remove balance shaft rear bearing cap.

1. Remove bolts - 2 - and - 4 -.
2. Remove balance shaft cover.
3. Remove bolts - 1 - and - 3 -.
4. Remove balance shaft front bearing cap.

1. Carefully remove balance shaft from cylinder block.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets and O-rings.

1. Carefully insert balance shaft in cylinder block.

1. Tighten balance shaft rear bearing cap - arrows -.
2. Insert balance shaft in rear bearing cap.

Scheme 196

1. Insert balance shaft front bearing cap - arrow -.

Note. The bolts for the balance shaft front bearing cap are installed later after the balance shaft is adjusted. Balance shaft, adjusting --> Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing .

1. Install oil pump drive chain and balance shaft --> «Power Take-Off, Oil Pump and Balancing Shaft Drive Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Tightening specifications

Crankshaft

> Crankshaft, Component Overview

> Main Bearing Shells, New Crankshafts, Allocating

> Main Bearing Shears, Used and Reworked Crankshafts, Allocating

> Crankshaft Dimensions

> Axial Clearance, Measuring

> Radial Clearance, Measuring

Crankshaft, Component Overview

Note. For performing work, secure engine using Bracket VAS 6095/1-7 to Engine and Transmission Holder VAS 6095 --> Engine, Securing to Assembly Stand .

Scheme 197

1 - Cylinder block

1. Paired to - 12
2. Sealant applied on cylinder block (for guide frame) --> «Guide frame sealant application on cylinder block»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

2 - Seals

1. Replace

3 - Crankshaft seal, ribbed belt side

1. Replacing --> «Crankshaft Seal, Ribbed Belt Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-ribbed-belt-side-replacing) .

4 - Alignment bushing

1. 3 pieces
2. Insert into guide frame
3. Installed location --> «Guide frame sealant application on cylinder block»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

5 - 9 Nm

6 - Guide tube for oil dipstick

7 - O-ring

1. Replace

8 - Bolts

1. For guide frame
2. Replace
3. Various bolt sizes
4. Tightening order --> «Installing guide frame»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

9 - Baffle plate

10 - 9 Nm

1. Tightening order --> «Baffle plate tightening plate»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

11 - Bolt

1. For sealing surfaces of cylinder block/guide frame
2. Different bolt lengths
3. Tightening specifications and tightening sequence --> «Installing guide frame»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

12 - Bearing bracket

1. Paired to - item 1
2. Sealant applied on cylinder block (for guide frame) --> «Guide frame sealant application on cylinder block»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
3. Tightening order --> «Installing guide frame»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

13 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Note locating point in guide frame
4. Measuring crankshaft axial clearance --> «Axial Clearance, Measuring»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__axial-clearance-measuring)

14 - Bearing shell

1. For guide frame without lubricating groove
2. Do not interchange used bearings (mark)
3. Insert new bearing shells for guide frame with proper color marking

1. New crankshafts --> «Main Bearing Shells, New Crankshafts, Allocating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
2. Used and reworked crankshafts --> «Main Bearing Shears, Used and Reworked Crankshafts, Allocating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__main-bearing-shears-used-and-reworked)

15 - Crankshaft

1. Measuring axial play --> «Axial Clearance, Measuring»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__axial-clearance-measuring)
2. Radial clearance, measuring --> «Radial Clearance, Measuring»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__radial-clearance-measuring)
3. Do not turn crankshaft when measuring radial play
4. Crankshaft dimensions --> «Crankshaft Dimensions»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-dimensions)

16 - Thrust washer

1. Only at 4th crankshaft bearing
2. Lubricating grooves face outward
3. Measuring crankshaft axial clearance --> «Axial Clearance, Measuring»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__axial-clearance-measuring)

17 - Bearing shell

1. For cylinder block with oil groove
2. Do not interchange used bearings (mark)
3. Insert new bearing shells for cylinder block with proper color marking: With new crankshafts --> «Main Bearing Shells, New Crankshafts, Allocating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) , with used and reworked crankshafts --> «Main Bearing Shears, Used and Reworked Crankshafts, Allocating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__main-bearing-shears-used-and-reworked)

18 - Seals

1. Replace

Scheme 198

1. Then tighten bolts in sequence - 1 to 21 -.

Scheme 199

1. Clean sealing surfaces, they must be free of oil and grease.
2. Apply sealant beads - arrows - on clean sealing surfaces of guide frame as shown in illustration.

1. Thickness of sealant beads: 2.0 mm.

1. Install seals - 1 to 4 -.

Scheme 200

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

Scheme 201

1. Replace bolts - 1 to 24 -.
2. Tighten bolts for guide frame as follows
3. Tighten bolts - 1 to 12 - to 30 Nm using a torque wrench.
4. Tighten bolts - 13 to 24 - to 20 Nm using a torque wrench.

1. Tighten bolts - 1 to 12 - to 50 Nm using a torque wrench.
2. Tighten bolts - 13 to 24 - to 30 Nm using a torque wrench.
3. Tighten bolts - 1 to 12 - 90 ( 1 / 4 turn) using a rigid wrench.
4. Tighten bolts - 13 to 24 - 90 ( 1 / 4 turn) using a rigid wrench.

1. Tighten cylinder block/guide frame bolts - dark shaded - in a diagonal sequence to 9 Nm.

Scheme 202

Allocation of crankshaft bearing shells for cylinder block

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

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

Scheme 203

Allocation of crankshaft bearing shells for guide frame - Version I

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

Scheme 204

Allocation of crankshaft bearing shells for guide frame - Version II

1. Bearing shells with the correct thickness are allocated to the guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
2. Allocation of bearing shells to guide frame is marked by one colored dot each on front crankshaft counterweight as shown in the illustration. The "X" marks the end of the letter series and stand next to color identification for bearing 1, belt pulley side.

Main Bearing Shears, Used and Reworked Crankshafts, Allocating

Allocation of crankshaft bearing shells for cylinder block

1. Bearing shells are allocated to cylinder block corresponding to color markings stamped into cylinder block.
2. For used and reworked crankshafts, the main crankshaft journals must be measured in order to allocate the matching bearing shells.
3. Basic dimension of main crankshaft journals = dia. 65.00 mm.
4. Repair stage of main crankshaft journals = dia. 64.75 mm.

1. Thicker, over-sized bearing shells are available for reworked crankshafts. These have the same color markings as the original-size bearing shells.

Allocation of crankshaft bearing shells for guide frame

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

Crankshaft Dimensions

Axial Clearance, Measuring

Special tools, testers and auxiliary items required

Scheme 205

1. Dial gauge holder VW 387

Scheme 206

1. Dial gauge VAS 6079

Procedure

Scheme 207

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

1. Axial clearance: 0.090 to 0.158 mm.

Radial Clearance, Measuring

Special tools, testers and auxiliary items required

1. Plastigage

Procedure

Note. Do not interchange used bearings Bearing shells that are worn down to the nickel layer must be replaced.

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

1. Plastigage must rest in center of bearing shell.

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

Radial clearance

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

Piston and Connecting Rod

> Piston and Connecting Rod, Component Overview

> Piston and Cylinder Dimensions

> Connecting Rod, Measuring Radial Clearance

Piston and Connecting Rod, Component Overview

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

Scheme 208

1 - Connecting rod bolt - 50 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace
2. Lubricate threads and contact surface
3. Tighten to 50 Nm to measure radial play, do not turn further

2 - Connecting rod bearing cap

1. Do not interchange
2. Mark affiliation to cylinder with paint --> «Mark connecting rod»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
3. Installation position of connecting rod pairs --> «Connecting rod, installed location»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

3 - Bearing shells

1. Check that retaining tabs are secured
2. Do not interchange used bearing shells (mark, but not on the running surface)
3. Radial clearance, measuring --> «Connecting Rod, Measuring Radial Clearance»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__connecting-rod-measuring-radial-clearance)
4. To measure radial play, tighten bolts - 1 - to 60 Nm but no further

1. Over-sized bearings are available for reworked crankshaft connecting rod journals

4 - Connecting rod

1. Only replace as set
2. Mark affiliation to cylinder with paint --> «Mark connecting rod»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
3. Installation position of connecting rod pairs --> «Connecting rod, installed location»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
4. Axial play for each new connecting rod pair: 0.20 to 0.38 mm

1. Radial clearance, measuring --> «Connecting Rod, Measuring Radial Clearance»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__connecting-rod-measuring-radial-clearance)

5 - Piston pin

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

6 - Circlip

7 - Piston

1. Installation position of pistons --> «Piston installation position»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
2. Piston and cylinder dimension, piston allocation to cylinder bore --> «Piston and Cylinder Dimensions»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__piston-and-cylinder-dimensions)
3. Checking --> «Checking piston»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
4. Install with piston ring compressor

1. Measuring cylinder bore --> «Measuring cylinder bore»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

8 - Piston rings

1. Offset gaps by 120
2. Use piston ring pliers for removal and installation
3. "TOP" marking or inscribed side must point to piston head
4. Gap, measuring --> «Piston ring end gap, measuring»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

1. Measuring side clearance --> «Measuring piston ring side clearance»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

Scheme 209

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

Scheme 210

1. Clean ring groove of piston before checking.

Scheme 211

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

1. Maximum deviation from nominal dimension: 0.03 mm.

Nominal dimension --> Piston and Cylinder Dimensions .

Scheme 212

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

1. Maximum deviation from nominal dimension: 0.08 mm.

Nominal dimension --> Piston and Cylinder Dimensions .

Scheme 213

1. Identify allocation to cylinder with paint on piston crown.

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

Installed location

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

Scheme 214

Note. Only replace connecting rod as a set. Do not interchange connecting rod bearings.

1. Before removing, mark allocation of connecting rod and connecting rod bearing caps to each other and to cylinder with paint - arrow -.

Scheme 215

1. Molded tabs - arrows - at the beveled surfaces of the connecting rod pairs 1 and 2, 3 and 4, 5 and 6, 7 and 8 as well as 9 and 10 must point toward each other.

Scheme 216

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

Piston and Cylinder Dimensions

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

Connecting Rod, Measuring Radial Clearance

Special tools, testers and auxiliary items required

1. Plastigage

Procedure

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

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

Radial clearance

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

1. Replace bolts for connecting rod bearings.

Cylinder Head

> Cylinder Head, Component Overview

> Left Cylinder Head Cover, Removing and Installing

> Right Cylinder Head Cover, Removing and Installing

> Cylinder Head, Removing and Installing

> Compression, Checking

Cylinder Head, Component Overview

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

Scheme 217

1 - Cylinder head gasket

1. Replacing --> «Cylinder Head, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Installed location: Part Number, points to cylinder head
3. After replacing, change coolant and engine oil

2 - Cylinder head

1. Removing and installing --> «Cylinder Head, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
2. Check for distortion --> «Checking cylinder head for distortion»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
3. Reworking dimension --> «Checking cylinder head for distortion»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
4. After replacing, change coolant and engine oil

3 - Cylinder head cover gasket

1. Replace if damaged or leaking

4 - Cylinder head cover

1. Removing and installing: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and)

5 - Gasket

1. For cap
2. Replace if damaged or leaking

6 - Cap

7 - Ignition coil

1. Remove with Ignition Coil Puller T40039

8 - Special bolt - 9 Nm

1. Replace if seal is damaged
2. Note tightening sequence --> see scheme 291

9 - Camshaft Adjustment Valve 2 N208

10 - 2.4 Nm

11 - O-ring

1. Replace

12 - Seal

1. Replace

13 - Locking bolt - 35 Nm

14 - 2.4 Nm

15 - Camshaft Adjustment Valve 2 (exhaust) N319

16 - O-ring

1. Replace

17 - Cylinder head bolt

1. Replace
2. Observe sequence for loosening --> (Scheme 233)
3. Note tightening sequence --> see scheme 313

Scheme 218

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

1. Max. permissible distortion: 0.1 mm.

Scheme 219

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

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

Left Cylinder Head Cover, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 220

1. Ignition Coil Puller T40039

Removing

1. Remove front engine cover - 1 - and rear - 2 - - arrows -.

1. Remove bolts - arrows - and remove left air duct.

1. Loosen hose clamp - 1 - and remove bolts - 2 to 4 -.
2. Remove upper part of left air filter housing.

1. Disconnect electrical connector - arrow - on mass air flow (MAF) sensor 2 G246.

Scheme 221

1. Remove bolt - arrow - and remove power steering reservoir from bracket, hydraulic lines remain connected.

Scheme 222

1. Remove crankcase ventilation hose from separator - 5 - and from cylinder head cover - 6 -.
2. Remove oil dipstick - 3 - from guide tube.
3. Disconnect electrical harness connectors - 1 - and - 7 -.
4. Remove bolts - 2 - and - 4 -.

1. Disconnect electrical connectors to ignition coils.
2. Free up electrical wiring harness by removing harness bracket.

Scheme 223

1. Remove ignition coils using Ignition Coil Puller T40039.

Scheme 224

1. Loosen bolts - 16 to 1 - in sequence and remove them.
2. Remove left cylinder head cover.

Installing

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover if damaged or leaking. Replace bolts for cylinder head cover if gasket is damaged.

1. Clean sealing surfaces, they must be free of oil and grease.
2. Tighten cylinder head cover in sequence - 1 to 16 -.
3. Install left upper section of air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

Tightening Specifications

Right Cylinder Head Cover, Removing and Installing

Special tools, testers and auxiliary items required

1. Ignition Coil Puller T40039

Removing

1. Remove front engine cover - 1 - and rear - 2 - - arrows -.

1. Remove bolts - arrows - and remove right air duct.

1. Disconnect vacuum hose - 5 - from air guide hose.

1. Loosen hose clamp - 6 - and remove bolts - 1, 2 and 3 -.
2. Remove upper part of right air filter housing.

1. Disconnect electrical connector - arrow - on Mass Air Flow (MAF) Sensor G70.
2. Remove lower part of air filter housing from side connection.

1. Tilt upper part of air filter housing up and out - arrow -.

1. Disconnect electrical connector - 1 - on Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.
2. Remove bolts - 2 - and - 3 - and lay aside coolant reservoir with connected coolant hoses - 4 - and - 5 -.

Scheme 225

1. Disconnect crankcase ventilation hose - 2 -.
2. Disconnect electrical harness connectors - 1 - and - 5 -.
3. Remove bolts - 3 - and - 4 -.
4. Disconnect electrical connectors to ignition coils.

1. Free up electrical wiring harness by removing harness bracket.

1. Remove ignition coils using Ignition Coil Puller T40039.

Scheme 226

1. Loosen bolts - 16 to 1 - in sequence and remove them.
2. Remove cylinder head cover.

Installing

Installation is in reverse order of removal, note the following

Note. Replace cylinder head cover if damaged or leaking. Replace bolts for cylinder head cover if gasket is damaged.

1. Clean sealing surfaces, they must be free of oil and grease.
2. Tighten cylinder head cover in sequence - 1 to 16 -.
3. Install right air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

Torque specifications

Scheme 227

Special tools, testers and auxiliary items required

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

Removing

Note. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation. The following removal and installation procedure is for the left cylinder head. The procedure for the other side is identical.

1. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
2. Leave engine with transmission installed on scissor lift platform VAS 6131.

1. Twist spindles of support elements at left and right at subframe completely downward.
2. Remove Tapered Mounting Pin VAS 6131/10-2 from Scissor Lift Table VAS 6131.
3. Remove subframe to side.
4. Remove exhaust system tract: left --> «Left Exhaust System Tract, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-exhaust-system-tract-removing-and) , right --> «Right Exhaust System Tract, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-exhaust-system-tract-removing-and) .

Scheme 228

1. Remove front power steering pressure line bracket from cylinder head - arrow -.

Scheme 229

1. Remove front secondary air injection connecting piece from cylinder head - arrows -.
2. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
3. Remove camshaft timing chains from camshafts --> «Camshaft Timing Chains, Removing from Camshafts»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

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

Scheme 230

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

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

Scheme 231

1. Remove locking bolt - arrow -.

Scheme 232

1. Remove bolts - arrows -.
2. Loosen cylinder head bolts - 1 to 12 - in sequence and remove them.
3. Remove cylinder head and place it on a soft surface (foam).

Installing

Note. Replace cylinder head bolts. Replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. Carefully remove sealant residue from cylinder head and cylinder block. Make sure that no long scrapes or scratches result. Carefully remove all grinding and sanding residue. There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block. Only unpack new cylinder head gasket immediately prior to installation. Handle gasket carefully. Damage in silicon layer and recessed area lead to leakage. Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked. After installing a replacement cylinder head with camshafts installed, oil contact surfaces between roller rocker levers and cam lubricating surfaces after installing cylinder head. Do not remove plastic bases protecting freed up valves until immediately before installing cylinder head. Secure all hose connections using hose clamps appropriate for the model type . During installation, all cable ties must be re-installed at the same location. After working on the valvetrain 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. When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.

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

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

1. Crankshaft holder 3242 must be installed.

1. Position cylinder head gasket.

Scheme 233

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

1. Install cylinder head.
2. Insert new cylinder head bolts and tighten by hand.

Scheme 234

1. Tighten cylinder head bolts in 4 stages - 1 to 12 - in sequence as follows
2. Using torque wrench, tighten to 30 Nm.
3. Using torque wrench, tighten to 60 Nm.
4. With Torx key, 90 ( 1 / 4 turn) additional turn.
5. With Torx key, 90 ( 1 / 4 turn) additional turn. NOTE: There is no requirement to retighten the cylinder head bolts after repairs.
6. Tighten bolts - arrows - to 9 Nm.
7. Tighten locking bolt - arrow -.
8. Check whether camshaft timing chain tensioner guide rail is secured using Locking Pin T40071. NOTE: If the tensioning element is to be removed from the chain tensioner, observe the installed position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail. Disregard - arrow -.
9. Clean chain tensioner oil screen - 2 - if necessary.
10. Place a new gasket - 3 - onto rear of chain tensioner - 1 -.
11. Set chain tensioner in place and install camshaft timing chain, as shown in the illustration.
12. Tighten bolts - 1 - and - 2 -.
13. Install camshaft timing chains --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing) .
14. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
15. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .
16. To tighten union nut (14 mm) at fuel rail use torque wrench V.A.G 1331 with 14 mm open end wrench socket V.A.G 1331/8.
17. To tighten SW 17 union nut at fuel rail, use torque wrench V.A.G 1331 with SW 17 socket V.A.G 1331/6.
18. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
19. Install exhaust system tract: left --> «Left Exhaust System Tract, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-exhaust-system-tract-removing-and) , right --> «Right Exhaust System Tract, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-exhaust-system-tract-removing-and) .
20. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .
21. Replace coolant --> «Cooling System, Draining and Filling»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Torque specifications

Scheme 235

Special tools, testers and auxiliary items required

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

Procedure

1. Engine oil temperature min. 30 C.
2. Battery voltage min. 12.5 V.

1. Switch off ignition.

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

1. Disconnect electrical connector on Engine Speed (RPM) Sensor G28 - arrow - at bottom of transmission.

1. Remove front engine cover - 1 - and rear - 2 - - arrows -.

1. Remove bolts - arrows - and remove left air duct.

1. Loosen hose clamp - 1 - and remove bolts - 2, 3, 4 -.
2. Remove upper part of left air filter housing.

1. Disconnect electrical connector - arrow - on mass air flow (MAF) sensor 2 G246.

1. Remove bolt - arrow - and remove power steering reservoir from bracket, hydraulic lines remain connected.

Scheme 236

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

1. Remove bolts - arrows - and remove right air duct.

1. Disconnect vacuum hose - 5 - from air guide hose.

1. Loosen hose clamp - 6 - and remove bolts - 1 ,2 and 3 -.
2. Remove upper part of right air filter housing.

1. Disconnect electrical connector - arrow - on Mass Air Flow (MAF) Sensor G70.

1. Remove lower part of air filter housing from side connection.
2. Tilt upper part of air filter housing up and out - arrow -.

1. Disconnect electrical connector - 1 - on Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.
2. Remove bolts - 2 - and - 3 - and lay aside coolant reservoir with connected coolant hoses - 4 - and - 5 -.

Scheme 237

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

1. Remove all ignition coils using Ignition Coil Puller T40039.
2. Using spark plug removal tool 3122 B , remove spark plugs.
3. Check compression using compression tester V.A.G 1763.

Note. Using tester --> operating instructions.

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

Assembly is in reverse order of removal, note the following

1. Install left upper part of air filter housing and right air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Install spark plugs --> «28 - IGNITION/GLOW PLUG SYSTEM»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
3. As a final step, check Engine Control Module (ECM) DTC memory and erase it, since malfunctions were stored by disconnecting electrical connectors

Torque specifications

Valvetrain, Servicing

> Valvetrain, Component Overview

> Camshafts, Checking Axial Clearance

> Camshafts, Removing and Installing

> Valve Stem Seals, Cylinder Head Installed, Replacing

> Valve Stem Seals, Cylinder Head Removed, Replacing

> Hydraulic Adjusting Elements, Checking

> Valve Dimensions

> Valve Guides, Checking

> Valves, Checking

Note. Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Valvetrain, Component Overview

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

Scheme 238

1 - Sealing plug

1. Insert with sealant; sealant

2 - Valve stem seal

1. Replacing, Cylinder Head Installed --> «Valve Stem Seals, Cylinder Head Installed, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
2. Replacing, Cylinder Head Removed --> «Valve Stem Seals, Cylinder Head Removed, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__valve-stem-seals-cylinder-head-removed)

3 - Valve spring

1. Installed location --> «Installed position of valve spring»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

4 - Hydraulic adjusting element

1. Clipped into roller rocker lever - 8
2. Checking --> «Hydraulic Adjusting Elements, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__hydraulic-adjusting-elements-checking)
3. Do not interchange
4. Lubricate contact surface

5 - Valve spring plate

6 - Valve keys

7 - Securing clip

1. Not available individually
2. Check for secure seat

8 - Roller rocker lever

1. Do not interchange
2. Check roller for easy movement
3. Lubricate contact surface
4. To assemble, clip onto the hydraulic adjusting element - 4 - using a circlip - 7

9 - Intake camshaft

1. Removing and installing --> «Camshafts, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-removing-and-installing)
2. Checking axial play --> «Camshafts, Checking Axial Clearance»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-checking-axial-clearance)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-dia. 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-dia. 36 mm: 0.100 to 0.325 mm
2. Run-out: max. 0.04 mm

10 - Gasket

1. Replace

11 - Bearing bracket

1. With integrated camshaft bearings
2. Removing and installing --> «Camshafts, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-removing-and-installing)

12 - 8 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace
2. Observe tightening sequence --> «Camshaft guide frame, tightening sequence»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

13 - 9 Nm

14 - Camshaft position (CMP) sensor 2 G163

15 - O-ring

1. Replace

16 - O-ring

1. Replace

17 - Camshaft position (CMP) sensor 4 G301

18 - 9 Nm

19 - Exhaust camshaft

1. Removing and installing --> «Camshafts, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-removing-and-installing)
2. Checking axial play --> «Camshafts, Checking Axial Clearance»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-checking-axial-clearance)
3. Check radial clearance using Plastigage (roller rocker lever removed)
4. Radial clearance at bearing-dia. 24 mm: 0.024 to 0.066 mm

1. Radial clearance at bearing-dia. 36 mm: 0.100 to 0.325 mm
2. Run-out: max. 0.04 mm

20 - Cylinder Head

1. Check valve guides --> «Valve Guides, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__valve-guides-checking)

21 - Intake valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve Dimensions»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
4. Check valve guides --> «Valve Guides, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__valve-guides-checking)

22 - Exhaust valve

1. Do not rework, only lapping is permitted
2. Mark installed position for re-installation
3. Valve dimensions --> «Valve Dimensions»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)
4. Check valve guides --> «Valve Guides, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__valve-guides-checking)

Scheme 239

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

Scheme 240

Note. The illustration shows the guide frame for the left cylinder head.

1. Tighten bolts in 3 stages in sequence - 1 to 28
2. Tighten bolts by hand.

1. The guide frame must be in contact with the entire contact surface of the cylinder head.

1. Tighten bolts to 8 Nm.
2. Tighten bolts an additional 90.

Camshafts, Checking Axial Clearance

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387

1. Dial gauge VAS 6079

Test sequence

1. Perform measurement with guide frame removed.

Scheme 241

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

1. Axial clearance: 0.100 to 0.191 mm.

Camshafts, Removing and Installing

Special tools, testers and auxiliary items required

Scheme 242

1. Locking pin 3242

Scheme 243

1. Camshaft Clamp T40070 , qty. 2

Scheme 244

1. Impact puller T10133/3 from the tool set T10133

Scheme 245

1. Securing pins 1 set = qty. 2 T40116
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Note. Removal and installation at left cylinder head is depicted in the following description.

Removing

1. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
2. Leave engine with transmission installed on the scissor lift platform VAS 6131 A.
3. Remove camshaft timing chains from camshafts --> «Camshaft Timing Chains, Removing from Camshafts»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Scheme 246

1. Remove ground wire - 1 - from guide frame.
2. Disconnect electrical connectors - 2 - and - 3 -.
3. Remove high-pressure pump --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

1. Loosen guide frame bolts in sequence - 28 to 1 -.

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

1. Carefully remove guide frame and lay it on a soft surface on the workbench.

1. Remove Camshaft Clamp T40070 at left cylinder head.

Scheme 247

1. Mark camshafts and remove.

Installing

Note. Always replace gaskets and seals. Secure crankshaft - 1 - using crankshaft holder 3242. The hydraulic adjusting elements and roller rocker lever are inserted.

1. Remove sealant residue on cylinder head and guide frame, e.g. with rotating plastic brush.
2. Clean sealing surfaces, they must be free of oil and grease.
3. Oil journal surfaces of camshafts.
4. Set camshafts into guide frame.

Scheme 248

1. The placement of the camshafts must be exactly within the axial bearings - arrows - of the guide frame.

1. Rotate guide frame with the camshafts installed while holding camshafts inside the frame.

1. Rotate camshafts until threaded holes - arrows - point upward.
2. Check whether camshafts still lie exactly in axial bearings of guide frame.

1. Install camshaft clamp T40070 at the intake and exhaust camshafts as shown in the illustration and tighten bolts to 25 Nm.

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

Scheme 249

1. Turn around guide frame again.
2. Lay a new seal - 2 - in guide frame groove.

Note. Sealant beads must not be thicker than specified, otherwise extra sealant can enter camshaft bearing.

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

1. Thickness of sealant beads: 2.5 mm.

Note. Because the sealant begins hardening immediately, guide frame must be promptly positioned and tightened.

1. Place guide frame on cylinder head.

Scheme 250

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

Note. After installing guide frame, sealant must dry for approximately 30 minutes.

1. Tighten guide frame bolts evenly by hand in the sequence - 1 to 28 -.
2. Fasten guide frame bolts in sequence - 28 to 1 - until they stop.
3. Clean sealing plug hole in the cylinder head. It must be free of oil and grease.

Scheme 251

1. Coat outer circumference of the sealing plugs - arrows - with sealant; sealant .
2. Install sealing plugs so they are flush.

Scheme 252

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

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

1. Install high pressure pump --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Position camshaft timing chains on camshafts --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing) .
3. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
4. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .

1. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .

Note. After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons). After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Tightening specifications

Scheme 253

Special tools, testers and auxiliary items required

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

1. Adapter T40012

Removing

1. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
2. Leave engine with transmission installed on scissor lift platform VAS 6131 A.
3. Remove camshaft timing chains from camshafts --> «Camshaft Timing Chains, Removing from Camshafts»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
4. Remove camshafts --> «Camshafts, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-removing-and-installing) .

1. Using spark plug removal tool 3122 B , remove spark plugs.

Scheme 254

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

Scheme 255

1. Place guide plate VAS 5161/19 A from valve cotter disassembly and assembly device VAS 5161 on cylinder head.
2. Secure guide plate with knurled screws VAS 5161/12.
3. Install adapter T40012 with gasket by hand into respective spark plug thread and apply constant pressure.

1. Minimum pressure: 6 bar positive pressure.

Scheme 256

1. Install 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 the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

1. Lightly move knurled bolt back and forth, causing the valve keepers to be pressed apart and be captured in the 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 spring plate.

Scheme 257

1. Pull off valve stem oil seals using Valve Seal Removal Tool 3364.

Scheme 258

Note. A plastic sleeve - A - is supplied with the new valve shaft 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 Valve Stem Seal Driver 3365.

1. Remove plastic sleeve again.

Scheme 259

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

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

1. Install valve spring and valve spring plate.

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

1. Install guide plate onto cylinder head again.
2. Insert installation cartridge into guide plate.
3. Press pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
4. Release pressure fork with the knurled bolt still pulled.

1. Make sure all the roller rocker levers seat properly on the valve stem ends and are clipped onto the respective hydraulic adjusting elements.
2. Install camshafts --> «Camshafts, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-removing-and-installing) .
3. Position camshaft timing chains on camshafts --> «Camshaft Timing Chain, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshaft-timing-chain-removing-and-installing) .
4. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .

1. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .
2. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .

Note. After installing camshafts, do not crank engine for at least 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons). After working on the valvetrain 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.

Valve Stem Seals, Cylinder Head Removed, Replacing

Special tools, testers and auxiliary items required

Scheme 260

1. Valve seal removal tool 3364

Scheme 261

1. Valve stem seal driver 3365

Scheme 262

1. Valve cotter disassembly and assembly device VAS 5161

Scheme 263

1. Engine and transmission holder VAS 6095
2. Tensioning element VAS 6419

Procedure

1. Remove camshafts --> «Camshafts, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-removing-and-installing) .

Scheme 264

1. Insert tensioning element VAS 6419 in the engine and transmission holder VAS 6095.
2. Tension cylinder head on tensioning element VAS 6419 as shown in the illustration.
3. Connect tensioning element VAS 6419 to compressed air.
4. Slide air cushion with lever - arrow - under cylinder onto the valve stem seal that will be removed.

1. Let enough compressed air flow into the air cushion until it contacts the valve plate.

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

Scheme 265

1. Place guide plate VAS 5161/19 A from valve cotter disassembly and assembly device VAS 5161 on cylinder head.
2. Secure guide plate with knurled screws VAS 5161/12.

Scheme 266

1. Install 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 the same time, turn knurled bolt of installation cartridge to the right, until the points engage in the valve keepers.

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

1. Remove valve spring with valve spring plate.

1. Pull off valve stem oil seals using Valve Seal Removal Tool 3364.

Note. A plastic sleeve - A - is supplied with the new valve shaft 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 Valve Stem Seal Driver 3365.

1. Remove plastic sleeve again.

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

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

1. Install valve spring and valve spring plate.

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

1. Install guide plate onto cylinder head again.
2. Insert installation cartridge into guide plate.
3. Press pressure fork down and pull the knurled bolt upward while turning it left and right to insert the valve keepers.
4. Release pressure fork with the knurled bolt still pulled.

1. Make sure all the roller rocker levers seat properly on the valve stem ends and are clipped onto the respective hydraulic adjusting elements.
2. Install camshafts --> «Camshafts, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-removing-and-installing) .

Hydraulic Adjusting Elements, Checking

Special tools, testers and auxiliary items required

1. Adapter T40058
2. Feeler gauge

Note. The hydraulic adjusting elements cannot be repaired. Irregular valve noises are normal while starting the engine.

Procedure

1. Start the engine and let it run until the radiator fan has switched on once.
2. Increase engine speed for about 2 minutes to approximately 2500 RPM, perform road test if necessary.

Note. If irregular valve noises disappear but reappear during short drives, replace the oil check valve --> Oil Check Valve and Spray Nozzle Valve, Removing and Installing .

If the hydraulic adjusting elements are still loud, determine which element is faulty

1. Bring lock carrier into service position --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .

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

1. Rotate crankshaft in direction of engine rotation - arrow - using adapter T40058 until the camshafts on the hydraulic adjuster that needs to be checked face upward.

Scheme 267

1. Determine play between the camshaft and roller rocker lever by pressing the lever down using a screwdriver - arrow -.

If a 0.20 mm feeler gauge can be inserted between camshaft and roller rocker lever

1. Replace hydraulic adjusting element --> «Camshafts, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__camshafts-removing-and-installing) .

Final procedures

1. Install cylinder head cover: Left --> «Left Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__left-cylinder-head-cover-removing-and) , right --> «Right Cylinder Head Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__right-cylinder-head-cover-removing-and) .
2. Install lock carrier with attachments --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 268

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

Valve Guides, Checking

Special tools, testers and auxiliary items required

1. Dial gauge holder VW 387

1. Dial gauge VAS 6079

Test sequence

Scheme 269

1. Insert valve into valve guide. Due to the slight difference in stem dimensions, ensure that only an intake valve is used in the intake guide and an exhaust valve in the exhaust guide.

1. Valve stem tip must seal with valve guide.

1. Determine tilt clearance.

1. Wear limit: 0.8 mm.

Note. If the valve is to be replaced as part of a repair, use a new valve for the calculation. If wear limit is exceeded, re-measure using new valves. If wear limit is still exceeded, replace cylinder head.

Valves, Checking

1. Perform a visual check for signs of wear at stem and at seating surface.

If significant wear is discovered

1. Replace respective valve.

Lubrication System Components, Removing and Installing

> Oil Pump, Oil Pan Lower Section, Component Overview

> Oil Pan Lower Section, Removing and Installing

> Oil Pump, Removing and Installing

> Oil Pan Upper Section, Component Overview

> Oil Pan Upper Section, Removing and Installing

> Oil Check Valve and Spray Nozzle Valve, Component Overview

> Oil Check Valve and Spray Nozzle Valve, Removing and Installing

> Crankcase Ventilation Hose, Removing and Installing

> Oil Filter Housing, Component Overview

> Oil Filter Housing, Removing and Installing

> Oil Cooler, Removing and Installing

> Oil Pressure Switch, Removing and Installing

> Oil Pressure and Oil Pressure Switch, Checking

> Engine Oil Specifications

> 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, lines and hoses must be carefully cleaned to prevent resulting damage and the oil cooler must be replaced. Oil level must not exceed max. marking danger of catalytic converter damage! The oil level must not exceed the max. marking or the catalytic converter could be damaged. Oil quantities, oil specifications and viscosity classes --> Fluid Capacity Chart located in ServiceNet.

Scheme 270

1 - Oil pan (lower section)

1. Removing and installing --> «Oil Pan Lower Section, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-pan-lower-section-removing-and)
2. With Oil Level Thermal Sensor G266
3. Oil Level Thermal Sensor G266 , removing and installing --> «Oil Level Thermal Sensor, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

2 - 9 Nm

1. Tighten diagonally in 2 stages --> Tighten bolts for lower part of oil pan in 2 stages as follows. under «Oil Pan Lower Section, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa)

3 - 9 Nm

4 - 9 Nm

5 - Oil pipe

6 - Gasket

1. Replace

7 - O-ring

1. Replace

8 - O-ring

1. Replace

9 - 9 Nm

10 - Housing

1. For oil cooler by-pass valve

11 - Oil cooler by-pass valve

12 - Gasket

1. Replace

13 - Oil check valve

14 - O-ring

1. Replace

15 - 9 Nm

16 - 9 Nm

17 - Oil pipe

18 - O-ring

1. Replace

19 - Alignment bushing

1. 2 pieces

20 - Drive shaft for coolant pump

21 - Gasket

1. Replace

22 - Oil pump

1. Do not disassemble
2. With relief valve approx. 5.5 bar
3. Removing and installing --> «Oil Pump, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-pump-removing-and-installing)

23 - Drive shaft for oil pump

24 - 8 Nm plus an additional 90 ( 1 / 4 turn)

1. Replace

25 - Gasket

1. Replace

26 - 9 Nm

27 - Intake tube

1. For oil pump

28 - Oil strainer

1. Clean

29 - Oil baffle

30 - 5 Nm plus an additional 45 ( 1 / 8 turn)

1. Replace

31 - Rubber buffer

32 - 9 Nm

33 - Seal

1. Replace

34 - Oil drain plug, 25 Nm

Scheme 271

1. Nut, 9 Nm
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

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

Removing

1. Remove stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 272

1. Remove nut - 2 - and bolt - 3 - on lower left coolant pipe.

Note. Ignore - 1 - and - 4 -.

Scheme 273

1. Remove bolts - 1 - and - 2 - on front lower coolant pipe.

Note. Ignore - 3 -.

Scheme 274

1. Remove bolt - 2 - on front lower coolant pipe.

Note. Ignore - 1 - and - 3 -.

Scheme 275

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

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

Installing

Note. Replace seals.

Scheme 276

1. Remove sealant residue lower part and upper part of oil pan, e.g. with rotating plastic brush.
2. Clean sealing surfaces, they must be free of oil and grease.

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

Scheme 277

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

1. Thickness of sealant bead: 2.5 mm.

Note. Sealant bead must not be thicker than specified, otherwise excess sealant may get into lower section of oil pan and clog strainer in intake tube. The oil pan (lower part) must be installed within 5 minutes after application of sealant.

1. Position lower part of oil pan and hand tighten all bolts.
2. Tighten bolts for lower part of oil pan in 2 stages as follows.
3. Pre-tighten all bolts in a diagonal sequence to 5 Nm.
4. Tighten all bolts in a diagonal sequence to 9 Nm. The rest of installation is in reverse order of removal, note the following: Install stabilizer bar --> «40 - FRONT SUSPENSION»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) . Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .

Tightening Specifications

Oil Pump, Removing and Installing

Special tools, testers and auxiliary items required

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

Removing

1. Remove coolant pump --> «Coolant Pump, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__coolant-pump-removing-and-installing) .

Scheme 278

1. Remove drive shaft - arrow - for coolant pump from oil pump.
2. Remove lower section of oil pan --> «Oil Pan Lower Section, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-pan-lower-section-removing-and) .

Scheme 279

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Remove bolts - arrows - and remove oil pipe.

Note. Oil escapes when removing oil pipes.

Scheme 280

1. Remove bolts - arrows - and remove intake tube with oil baffle.

Scheme 281

1. Remove bolts - arrows - and remove oil pipe together with oil cooler by-pass valve housing.

Note. Oil escapes when removing oil pipes.

Scheme 282

1. Remove bolts - arrows - and hold oil pump securely with hand.

Scheme 283

1. Pull oil pump input shaft - 1 - back against spring force with water pump pliers and remove oil pump.

Installing

Note. Always replace bolts that are tightened to torque as well as sealing rings and O-rings.

1. Check whether 2 alignment bushings are present in cylinder block, install if necessary.
2. Press oil pump input shaft - 1 - back with water pump pliers and place oil pump on cylinder block.
3. Open water pump pliers and let input shaft - 1 - glide into oil pump.

1. Tighten oil pump bolts - arrows -.

Scheme 284

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

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

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

1. Install lower section of oil pan --> «Oil Pan Lower Section, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-pan-lower-section-removing-and) .
2. Install coolant pump --> «Coolant Pump, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__coolant-pump-removing-and-installing) .
3. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .
4. Fill with coolant --> «Cooling System, Draining and Filling»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .

Tightening Specifications

Scheme 285

1 - Oil pan (upper section)

1. Removing and installing --> «Oil Pan Upper Section, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-pan-upper-section-removing-and)

2 - Seals

1. Replace

3 - O-ring

1. Replace

4 - 14 Nm

5 - Seal

1. Replace

6 - Locking bolt, 35 Nm

Oil Pan Upper Section, Removing and Installing

Special tools, testers and auxiliary items required

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

Removing

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
3. Remove engine --> «Engine, Removing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-removing) .
4. Separate engine and transmission --> «Engine and Transmission, Separating»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-and-transmission-separating) .

1. Secure engine to assembly stand --> «Engine, Securing to Assembly Stand»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Remove drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
3. Remove left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
4. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

1. Remove oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .
2. Remove lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
3. Remove generator --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
4. Remove front coolant pipe --> «Front Coolant Line, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__front-coolant-line-removing-and-installing) .

1. Remove coolant pump --> «Coolant Pump, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__coolant-pump-removing-and-installing) .

1. Disconnect electrical connector - 2 - at Oil Level Thermal Sensor G266.
2. Remove oil pan (lower part) - 1 - and pry out carefully.

Scheme 286

1. Remove oil pump --> «Oil Pump, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-pump-removing-and-installing) .
2. Remove bolts - 1 to 7 - for upper section of oil pan.
3. Press upper part of oil pan from alignment pins of cylinder block.

Installing

Note. Replace seals and O-rings.

Scheme 287

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

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

Scheme 288

1. Insert new seals - 1, 2 and 3 - into grooves on cylinder block.

Scheme 289

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

1. Thickness of sealant beads: 2.5 mm.

Note. Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the strainer on intake tube. The oil pan (upper part) must be installed within 5 minutes after application of sealant.

1. Position lower part of oil pan and hand tighten all bolts.
2. Tighten bolts - 1 to 7 - in 2 stages as follows.
3. Pre-tighten all bolts in a diagonal sequence to 5 Nm.
4. Tighten bolts in a diagonal sequence to 14 Nm.

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

1. Install oil pump --> «Oil Pump, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-pump-removing-and-installing) .
2. Install lower section of oil pan --> «Oil Pan Lower Section, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-pan-lower-section-removing-and) .
3. Install coolant pump --> «Coolant Pump, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__coolant-pump-removing-and-installing) .
4. Install front coolant pipe --> «Front Coolant Line, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__front-coolant-line-removing-and-installing) .

1. Install generator --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
2. Install lower timing chain cover --> «Lower Timing Chain Cover, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__lower-timing-chain-cover-removing-and) .
3. Install crankshaft seal, timing chain side --> «Crankshaft Seal, Timing Chain Side, Replacing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__crankshaft-seal-timing-chain-side-replacing) .
4. Install oil filter housing --> «Oil Filter Housing, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-filter-housing-removing-and-installing) .

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Install left and right timing chain covers --> «Timing Chain Covers, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__timing-chain-covers-removing-and-installing) .
3. Install drive plate --> «Drive Plate, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__drive-plate-removing-and-installing) .
4. Install engine --> «Engine, Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__engine-installing) .

1. Add engine oil and check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .

Tightening specifications

Scheme 290

1 - O-ring

1. Replace

2 - Spray nozzle valve

1. Removing and installing --> «Oil Check Valve and Spray Nozzle Valve, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-check-valve-and-spray-nozzle)

3 - Gasket

1. Replace

4 - Cover

5 - O-ring

1. Replace

6 - Hose

1. For crankcase ventilation

7 - 9 Nm

8 - 9 Nm

9 - Oil check valve

1. Removing and installing --> «Oil Check Valve and Spray Nozzle Valve, Removing and Installing»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-check-valve-and-spray-nozzle)

10 - O-ring

1. Replace

Oil Check Valve and Spray Nozzle Valve, Removing and Installing

Note. If irregular valve noise occurs repeatedly during short journeys and disappears after extended driving, the oil check valve must be replaced.

Removing

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

Scheme 291

1. Remove bolts - 2 - and - 3 -.
2. Remove high pressure line - 1 - from fuel rail.
3. Remove high pressure line from connections - 4 - and - 5 - on fuel rail. To do this, counterhold at hex head with and open-end wrench and loosen union nut.
4. Remove high pressure lines.

Scheme 292

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

Scheme 293

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

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets and O-rings.

1. Install high pressure lines --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

Tightening specifications

Crankcase Ventilation Hose, Removing and Installing

Removing

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

Scheme 294

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

Installing

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

Tightening specifications

Scheme 295

1 - Gasket

1. Replace

2 - 9 Nm

3 - Oil filter housing

1. With oil filter by-pass valve 1.3 bar

4 - 22 Nm

5 - O-ring

1. Oil filter element component

6 - Oil filter element

1. Removing and installing --> «01 - MAINTENANCE»(/audi/s6/c6-2006-2008/remont/procedures/#maintenance-procedures)

7 - O-ring

1. Replace

8 - Cover - 25 Nm

9 - Not installed

10 - Not installed

11 - Locking bolt - 50 Nm

12 - Locking bolt - 9 Nm

13 - Seal

1. Replace

14 - O-ring

1. Replace

Oil Filter Housing, Removing and Installing

Removing

1. Remove intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .

Note. Place a rag around oil filter housing to catch escaping engine oil.

Scheme 296

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

Installing

Installation is in reverse order of removal, note the following

Note. Replace seals and O-rings.

1. Install intake manifold --> «24 - MULTIPORT FUEL INJECTION (MFI)»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-fuel-injection-ignition-engine-codes-bxa) .
2. Check oil level --> «Oil Level, Checking»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa__oil-level-checking) .

Tightening Specifications

Oil Cooler, Removing and Installing

Special tools, testers and auxiliary items required

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

Removing

1. Drain coolant --> «Cooling System, Draining and Filling»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) .
2. Remove Generator --> «27 - STARTER, GENERATOR, CRUISE CONTROL»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

Scheme 297

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