3.2l v6 4v Engine Mechanical, Engine Code(s): Bhe Audi TT 8N рестайлинг

Scheme 94

The engine number (engine code and serial number) can be found at the joint between the engine and transmission (arrow).

There is also a sticker on the cylinder head cover showing the "engine code" and "serial number".

The engine code is also included on the vehicle data sticker.

Note. The engine code is additionally marked at the engine lifting eye (right side).

Engine data

1) Also Super-unleaded RON 95 is permissible, however with reduced performance.

Scheme 95

Special tools and equipment

1. VAG1306 drip tray for VAG1202A
2. VAG1383A engine/transmission jack
3. Hose clamps up to 25 mm in diameter 3094
4. Stepladder VAS 5085

1. T10102 Engine bracket
2. Puller T10130

Removing

Note. Engine is removed from underneath together with the transmission. All cable ties opened or cut during engine removal must be reinstalled at the same locations. Heat insulation sleeves, which are removed during engine removal must be reinstalled at the same locations when re-installing the engine. Drained coolant must be stored in a clean container for disposal or reuse.

Scheme 96

1. Switch ignition off and disconnect Ground cable (arrow) at battery (in luggage compartment under floor cover).

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

Scheme 97

1. Unbolt bracket for headlight range control in left wheel housing (arrows).

Scheme 98

1. Remove fasteners -1...3- and center sound insulation.

Scheme 99

1. Remove left sound insulation (arrows).

Scheme 100

1. Remove right sound insulation (arrows).

Scheme 101

1. Place drip tray V.A.G 1306 under engine.
2. Turn drain plug -1- on radiator counter-clockwise. Install an auxiliary hose to connection if necessary.
3. Remove lower coolant hose from radiator by pulling off retaining clip -2-.

Scheme 102

1. In addition, remove lower coolant hose at After-run coolant pump -V51- (arrow) and drain remaining coolant.

Scheme 103

1. To remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

Scheme 104

1. Remove left side covers -1- and -2- at lock carrier and above main fuse box (arrows).

Scheme 105

1. Remove body brace -1- (arrows).

Scheme 106

1. Remove bracket (right side) for body brace (arrows).

Scheme 107

1. Disconnect air hose -2- at Throttle valve control module -J338-.
2. Disconnect electrical connector for Mass Air Flow sensor -G70-, -3-.
3. Remove bolts -1- and -4-.
4. Take out air cleaner housing.

Scheme 108

1. Unclip protective cover -1- for electrical cables.
2. Fold bracket for fuse box upward (arrows).

1. Remove fuse box by releasing retaining tabs (arrow).

Note. The wires remain connected.

Scheme 109

1. Remove carrier (arrows).

Scheme 110

1. Use screwdriver to pry off covers at wiper arms (arrows) and unscrew hex nuts.

Scheme 111

1. Use puller T10130 to remove wiper arms -1- from wiper shafts.

Scheme 112

1. Pull off rubber seal -1- on plenum chamber cover.
2. Take off plenum chamber cover -2-.
3. Disconnect washer hose and electrical connectors at windshield washer jets.
4. Lay plenum chamber cover aside (toward windshield).

Scheme 113

1. Unclip cover -2-.
2. Disconnect multi-pin connector -1- at engine control module.
3. Release retaining tab (arrow) and pull engine control module forward out of bracket.

Note. The multi-pin connector -3- remains attached to the engine control module.

Scheme 114

1. Open cable duct (left side) in engine compartment (arrows).
2. Disconnect connector in cable duct.

1. Remove electrical connector from bracket (near left-side headlight) and disconnect (arrow).
2. Set aside wiring harness leading to engine control module.
3. Place engine control module with wiring harness on top of engine.
4. Secure engine control module to prevent it from falling.

Scheme 115

1. Disconnect coolant hoses going to heat exchanger at bulkhead (arrows) by releasing retaining clips.

Note. To disconnect vacuum connections at the intake manifold, push back rubber cap -1- and release retaining tab -2-.

Scheme 116

1. Mark installed position of hoses at hose bracket behind intake manifold.
2. Disconnect hoses from hose bracket at indicated locations

1 - Coolant hose to expansion tank

2 - Vacuum hose to EVAP canister purge regulator valve -N80- and to vacuum canister

3 - Vacuum hose to exhaust flap

4 - Coolant hose to expansion tank

5 - Coolant hose to connection at heat exchanger

6 - Coolant hose to heat exchanger

7 - Vacuum hose to EVAP canister purge regulator valve -N80

8 - Vacuum hose to exhaust flap

9 - Vacuum hose to brake servo

1. Unbolt hose bracket (arrows) and remove.

Scheme 117

1. Disconnect fuel supply line -1- and fuel return line -2- by pressing release tabs.

Note. Before removing, mark the direction of rotation of the poly V-belt with chalk or a felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, this can cause breakage.

Scheme 118

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt.

Scheme 119

1. Remove upper securing bolt -2- for Generator.

Scheme 120

1. Remove upper coolant hose leading to radiator (arrows).

Scheme 121

1. Disconnect hoses at connections indicated (arrows).
2. Unscrew nut at bracket for power steering pressure line -1-.
3. Move line clear.

Scheme 122

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

Scheme 123

1. Disconnect electrical connectors -1-, -3- and -4-.
2. Unscrew wire -2- at solenoid switch for starter.
3. Disconnect Ground cable -5-.

Scheme 124

1. Remove upper securing bolts (upper arrows) for radiator cowl.

Scheme 125

1. Remove bolts -1- for support bracket -D-.
2. Pull off retaining clip -A- upward (arrow) and disconnect selector lever cable from transmission.

Note. Ignore items marked -B- and -C- in the illustration.

Scheme 126

1. Remove securing bolt (arrow) for power steering reservoir.

Scheme 127

1. Loosen bolts of assembly mounting on engine (arrows)...

Scheme 128

1. ..and on transmission (arrows) approx. 2 turns.

Scheme 129

1. Remove cross piece (arrows).

Scheme 130

1. Unbolt pulley -1- for power steering pump (counterhold with mandrel).
2. Use hose clamps 3094 to clamp off both hydraulic hoses to power steering pump.

Scheme 131

1. Place drip tray beneath power steering pump.
2. Disconnect hydraulic hoses -1- and -2- at power steering pump.
3. Remove bolts (arrows) and remove power steering pump from bracket.

Scheme 132

1. Disconnect electrical connector (arrow) at Secondary Air Injection (AIR) solenoid valve -N112-.

Scheme 133

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wire clear.
3. Unscrew bracket -2- for coolant hose.
4. Unscrew bracket -3- for secondary air injection pump air filter.

Scheme 134

1. Remove bolts -1- and -2- and remove secondary air injection pump with bracket -A-.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Remove lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

Scheme 135

1. Disconnect electrical connector -1- for air conditioning compressor clutch.

Note. The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To do this, press the engine simultaneously to the left side with an assembly lever (2nd technician required). If required, loosen all bolts of the assembly mounting 1 turn.

1. Remove bolt (arrow) for air conditioning compressor.
2. Tie up air conditioning compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).

1. Remove lower securing bolt -1- for Generator.
2. Remove Generator from bracket for ancillary units (electrical wiring remains connected).

Scheme 136

1. Unscrew clamp -3-.
2. Disconnect wire -1- at Generator.
3. Disconnect electrical connector -2-.
4. Remove Generator.

Scheme 137

1. Unbolt and remove protective cover (arrows).
2. Disconnect electrical connectors for both oxygen sensors (behind catalytic converter) and move clear to side.

Scheme 138

1. Remove fasteners (arrows) and wire guide.

Note. To avoid damage, do not bend the flexible joints in the front exhaust pipe more than 10°.

Scheme 139

1. Unbolt catalytic converter from front exhaust pipe (arrows).

Scheme 140

1. Separate exhaust system at clamp (arrows).
2. Push clamp back and remove catalytic converter.

Scheme 141

1. Unbolt front exhaust pipe at exhaust manifold (arrows) and move clear to rear.

1. Press brake pedal (2nd technician required).

Scheme 142

1. Remove flange bolt -2- from right side axle shaft.
2. Disconnect axle shaft (left side) from flange of transmission.

Scheme 143

1. Remove bolts (arrows) and remove axle shaft heat shield from bevel box.
2. Remove right side axle shaft.

Refer to 40 FRONT SUSPENSION

1. Remove bolts and remove left axle shaft from transmission flange.
2. Mark position of flexible coupling and flange for bevel box in relation to each other.

Scheme 144

1. Unbolt flexible coupling for driveshaft at bevel box (arrows)

Note. When loosening bolts, counterhold at driveshaft flange/final drive with a suitable lever.

1. Push driveshaft horizontally as far back as possible.

Scheme 145

Scheme 146

1. First, remove bolts (arrows -A-) and then bolts (arrows -B-) from pendulum support.
2. Remove pendulum support.

Scheme 147

1. Separate electrical connector (arrow) for Oil level thermal sensor -G266-.

Scheme 148

1. Attach engine bracket T10102 with securing nuts to cylinder block. Torque nuts to approx. 20 Nm.
2. Insert engine and transmission jack V.A.G 1383 A in engine bracket T10102 and raise engine/transmission assembly slightly.

Note. To unscrew bolts for assembly mounting use stepladder VAS 5085 or equivalent.

1. Remove bolts of assembly mounting on engine (arrows)...

1. ..and on transmission (arrows).

Note. Check that all hoses and wiring connections between engine, transmission and body have been disconnected. Be careful when guiding engine/transmission assembly during lowering to avoid damage.

1. Pull engine/transmission assembly as far forward as possible and lower gradually.

Engine and transmission, separating

Special tools and equipment required

Scheme 149

1. Workshop crane VAS 6100

Scheme 150

1. Bracket T10013
2. Bolt M8 x 40 with nut and 30 mm diameter washer

Work sequence

1. Engine/transmission assembly removed and attached to engine bracket T10102

Scheme 151

1. Remove bolts -1- and -2- at bracket for bevel box and remove bracket.

Scheme 152

1. Disconnect coolant hose at ATF cooler (arrow).

Scheme 153

1. Remove circlip and remove pin from bracket T10013.
2. Secure bracket T10013 with bolt M8 x 40 and 30 mm diameter washer to transmission lifting eye.
3. Attach workshop crane VAS 6100 to bracket T10013.

Scheme 154

1. Remove bolts -1...10- on engine/transmission flange.
2. Separate transmission from engine.

Scheme 155

Special tools and equipment

1. Engine and transmission support VW 540
2. Engine and transmission support supplement VW540/1B
3. Lifting tackle 3033
4. Engine stand VAS 6095

1. Workshop crane VAS 6100

Not illustrated

1. Bolt M12 x 160

Work sequence

Scheme 156

1. Attach lifting tackle 3033 to engine and workshop crane VAS 6100 as shown in illustration.
2. Lift engine off engine bracket T10102 using workshop crane VAS 6100.

Scheme 157

1. Secure engine and transmission support VW 540 with parts from engine and transmission support supplement VW 540/1B to cylinder block.

Note. Use the M12 x 160 bolt to secure the lower right arm (arrow).

1. Fasten engine to engine and transmission support VW 540 for assembly work.

Installing

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

Note. On assembly, replace the self-locking nuts and bolts that are tightened by turning through to a specified angle, as well as oil seals and gaskets. Secure all hose connections with the correct type of hose clamps (same as original equipment).

1. Check whether dowel sleeves for centering engine/transmission assembly are installed in cylinder block; install dowel sleeves if necessary.
2. Bolt transmission to engine using new bolts.

Note. Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricant such as engine oil or transmission oil may be used, but do not use lubricant containing graphite. Do not use degreased parts. Tolerance for tightening torques: ± 15 %.

Securing engine to transmission

A - dowel sleeves for centering

1) Bolt with M8 stud

2) Bolt is only used to secure starter to transmission

1. Install bracket -A- for bevel box; note following procedure
2. Initially tighten bolts -1- to 3 Nm.
3. Tighten bolts -2- to 35 Nm.
4. Tighten bolts -1- to 45 Nm.

1. Guide engine/transmission assembly into body.

1. Tighten bolts (use new bolts) for engine support to engine console (arrows)...

1. ..and transmission support to transmission mount (arrows) initially finger tight.

Note. The bolts are tightened to final torque only after adjusting the engine mountings. Refer to Engine mountings, checking and adjusting .

1. Remove engine bracket T10102 from engine.
2. Install axle shafts and tighten bolts hand tight.

Refer to 40 FRONT SUSPENSION

Note. Axle shafts must be installed prior to further assembly.

Scheme 158

1. Secure pendulum support at transmission (arrows -B-). Use new bolts.

1. Push engine/transmission assembly toward bulkhead. Journal of bevel box must be simultaneously inserted horizontally and carefully into flange of driveshaft.

Scheme 159

1. Secure pendulum support at subframe (arrows -A-). Use new bolts.

1. Secure driveshaft with flexible coupling to flange of bevel box (arrows).
2. Tighten axle shaft bolts.

Refer to 40 FRONT SUSPENSION

Perform further installation in reverse order. Pay attention to the following

1. Install exhaust system and align it free of stress. Refer to «Exhaust system, aligning free of stress»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__exhaust-system-aligning-free-of-stress) .
2. Install selector lever cable.

Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING

1. Install bracket for ancillary units. Refer to «Bracket for ancillary units, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
2. Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and A/C compressor.
3. Install Generator.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Install air conditioning compressor.

Refer to 87 AIR CONDITIONING

1. Install radiator cowl. Refer to «Radiator, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__radiator-removing-and-installing) .
2. Install power steering pump.

Refer to 48 STEERING

1. Install body brace and cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt.
2. Adjust engine mountings. Refer to «Engine mountings, checking and adjusting»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__engine-mountings-checking-and-adjusting) .
3. Connect electrical connections and check routing.

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

1. Connect Ground strap to battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Check oil level. Refer to «Oil pump, component overview»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

1. Fill cooling system. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Note. Drained coolant may only be used again if the original cylinder head or cylinder block are reinstalled. Contaminated or dirty coolant must not be used again.

Tightening torques

1) Replace nuts and bolts

2) 90° equals one quarter turn

1) Replace nuts and bolts

2) 90° equals one quarter turn

Engine mountings, checking and adjusting

Checking

1. Remove securing bolt (arrow) for power steering reservoir.

1. Disconnect fuel supply line -1- and fuel return line -2- by pressing release tabs.

Scheme 160

1. Check following dimensions at engine/transmission assembly mounting (right side)

1. Both bolt heads -2- must be parallel to edge of support arm -3-.
2. There must be a distance of -x- = 10...13 mm between engine mount -1- and engine support -4-.

1. Check gap -x- with 12 mm iron bar (or support bridge 2011).

1. Bar must be easy to insert

If the distance measured is too large or small, proceed as follows

Adjusting

Special tools and equipment required

Scheme 161

1. Support bracket 10-222 A

1. Disconnect air hose -2- at Throttle valve control module -J338-.
2. Disconnect electrical connector for Mass Air Flow (MAF) sensor -G70-, item -3-.
3. Remove bolts -1- and -4-.
4. Take out air cleaner housing.

Scheme 162

1. Secure one shackle 10-222 A/12 item -1- to engine lifting eye at right rear.
2. Set up support bracket 10-222 A with adapters 10-222 A/3 on surface of panel flange.
3. Attach spindles to lifting eye and to shackle.
4. Lift engine evenly a short distance with both spindles.

1. Unscrew bolts of assembly mounting on engine (arrows)...

1. ..and on transmission (arrows) one after another.
2. Replace all 5 bolts one by one (if not already replaced when engine was installed) and tighten them finger tight.
3. Loosen bolts for support arms on right and left approx. 2 turns.

1. Move engine slightly with an assembly lever.

1. Both bolt heads -2- must be parallel to edge of support arm -3-.
2. There must be a distance of -x- = 10...13 mm between engine mount -1- and engine support -4-.

1. Check gap -x- with 12 mm iron bar (or support bridge 2011).

1. Bar must be easy to insert.

1. Tighten bolts -2- for engine assembly mounting.

Scheme 163

1. Ensure that edges on support arm (on transmission assembly mounting) -1- and transmission mount -2- are parallel.

1. Distance -x- = -x

1. Tighten bolts for transmission assembly mounting.

The remaining installation steps are performed in the reverse sequence.

Scheme 164

Note. Before removing, mark the direction of rotation of the poly V-belt with chalk or a fel-tipped pen. If the belt runs in the opposite direction when it is reinstalled, this can cause breakage. Ensure that the belt is properly seated in the pulleys when installing.

1 - Poly V-belt

1. Poly V-belt routing. See «Poly V-belt routing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Check for wear
3. Do not kink
4. Removing and installing. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing)

2 - Vibration damper

1. With pulley for poly V-belt
2. Removing and installing. Refer to «Vibration damper, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__vibration-damper-removing-and-installing)

3 - 100 Nm + 90° (1/4 turn) further

1. Replace
2. Use counterhold tool T10069 to loosen and tighten

4 - Pulley for coolant pump

5 - 20 Nm

6 - Coolant pump

1. Removing and installing. Refer to «Coolant pump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

7 - 8 Nm

8 - 23 Nm

9 - Tensioner for poly V-belt

1. To release tension of poly V-belt, screw a bolt M8 x 40 into bore on tensioning element

10 - Bracket for ancillary units

1. Removing and installing. Refer to «Bracket for ancillary units, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

11 - Washer

12 - Dowel bolt, 23 Nm

1. 2x
2. Tightening sequence. Refer to «Installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__installing)

13 - 23 Nm

14 - Generator

1. Removing and installing

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. To facilitate attachment of Generator, slightly drive back threaded bushing for Generator securing bolts.

15 - Air conditioning compressor

1. Do not unscrew or disconnect refrigerant hoses or lines
2. To facilitate attachment of air conditioning compressor, slightly drive back threaded bushing for compressor securing bolts.

16 - 45 Nm

17 - 23 Nm

18 - 23 Nm

1. 3x
2. Tightening sequence. Refer to «Installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__installing)

19 - 23 Nm

20 - Power steering pump

1. Removing and installing

Refer to 48 STEERING

1. To facilitate attachment of power steering pump, slightly drive back threaded bushing for pump securing bolts.

21 - Pulley for power steering pump

22 - 23 Nm

Scheme 165

1 - Tensioning roller

2 - Poly V-belt for Generator

3 - Poly V-belt pulley for air conditioning compressor

4 - Poly V-belt pulley for power steering pump

5 - Vibration damper/poly V-belt pulley

6 - Poly V-belt pulley for coolant pump

Poly V-belt, removing and installing

Removing

Scheme 166

1. Remove screw -1- and remove cover over coolant expansion tank (arrow).

Note. Before removing, mark the direction of rotation of the poly V-belt with chalk or a fel-tipped pen. If the belt runs in the opposite direction when it is reinstalled, this can cause breakage. Ensure that the belt is properly seated in the pulleys when installing.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Remove fasteners -1...3- and center sound insulation.

1. Remove right sound insulation (arrows).
2. Remove poly V-belt from remaining pulleys.

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

Note. Before installing the poly V-belt ensure that all mechanical units (Generator, air conditioning compressor, power steering pump) are tightened.

1. Place poly V-belt on pulleys in following order: -1...6

1. Release tension of tensioning element as necessary by loosening bolt (arrow).
2. Check poly V-belt for proper seating.
3. Start engine and check that belt runs properly.

Vibration damper, removing and installing

Special tools and equipment required

Scheme 167

1. Counterhold T10069

Removing

1. Remove screw -1- and remove cover over coolant expansion tank (arrow).

Note. Before removing, mark the direction of rotation of the poly V-belt with chalk or a fel-tipped pen. If the belt runs in the opposite direction when it is reinstalled, this can cause breakage. Ensure that the belt is properly seated in the pulleys when installing.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Remove fasteners -1...3- and center sound insulation.

1. Remove right sound insulation (arrows).
2. Remove poly V-belt from pulley for vibration damper.

Scheme 168

1. Remove bolt for vibration damper using counterhold T10069.

Installation is performed in reverse order. Note the following

1. Use a new bolt and counterhold tool T10069 to install vibration damper.
2. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .

Tightening torque

1) Replace bolt

2) 90° equals one quarter turn

Removing

1. Remove screw -1- and remove cover over coolant expansion tank (arrow).

Note. Before removing, mark the direction of rotation of the poly V-belt with chalk or a fel-tipped pen. If the belt runs in the opposite direction when it is reinstalled, this can cause breakage. Ensure that the belt is properly seated in the pulleys when installing.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Remove upper securing bolt -2- for Generator.

1. Remove fasteners -1...3- and remove center sound insulation.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).
2. Unbolt pulley for power steering pump (counterhold with mandrel).

1. Remove bolts (arrows) and remove power steering pump from bracket.
2. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- attached.

1. Disconnect electrical connector -1- for air conditioning compressor clutch.

Note. The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To do so, press the engine simultaneously to the left side with an assembly lever (2nd technician required). If required, loosen all bolts of the assembly mounting 1 turn.

1. Remove bolts (arrows) and air conditioning compressor.
2. Tie up compressor together with refrigerant hoses at front longitudinal member (refrigerant hoses remain attached).
3. Remove lower securing bolt -1- for Generator.
4. Remove Generator from bracket for ancillary units (electrical wiring remains connected).

1. Unscrew clamp -3-.
2. Disconnect wire -1- at Generator.
3. Separate electrical connector -2-.
4. Remove Generator.

Scheme 169

1. Remove bolt (arrow) at bracket for After-run coolant pump -V51-.
2. Remove bolts -1...5- and take off bracket for ancillary units.

Installing

Installation is performed in the reverse order. Note the following

Note. Bolts -1- and -2- are dowel bolts.

1. Tighten bolts in sequence -1...5- initially only finger-tight.
2. Then tighten bolts in sequence -1...5- to specified torque.
3. Tighten bolt (arrow) at bracket for After-run coolant pump -V51-.
4. Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and air conditioning compressor.

1. Install Generator.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Install air conditioning compressor.

Refer to 87 AIR CONDITIONING

1. Install power steering pump.
2. Install cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .

Sealing flanges and flywheel, removing and installing

Note. Secure the engine to an engine stand when performing assembly work. Refer to Engine, securing to engine stand .

Scheme 170

1 - 100 Nm + 90° (1/4 turn) further

1. Replace
2. Use counterhold T10069 to loosen and tighten

2 - Vibration damper

1. With pulley for poly V-belt
2. Removing and installing. Refer to «Vibration damper, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__vibration-damper-removing-and-installing)

3 - 10 Nm

4 - Oil seal

1. Replace

5 - Front sealing flange

1. Coat sealing surfaces with sealing paste when installing

6 - Cylinder block

1. Removing and installing crankshaft. Refer to «Crankshaft, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Disassembling and assembling pistons and connecting rods. Refer to «Pistons and connecting rods, component overview»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

7 - Lower cover for timing chain

1. Coat sealing surfaces with sealing paste when installing

8 - Oil seal

1. Replace. Refer to «Crankshaft oil seal - timing chain end, replacing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__crankshaft-oil-seal-timing-chain)

9 - Dual-mass flywheel

1. Removing and installing. Refer to «Dual mass flywheel, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__dual-mass-flywheel-removing-and-installing)

10 - 60 Nm + 90° (1/4 turn) further

1. Replace

11 - 23 Nm

Scheme 171

Special tools and equipment required

1. Oil seal extractor 3203
2. Installation sleeves 3266
3. Assembly tool T10053
4. Counterhold tool T10069

Removing

1. Remove screw -1- and remove cover over coolant expansion tank (arrow).

Note. Before removing the poly V-belt, mark the direction of rotation on the belt with chalk or a felt-tipped pen. A reversed rotation direction can cause the belt to be damaged in operation. Ensure that the belt is properly seated in the pulleys when installing.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Remove fasteners -1...3- and center sound insulation.

1. Remove right sound insulation (arrows).
2. Remove poly V-belt from pulley for vibration damper.

1. Remove bolt for vibration damper using counterhold T10069.

Scheme 172

1. Unscrew inner section of oil seal extractor 3203 3 turns (approx. 4 mm) out of outer section and lock with knurled screw.
2. Lubricate threaded head of oil seal extractor, place it in position and, exerting firm pressure, screw it into oil seal as far as possible.
3. Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out.
4. Clamp flats of oil seal extractor in vise. Remove oil seal with pliers.

1. Clean running surface and sealing surface.

Installing

Note. Do not lubricate the oil seal before installing.

Scheme 173

1. Place guide sleeve T10053/1 onto crankshaft journal.
2. Push oil seal carefully over guide sleeve onto crankshaft journal as far as possible.
3. Remove guide sleeve.

Scheme 174

1. Press oil seal in as far as stop using old securing bolt for vibration damper and installation sleeve from 3266.
2. Install vibration damper with new securing bolt. Refer to «Vibration damper, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__vibration-damper-removing-and-installing) .
3. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .

Front sealing flange, removing and installing

Special tools, testers and auxiliary items required

1. Sealant

Removing

1. Engine installed

1. Remove screw -1- and remove cover over coolant expansion tank (arrow).

Note. Before removing the poly V-belt, mark the direction of rotation on the belt with chalk or a felt-tipped pen. A reversed rotation direction can cause the belt to be damaged in operation.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Remove fasteners -1...3- and center sound insulation.

1. Remove right sound insulation (arrows).
2. Remove poly V-belt from pulley for vibration damper.

1. Remove bolt from vibration damper using counter-hold T10069.

Scheme 175

1. Remove bolts -1...11-.
2. Pry off and remove front sealing flange.
3. Drive seal out of removed flange.

Installing

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

Note. Place a rag over the open portion of the oil sump

Scheme 176

1. Remove residual sealant from sealing flange with a rotating plastic brush.
2. Clean sealing surfaces. They must be free of oil and grease.

Scheme 177

1. Cut off nozzle on tube of sealant at front mark (diameter of nozzle approx. 3 mm).

Scheme 178

1. Apply a thin bead of sealant to edge between cylinder block and oil sump (arrow).

Scheme 179

1. Lightly coat lower sealing surface of sealing flange with sealant (shaded area).

Scheme 180

1. Apply a thin bead of sealant (arrow) to clean sealing surface of sealing flange, as shown in illustration.

1. Thickness of sealant bead (arrow): 2 to 3 mm

Note. The sealant bead may not be thicker than 2 to 3 mm. If thicker, the excess sealant could enter the oil sump and clog the oil intake tube. The sealing flange must be installed within 5 minutes of applying the sealant.

1. Carefully push sealing flange onto locating pins on cylinder block.

Note. To install the sealing flange with an installed seal, use guide sleeveT10053/1.

1. Fasten bolts in specified order
2. Fasten bolts -1...6-.
3. Fasten bolts -7...16-.
4. Install crankshaft seal for vibration damper side. Refer to «Crankshaft oil seal - vibration damper end, replacing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

1. Install vibration damper with new bolt. Refer to «Vibration damper, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__vibration-damper-removing-and-installing) .
2. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) ..

Tightening torque

Scheme 181

Note. To perform assembly work, secure engine to engine stand. Refer to Engine, securing to engine stand .

1 - 60 Nm + 90° (1/4 turn) further

1. Replace

2 - Dual-mass flywheel

1. Removing and installing. Refer to «Dual mass flywheel, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__dual-mass-flywheel-removing-and-installing)

3 - Seal

1. Replace. Refer to «Crankshaft oil seal - timing chain end, replacing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__crankshaft-oil-seal-timing-chain)

4 - 23 Nm

1. Tightening order. Refer to «Drive chain for valve gear and camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__drive-chain-for-valve-gear-and)

5 - Thermostat housing

1. Removing and installing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing)

6 - 10 Nm

7 - Secondary air hose retainer

8 - Gasket

1. Replace

9 - Seal

1. 2 pieces
2. For Valve -1- for camshaft adjustment -N205- and Camshaft adjustment valve 1 (exhaust) -N318
3. Removing and installing. Refer to «Oil seals in upper cover for camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__oil-seals-in-upper-cover-for)

10 - 10 Nm

11 - Camshaft position sensor

1. 2 pieces
2. Mark electrical connector before disconnecting

12 - O-ring

1. 2 pieces
2. Replace

13 - Upper timing chain cover

1. Coat sealing surfaces with sealant when installing

14 - Guide sleeve

1. 2 pieces

15 - Gasket

1. Replace

16 - O-ring

1. Replace

17 - Seal

1. Replace

18 - Chain tensioner for camshaft timing chain

1. Fasten to 40 Nm

19 - 10 Nm

1. Tightening order. Refer to «Drive chain for valve gear and camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__drive-chain-for-valve-gear-and)

20 - Cylinder head gasket

1. Clean holes and fill with sealing compound. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

21 - Guide pin

22 - Lower timing chain cover

1. Coat sealing surfaces with sealant.

23 - 10 Nm

1. Fasten diagonally in steps

Dual mass flywheel, removing and installing

Special tools and equipment required

1. Counterhold T10069

Removing

1. Transmission removed

1. Mark installation position of flywheel on engine.

Note. To prevent damage to the dual-mass flywheel when removing, the bolts -B- must not be removed with an impact wrench or similar. Removing the bolts must be done by hand with conventional tools.

1. Rotate dual-mass flywheel -A- so that bolts align with holes (arrows).

Note. When removing the bolts, make sure that the bolt heads do not come into contact with the dual-mass flywheel. The flywheel will otherwise be damaged as the bolts are unscrewed.

1. Unbolt dual-mass flywheel (counterhold on vibration damper with T10069).

Installing

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

Note. Use new bolts for securing the flywheel.

Tightening torque

Crankshaft needle bearing, removing and installing

Special tools and equipment

Scheme 182

1. Drift VW 207 C or centering drift 3176

Scheme 183

1. 1 - Kukko 21/1 interior extractor
2. 4 - Kukko 22/1 counterhold
3. Depth gauge

Removing

1. Transmission removed

Scheme 184

1. Remove needle bearing using internal extractor Kukko 21/1 and counterhold Kukko 22/1.

Installing

Scheme 185

1. Drive in needle bearing using drift VW 207 C or centering drift 3176.

Inscription on needle bearing must be visible when installed.

Scheme 186

Installed position for needle bearing

1. Dimension -a- = 2.0 mm

Crankshaft oil seal - timing chain end, replacing

Special tools and equipment

Scheme 187

1. Installation tool T10122

Scheme 188

1. Pressing-out tool T20143/2

Work sequence

1. Transmission removed

Scheme 189

1. Remove dual-mass flywheel. Refer to «Dual mass flywheel, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__dual-mass-flywheel-removing-and-installing) .

Scheme 190

1. Pry out oil seal using pressing-out tool T20143/2.
2. Clean running surface and sealing surface.

Note. Do not lubricate the oil seal before installing.

Scheme 191

1. Press new oil seal -A- over installation sleeve T10122/1 onto guide sleeve T10122/2.

1. Installed position: closed side faces installation sleeve

1. Separate both sleeves.

Scheme 192

1. Insert guide sleeve T10122/2 with oil seal -1- onto crankshaft.

Scheme 193

1. Press in oil seal with press tool T10122/3 evenly and flush.

Perform further installation in reverse order. Note the following

1. Install dual-mass flywheel. Refer to «Dual mass flywheel, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__dual-mass-flywheel-removing-and-installing) .

Scheme 194

1 - Cable bracket

1. For coolant hoses and wiring harness

2 - 8 Nm

3 - Camshaft Position (CMP) sensor 2 -G163

1. For exhaust camshaft
2. Mark electrical connector before disconnecting

4 - Chain tensioner for camshaft timing chain

1. Tighten to 40 Nm

5 - Seal

1. Replace if damaged or leaking

6 - Not installed

7 - Not installed

8 - Not installed

9 - Oil seal

1. 2x
2. For Valve -1- for camshaft adjustment -N205
3. Replace if damaged or leaking
4. Removing and installing. Refer to «Oil seals in upper cover for camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__oil-seals-in-upper-cover-for)

10 - 23 Nm

11 - Bracket for wiring harness

12 - Thermostat housing

1. Removing and installing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing)

13 - Seal

1. Replace

14 - Upper cover for camshaft timing chain

1. Removing and installing. Refer to «Oil seals in upper cover for camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__oil-seals-in-upper-cover-for)

15 - Camshaft Position (CMP) sensor -G40

1. For intake camshaft
2. Mark electrical connector before disconnecting

16 - O-ring for oil chained seal

1. Replace
2. Lubricate before installing

Oil seals in upper cover for camshaft timing chain, removing and installing

Special tools and equipment

Scheme 195

1. Assembly tool 3253

Scheme 196

1. Installation sleeve 3378

Removing

1. Upper cover for camshaft timing chain must be removed.

1. Drive out oil seals using a drift.

Installing

Scheme 197

1. Insert oil seal into upper cover for camshaft timing chain -1- with installation sleeve 3378 and then use assembly tool 3253/6 to press it in flush.

Scheme 198

1 - Valve timing housing

1. Removing and installing. Refer to «Camshafts, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshafts-removing-and-installing)
2. Disassembling and assembling. Refer to «Disassembling and assembling valve timing housing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
3. Check filter for dirt. Refer to «Checking filter of valve timing housing for dirt»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
4. Lightly coat contact surfaces of oil seals before installing

2 - 8 Nm

1. Replace

3 - Camshaft timing chain

1. Mark rotation direction before removing. (Scheme 201)
2. Removing from camshafts. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)
3. Removing and installing. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

4 - Camshaft adjuster - exhaust

1. Identification: 32A
2. Removing and installing. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

5 - Intermediate shaft

6 - Thrust washer

7 - 8 Nm

1. Install using locking fluid

8 - Guide rail for timing chain

1. To remove it is first necessary to remove both upper and lower covers for timing chains

9 - Pivot pin

10 - Chain tensioner for camshaft timing chain, 40 Nm

1. Removing and installing. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

11 - Seal

1. Replace if damaged or leaking

12 - Sprocket for drive chain for valve gear

1. Removing and installing. Refer to «Drive chain for valve gear and camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__drive-chain-for-valve-gear-and)

13 - Sprocket for camshaft timing chain

1. Removing and installing. Refer to «Drive chain for valve gear and camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__drive-chain-for-valve-gear-and)

14 - 60 Nm + 90° (1/4 turn) further

1. Replace
2. When loosening and tightening, counterhold vibration damper with counterhold tool T10069

15 - Chain tensioner with guide rail

1. For drive chain
2. Before installing, release locking spline in chain tensioner with a small screwdriver and press guide rail against chain tensioner

16 - Drive sprocket chain

1. Integral part of chain

17 - Drive chain for valve gear

1. Mark rotation direction before removing. (Scheme 201)
2. Removing and installing. Refer to «Drive chain for valve gear and camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__drive-chain-for-valve-gear-and)

18 - Guide rail for drive chain for valve gear

1. Removing and installing. Refer to «Drive chain for valve gear and camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__drive-chain-for-valve-gear-and)

19 - Pin, 10 Nm

1. For guide rail

20 - 18 Nm

21 - 23 Nm

22 - Camshaft adjuster - intake

1. Identification: 24E
2. Removing and installing. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

23 - 60 Nm + 90° (1/4 turn) further

1. Replace
2. Contact surface of sender wheel at bolt head must be dry when installing
3. To remove and install: counterhold with 32 mm open end wrench on camshaft. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

24 - Guide rail for camshaft timing chain

1. Removing and installing. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

25 - Valve -1- for camshaft adjustment -N205

1. For intake camshaft
2. Mark electrical connector before disconnecting

26 - Camshaft adjustment valve 1 (exhaust) -N318

1. For exhaust camshaft
2. Mark electrical connector before disconnecting

27 - Guide rail for camshaft timing chain

1. Clipped onto valve timing housing

Scheme 199

1. Mark rotation direction of timing chains with colored arrows before removing (arrows).

Note. Do not mark chains using a center punch or by notching.

Camshaft timing chain, removing from camshafts

Special tools, equipment, and material required

Scheme 200

1. Camshaft plate T10068
2. Gasket sealant, black, Part No AMV 174 04 01
3. Gasket paste, Part No. AMV 188 001 02

Removing

1. Engine in vehicle

1. Drain coolant. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
2. Remove intake manifold. Refer to «Intake manifold, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
3. Disconnect electrical connector for Mass Air Flow (MAF) sensor -G70-.

Scheme 201

1. Remove bolts -1- and -3-.
2. Take out air cleaner housing.

1. Unclip protective cover -1- for electrical wiring.
2. Fold bracket box upward (arrows).

1. Remove fuse box by releasing retaining tabs (arrow).

Note. The wires remain connected.

1. Remove carrier (arrows).

Scheme 202

1. Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor -G62-.

Scheme 203

1. Disconnect coolant hoses at connections indicated (arrows).

Scheme 204

1. Remove bolts (arrows).
2. Swing bracket for secondary air injection hose forward.

Scheme 205

1. Remove bolt (arrow) on bracket for wiring harness.

Scheme 206

1. Remove thermostat housing -2-. To do so, press coolant pipe -1- toward coolant pump with an assembly lever.

Scheme 207

1. Disconnect air hose -4- and vacuum hose -1- at combination valve for secondary air injection system.
2. Disconnect Ground cable -2-.
3. Disconnect coolant hoses -3- and -5-.
4. Place Throttle valve control module -J338- on bulkhead.

Scheme 208

1. Mark and disconnect electrical connectors

1 - Camshaft Position (CMP) sensor -G40

2 - Camshaft Position (CMP) sensor 2 -G163

3 - Valve -1- for camshaft adjustment -N205

4 - Camshaft adjustment valve 1 (exhaust) -N318

1. Disconnect electrical connector (left side) on cylinder head and move connector clear.

1. Disconnect fuel supply line -1- and fuel return line -2- by pressing release tabs.
2. Unscrew and move clear all electrical connectors on cylinder head and lay them back together with fuel rail.

Scheme 209

1. Unscrew cylinder head cover bolts in sequence -11...1-.

Scheme 210

1. Turn crankshaft to TDC marking (arrow) in normal direction of rotation via securing bolt on vibration damper...

Scheme 211

1. Simultaneously insert camshaft plate T10068 into grooves on both camshafts. If necessary, turn crankshaft 1 rotation further.

Scheme 212

1. Remove bolt for camshaft timing chain tensioner (arrow).

Scheme 213

1. Remove bolts -1...3- and remove upper cover for camshaft timing chain from cylinder head horizontally. Take care not to damage cylinder head gasket when removing.

Scheme 214

1. Remove bolts (arrows) and remove guide rail -1-.
2. Remove camshaft plate T1068.

Note. The camshaft plate T10068 must not be inserted when loosening and tightening the securing bolts for the camshaft adjuster.

Scheme 215

1. Unscrew securing bolt at camshaft adjuster (intake side). Counterhold with open end wrench (32 mm) on hex flats of camshaft.
2. Remove camshaft adjuster (intake side).

Scheme 216

1. Unscrew securing bolt at camshaft adjuster (exhaust side). Counterhold with open end wrench (32 mm) on hex flats of camshaft.
2. Remove camshaft adjuster (exhaust side).
3. Remove camshaft timing chain over valves for camshaft adjustment and set aside.

Installing

1. Install guide rail -1- and tighten bolts (arrows).

1. Recheck TDC position of crankshaft (arrow)

1. Check TDC position of camshafts

It must be possible to insert camshaft plate T10068 into both camshaft grooves...

Scheme 217

1. ..If necessary, turn camshafts to correct position at hex flats (arrows) using an open end wrench (32 mm).

Note. The crankshaft must not be at TDC at any cylinder when the camshafts are turned. Otherwise, there is a risk of damage to the valves and piston crowns.

1. First install camshaft adjuster for intake side.

Scheme 218

1. Turn sender wheel -1- clockwise (arrow) in camshaft adjuster as far as stop.

Note. The camshaft plate must not be used as a counterhold.

Scheme 219

1. Tighten camshaft adjuster (intake side) in this position to intake camshaft finger-tight.

1. Contact surface of sender wheel at bolt head must be dry when installing
2. Inscription "24E" item -1- and tooth just behind it -2- must align with notch -3- in valve timing housing.

1. Lay camshaft timing chain in this position tautly onto sprocket of camshaft adjusted (intake side).

Scheme 220

1. Count exactly 16 rollers of timing chain starting from inscription "24E" on camshaft adjuster (intake side) moving toward exhaust side.
2. Place tooth at inscription "32A" on camshaft adjuster (exhaust side) exactly behind 16th roller of chain.

1. There should be now 16 chain rollers between teeth.
2. Inscription "32A" and tooth just behind it must also align with notch in valve timing housing.

Scheme 221

1. Turn sender wheel -2- clockwise (arrow) in camshaft adjuster -1- (exhaust side) as far as stop.
2. Tighten camshaft adjuster (exhaust side) in this position to exhaust camshaft finger-tight.

1. Contact surface of sender wheel at bolt head must be dry when installing.

Note. When turning the crankshaft, it is necessary to press the guide rail firmly against the camshaft timing chain manually (instead of using the tensioning element) -arrow- to prevent the chain from slipping.

1. Turn crankshaft via securing bolt for vibration damper 2 revolutions in normal direction of rotation until marking is at TDC (arrow)...

1. ..and simultaneously be able to insert camshaft plate T10068 in both camshaft grooves.

If the camshaft plate cannot be inserted

1. Repeat adjustment of valve timing.

Scheme 222

1. Clean any old sealing compound from 3 mm bores (arrows) in cylinder head gasket.
2. Fill 3 mm bores in cylinder head gasket with sealing compound (black) AMV 174 04 01.

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

1. Replace oil seals in upper cover for camshaft timing chain. Refer to «Oil seals in upper cover for camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__oil-seals-in-upper-cover-for) .
2. Clean sealing surfaces.

1. Sealing surfaces must be free of grease and oil.

Scheme 223

1. Check if dowel sleeves -2- and -3- are inserted in upper cover for camshaft timing chain.
2. Insert a new oil seal -1- and a new seal -4-.
3. Thinly coat clean surface of upper cover for camshaft timing chain (hatched surface in illustration) with sealing past AMV 188 001 02.

Note. Also apply a thin coat of sealing paste to the surface beneath the cylinder head gasket (do not kink gasket). The upper cover for the camshaft timing chain must be installed within 5 minutes after applying the sealing paste.

1. Install upper cover for camshaft timing chain and tighten bolts in following sequence

1 - Tighten bolts -1- and -2- to 5 Nm

2 - Tighten bolts -3- to 23 Nm

3 - Tighten bolts -1- and -2- to 10 Nm

1. Secure chain tensioner (arrow) for camshaft timing chain.
2. Turn crankshaft 2 revolutions in normal direction of rotation and recheck valve timing.
3. Install cylinder head cover. Refer to «Cylinder head cover, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-cover-removing-and-installing) .
4. Install intake manifold. Refer to «Intake manifold, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

1. Install thermostat housing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing) .

Tightening torques

1) Replace bolt

2) 90° equals one quarter turn

Drive chain for valve gear and camshaft timing chain, removing and installing

Special tools and equipment required

1. Camshaft plate T10068

1. Counterhold T10069

Removing

1. Engine removed. Refer to «Engine, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
2. Engine separated from transmission. Refer to «Engine and transmission, separating»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__engine-and-transmission-separating) .
3. Dual-mass flywheel removed. Refer to «Dual mass flywheel, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__dual-mass-flywheel-removing-and-installing) .
4. Intake manifold removed. Refer to «Intake manifold, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

1. Cylinder head cover removed. Refer to «Cylinder head cover, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-cover-removing-and-installing) .
2. Thermostat housing removed. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing)
3. Sump removed. Refer to «Sump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__sump-removing-and-installing) .

1. Turn crankshaft to TDC marking (arrow) in normal direction of rotation via securing bolt on vibration damper...

1. ..camshaft plate must simultaneously be inserted in camshaft grooves. If necessary, turn crankshaft 1 rotation further.

1. Mark and disconnect electrical connectors

1 - Camshaft Position (CMP) sensor -G40

2 - Camshaft Position (CMP) sensor 2 -G163

3 - Valve -1- for camshaft adjustment -N205

4 - Camshaft adjustment valve 1 (exhaust) -N318

1. Remove bolt for chain tensioner for camshaft timing chain (arrow).

1. Remove bolts -1...3- and remove upper cover for camshaft timing chain from cylinder head horizontally. Take care not to damage cylinder head gasket when removing.

Scheme 224

1. Remove bolts and remove lower cover (arrow) for timing chains horizontally from cylinder block. Take care not to damage cylinder head gasket when removing.
2. Press out crankshaft oil seal (timing chain end) from timing chain cover.

1. Mark rotation direction of timing chains with colored arrows before removing (arrows).

Note. Do not mark the chains using a center punch, a notch or similar.

1. Remove bolts (arrows) and remove guide rail -1-.
2. Remove camshaft timing chain from sprocket for intermediate shaft.
3. Remove camshaft timing chain carefully from behind projection of cylinder head gasket.

Scheme 225

1. Loosen bolt (arrow) for chain sprocket of intermediate shaft approx. 1 turn...

1. ..by counterholding with T10069 on vibration damper for support.

Scheme 226

1. Unscrew chain tensioner for drive chain for valve gear (arrows).

1. Unscrew bolt (arrow) and remove drive chain together with gears for intermediate shaft.

Installing

Note marking for rotation direction (lower arrow) when reinstalling a used drive chain for valve gear.

Scheme 227

1. Install drive chain together with large sprocket of intermediate shaft.
2. Note installation position of sprocket

1. Sprocket can only be installed on intermediate shaft in one position. If necessary, turn intermediate shaft slightly.

1. Check TDC position of crankshaft

1. Ground-down tooth of drive chain sprocket must align with main bearing joint (arrow -A-).
2. Notch on sprocket for intermediate shaft must align with groove (arrow -B-) on thrust washer for intermediate shaft.

1. Install small sprocket for intermediate shaft

1. Sprocket can only be installed in one position on intermediate shaft.

1. Replace securing bolt (arrow) for chain sprockets of intermediate shaft.
2. Tighten bolt finger-tight.

Scheme 228

1. Release locking spline in chain tensioner with a small screwdriver (arrow) and press guide rail against chain tensioner.
2. Secure chain tensioner in this position.

1. Tighten securing bolt for chain sprockets (arrow)...

1. ..by counterholding at vibration damper with T10069 for support.

Scheme 229

1. Install camshaft timing chain as follows

1. Yellow chain link -1- must align with marking -2- on small chain sprocket for intermediate shaft.
2. Copper-colored chain links -4- must align with arrows -3- on camshaft adjusters and notches -5- on valve timing housing.
3. There must be 16 chain rollers between arrows.

1. Install guide rail -1- and tighten bolts (arrows).
2. Remove camshaft plate T10068.

Note. When turning the crankshaft, it is necessary to press the guide rail firmly against the camshaft timing chain manually (instead of using the tensioning element) -arrow- to prevent the chain from slipping.

1. Turn crankshaft via securing bolt for vibration damper 2 revolutions in normal direction of rotation until marking is at TDC (arrow)...

1. ..and simultaneously be able to insert camshaft plate T10068 in both camshaft grooves.

Note. The marked chain links will now be in an undefined position.

If the camshaft plate cannot be inserted

1. Repeat adjustment of valve timing.

1. Clean old sealing compound from 3 mm bores (arrows) in cylinder head gasket.

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

1. Clean sealing surfaces on engine and on both covers; they must be free of oil and grease.
2. Check whether dowel pins for lower cover for timing chains are inserted in cylinder block.

Scheme 230

1. Thinly coat clean surface of lower cover for timing chains (hatched surface in illustration) with sealing paste AMV 188 001 02.

Note. The lower cover for the timing chains must be installed within 5 minutes after applying the sealing paste.

1. Tighten bolts securing lower cover (arrow) for timing chains in diagonal sequence and in stages.

1. Fill 3 mm bores (arrows) in cylinder head gasket with sealing compound (black) AMV 174 04 01.
2. Replace oil seals in upper cover for camshaft timing chain. Refer to «Oil seals in upper cover for camshaft timing chain, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__oil-seals-in-upper-cover-for) .

1. Check if dowel sleeves -2- and -3- are inserted in upper cover for camshaft timing chain.
2. Insert a new oil seal -1- and a new seal -4-.
3. Thinly coat clean surface of upper cover for camshaft timing chain (hatched surface in illustration) with sealing past AMV 188 001 02.

1. Install upper cover for camshaft timing chain and tighten bolts in following sequence

1 - Tighten bolts -1- and -2- to 5 Nm

2 - Tighten bolts -3- to 23 Nm

3 - Tighten bolts -1- and -2- to 10 Nm

1. Secure chain tensioner (arrow) for camshaft timing chain.
2. Turn crankshaft 2 revolutions in normal direction of rotation and recheck valve timing.
3. Install crankshaft oil seal (timing chain side). Refer to «Crankshaft oil seal - timing chain end, replacing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__crankshaft-oil-seal-timing-chain) .
4. Install cylinder head cover. Refer to «Cylinder head cover, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-cover-removing-and-installing) .

1. Install intake manifold. Refer to «Intake manifold, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
2. Install thermostat housing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing)
3. Install sump. Refer to «Sump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__sump-removing-and-installing) .
4. Install dual-mass flywheel. Refer to «Dual mass flywheel, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__dual-mass-flywheel-removing-and-installing) .

1. Install engine. Refer to «Engine, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
2. Fill engine with oil and check oil level. Refer to «Oil pump, component overview»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Tightening torques

1) Replace bolt

2) 90° equals one quarter turn

Crankshaft, removing and installing

Note. Secure the engine to an engine stand when performing assembly work. If large quantities of metal shavings or abrasions are found when performing engine repairs, it may indicate damage to the crankshaft or connecting rod bearings. To prevent further damage, the following procedures must be performed during or after completion of repair work: the oil galleries must be carefully cleaned and the oil spray jets, oil cooler and oil filter must be replaced.

Scheme 231

1 - Cylinder block

1. Cylinder bore, checking. Refer to «Checking cylinder bore»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Piston and cylinder dimensions. Refer to «Piston and cylinder dimensions»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__piston-and-cylinder-dimensions)

2 - Oil spray nozzle for piston cooling

1. For crankshaft bearings 2...7
2. Opening pressure: 2.0 bar
3. Removing and installing. Refer to «Removing and installing oil spray jet»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__removing-and-installing-oil-spray-jet)

3 - Bearing shell

1. For cylinder block with oil intake bore
2. Do not interchange used bearings (mark)
3. Replacement parts are only color coded "yellow"

4 - Crankshaft

1. After removal, lay aside so that sensor wheel item -10- is not supporting weight or it will be damaged
2. Axial play, New: 0.07...0.23 mm; Wear limit: 0.30 mm
3. Measure radial play with Plastigage
4. Do not turn crankshaft when measuring radial play

1. Radial play, New: 0.02...0.06 mm; Wear limit: 0.10 mm
2. Crankshaft dimensions. Refer to «Crankshaft dimensions»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__crankshaft-dimensions)

5 - Thrust washer

1. For bearing 5
2. Observe locating point
3. Lubricating groove faces crankshaft

6 - Bearing cap

1. Bearing cap 1: belt pulley side
2. Bearing cap 5 with notches for thrust washers
3. Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another

7 - 30 Nm + 180° (1/2 turn) further

1. Replace

8 - Bearing shell

1. For bearing cap without bore
2. Do not interchange used bearings (mark)
3. Replacement parts are only color coded "yellow"

9 - Thrust washer

1. For bearing 5
2. Observe locating point
3. Lubricating groove faces crankshaft

10 - Sensor wheel

1. For Engine speed sensor -G28
2. Sensor wheel must be replaced every time bolts are loosened. Refer to «Removing and installing sensor wheel»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__removing-and-installing-sensor-wheel)
3. Installing. Refer to «Removing and installing sensor wheel»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__removing-and-installing-sensor-wheel)

11 - 10 Nm + 90° (1/4 turn) further

1. Replace
2. Sensor wheel must be replaced every time bolts are loosened. Refer to «Removing and installing sensor wheel»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__removing-and-installing-sensor-wheel)

Removing and installing sensor wheel

The sensor wheel and securing bolts must be replaced every time the bolts are loosened.

1. Contact surface of crankshaft/sensor wheel must be free of oil and grease.

1. Thinly coat contact surface of crankshaft/sensor wheel with locking fluid

Scheme 232

1. "VR6" marking -2- must be positioned at bore of bolt -3- that goes into crankshaft crankpin (contour of crankshaft is shown by dashed line -1-)
2. Gap (arrow) in ring gear lies across from designation
3. Second "VR6" marking -4- may be ignored

1. Tighten new bolts only finger-tight.
2. Tighten bolt -1-.
3. Tighten bolt -2-.

Tightening torques

1) 90° equals one quarter turn

Crankshaft dimensions

1) 90° equals one quarter turn

Scheme 233

1 - Connecting rod bolt, 30 Nm + 90° (1/4 turn) further

1. Replace
2. Lubricate threads and contact surface
3. To measure radial clearance, tighten to 30 Nm but not further

2 - Connecting rod bearing cap

1. Mark cylinder allocation -B
2. Installed position: Markings -A- must be on same side

3 - Bearing shells

1. Installed position: retaining tabs of both bearing shells lie on same side of connecting rod
2. Do not interchange used bearing shells (mark)
3. Retaining tabs on bearing shells must fit tightly in recesses
4. Axial clearance, New: 0.05...0.31 mm; Wear limit: 0.40 mm

1. Measure radial clearance with Plastigage
2. Do not rotate crankshaft when measuring radial clearance
3. Radial clearance, New: 0.02...0.07 mm; Wear limit: 0.10 mm
4. Replacement parts are color coded "yellow" for lower and "red" for upper

4 - Connecting rod

1. With hole for piston pin lubrication
2. Only replace as a set
3. Mark cylinder allocation -B
4. Installed position: Mark -A- faces toward shallow side of piston (shallow side of piston crown faces cylinder block center)

5 - Circlip

6 - Piston pin

1. If difficult to move, heat piston to 60° C
2. Remove and install using drift VW 222 A

7 - Piston

1. Checking. Refer to «Checking piston»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Mark installed position to connecting rod and cylinder allocation
3. Shallow side of piston crown faces center of cylinder block
4. Piston and cylinder dimensions. Refer to «Piston and cylinder dimensions»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__piston-and-cylinder-dimensions)

1. Install using T10147. Refer to «Installing piston with tool T10147»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__installing-piston-with-tool-t10147)

8 - Piston rings

1. Compression rings
2. Offset gaps by 120°
3. Remove and install using piston ring pliers
4. "TOP" must face toward piston crown

1. Checking ring gap. Refer to «Checking piston ring gap»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Checking ring to groove clearance. Refer to «Checking ring to groove clearance»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

9 - Piston ring

1. Oil scraping ring
2. 3-part
3. Install upper steel ring so gap is offset by 120° to neighboring compression ring
4. Offset all gaps of oil scraping ring components to each other

Scheme 234

1. Insert ring at right angle to cylinder wall from above and push down into lower cylinder opening approx. 15 mm from bottom of cylinder. To do so, use a piston without rings.
2. Use a feeler gauge to measure.

Scheme 235

1. Clean groove in piston before checking clearance.
2. Use a feeler gauge to measure.

Scheme 236

1. Measure approx. 6 mm from lower edge, perpendicular to piston pin axis. Use an external micrometer, 75...100 mm, to measure.

1. Max. deviation from nominal dimension: 0.04 mm

Scheme 237

1. Make measurements at three positions diagonally in transverse direction -A- and in longitudinal direction -B-. Use a cylinder gauge, 50...100 mm, to measure.

1. Max. deviation from nominal dimension: 0.08 mm

Installing piston with tool T10147

Note. If a new installing tool (funnel) is used to install the pistons, first pass a piston (with oiled piston rings) twice through the tool and remove any resulting metal debris. Only then install the piston with the piston rings.

Scheme 238

1. Lubricate tool and push piston in by hand.

1. Flat side of piston crown must face projection on installing tool (arrow).

1. Hold tool (with piston inserted) on upper edge and press piston in with both thumbs.
2. Push piston in until it protrudes approx. 15 mm from lower edge of installing tool.
3. Place piston in appropriate cylinder bore.

1. Projection on installing tool (arrow) must face center of cylinder block.

1. Hold installing tool firmly against cylinder block and push in piston.

Piston and cylinder dimensions

Cylinder head, removing and installing

Note. Replace cylinder head bolts. On assembly, replace self-locking nuts and bolts that are tightened by turning through to a specified angle, as well as oil seals and gaskets. When installing an exchange cylinder head, the contact surfaces between supporting elements, roller rocker fingers and cams must be oiled before installing the head. The plastic protectors fitted to protect the open valves must only be removed immediately before installing the cylinder head. When installing a new cylinder head or cylinder head gasket, drain all of the old coolant and refill with new coolant.

Scheme 239

1 - Cylinder head gasket

1. Metal gasket
2. Replace
3. After replacing, fill with new coolant

2 - Cylinder head

1. Removing. Refer to «Cylinder head, removing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-removing)
2. Checking for distortion. Refer to «Checking cylinder head for distortion»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
3. Installing. Refer to «Cylinder head, installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-installing)
4. After replacing, fill with new coolant

3 - Lifting eye

4 - 23 Nm

5 - Cylinder head cover gasket

1. Replace if damaged

6 - Cylinder head cover

1. Removing and installing. Refer to «Cylinder head cover, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-cover-removing-and-installing)

7 - Spacing sleeve

1. With seal
2. Replace seal if damaged

8 - 10 Nm

9 - Filler cap

10 - Filler cap seal

1. Replace if damaged

11 - Rubber buffer

1. Replace if damaged

12 - Ignition coil

1. Use puller for ignition coil T10095 A for removal

13 - 10 Nm

1. Bolt with spacer sleeve and seal
2. Replace seal if damaged

14 - 10 Nm

15 - 10 Nm

16 - Wire harness retainer

17 - Cylinder head bolt

1. Replace
2. Note sequence when loosening. Refer to «Cylinder head, removing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-removing)
3. Note sequence when tightening. Refer to «Cylinder head, installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-installing)

18 - Lifting eye

19 - 23 Nm

20 - 10 Nm

21 - Combination valve for secondary air injection system

1. Removing and installing. Refer to «Combination valve for secondary air system, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__combination-valve-for-secondary-air-system)

Scheme 240

1. Use a straight edge and feeler gauge to measure for distortion at several points.

1. Max. permissible distortion: 0.05 mm

Cylinder head cover, removing and installing

Removing

Note. All cable ties which are released or cut open when removing must be replaced in the same position when installing.

1. With ignition switched off, disconnect ground cable (arrow) at battery in rear compartment under floor covering.

1. To remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

Scheme 241

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).
2. Pull out oil dipstick.

Note. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, it can be damaged.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Unscrew upper securing bolt -2- for Generator.

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

1. Remove center sound insulation fasteners -1...3-.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).
2. Unbolt pulley for power steering pump (counterhold with mandrel).

1. Remove bolts (arrows) and remove power steering pump from bracket.
2. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- still attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wire clear.
3. Unscrew bracket -2- for coolant hose.
4. Unscrew bracket -3- for air filter for secondary air pump.

1. Remove bolts -1- and -2- and remove secondary air injection pump with bracket -A-.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Remove lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

1. Disconnect electrical connector -1- for air conditioning compressor clutch.

1. Unscrew bolt (arrow) for air conditioning compressor.

Note. The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To do so, press the engine simultaneously to the left side with an assembly lever (2nd technician required). If required, loosen all bolts of the assembly mounting 1 turn.

1. Tie up air conditioning compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).

1. Remove lower securing bolt -1- for Generator.
2. Remove Generator from bracket for ancillary units (electrical wires remain connected).

1. Unscrew clamp -3-.
2. Unscrew wire -1- at Generator.
3. Disconnect electrical connector -2-.
4. Remove Generator.

Scheme 242

1. Remove bolt -3- and pull out guide tube for oil dipstick -2-.
2. Remove bolt -4- and disconnect vacuum reservoir from manifold.
3. Move vacuum reservoir to side (hoses still attached).

1. Remove bolt (arrow) at bracket for coolant pump for After-run coolant pump -V51-.
2. Remove bolts -1...5- and take off bracket for ancillary units.

Scheme 243

1. Remove bolts (arrows) at front of intake manifold.

Scheme 244

1. Disconnect electrical connectors at ignition coils by releasing tab (arrow) with assembly tool T10118 and carefully pulling connector.

Scheme 245

1. Attach puller T10095A to ignition coils as shown in illustration (arrow) and remove ignition coils one at a time.

1. Remove body brace -1- (arrows).

Scheme 246

1. Move electrical wire (arrow) clear.
2. Loosen hose clamps -1- and -2- and remove air hose between air cleaner housing and Throttle valve control module -J338-.

Scheme 247

1. Disconnect electrical connectors -2- and -3-.
2. Disconnect crankcase breather hose -1-.

Scheme 248

1. Remove bolts (arrows) for Throttle valve control module -J338- and move it clear to one side (coolant hoses remain attached).

Scheme 249

1. Disconnect vacuum hoses -1...4- at rear of intake manifold.

Note. The other hoses remain attached on hose bracket.

1. Unbolt hose bracket from intake manifold (arrows).

Scheme 250

1. Remove rear securing bolts (arrows) for intake manifold.

Scheme 251

1. Protect intake manifold from damage with a clean cloth -1-.
2. Swing intake manifold forward (arrow).

Note. Cover or plug the intake ports in the cylinder head with a clean cloth or foam plastic to prevent small items from falling in.

Scheme 252

1. Disconnect vacuum hose (arrow) at vacuum unit for intake manifold change-over.

Note. Items -1- and -2- are not applicable here.

1. Unbolt brackets for electrical wires at left on cover for timing chains and at right on cylinder head cover.

1. Unscrew cylinder head cover bolts in sequence -11...1-.

Installing

Installation is performed in the reverse order. Note the following

Note. Replace gaskets for the cylinder head cover and securing bolts if damaged. Replace gaskets for the ignition coils if damaged.

1. Tighten cylinder head cover bolts in sequence -1...11-.
2. Install bracket for ancillary units. Refer to «Bracket for ancillary units, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
3. Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and air conditioning compressor.
4. Install Generator.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Install air conditioning compressor.

Refer to 87 AIR CONDITIONING

1. Install radiator cowl. Refer to «Radiator, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__radiator-removing-and-installing) .
2. Install secondary air injection pump. Refer to «Secondary air injection pump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__secondary-air-injection-pump-removing-and) .
3. Install power steering pump.

Refer to 48 STEERING

1. Install body brace and cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .
2. Connect Ground strap to battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Tightening torques

Scheme 253

Overview of intake manifold components

1 - Change-over mechanism

2 - Bushing

3 - O-ring

1. Replace

4 - Panel bolt

5 - Bearing cap

6 - Intake manifold

7 - 20 Nm

8 - 20 Nm

9 - Seal

10 - Connection for crankcase breather

1. With Positive Crankcase Ventilation (PCV) heating element -N79

11 - O-ring

12 - Throttle valve control module -J338

13 - 10 Nm

14 - 20 Nm

15 - Heat shield for exhaust manifold

1. With support for intake manifold

16 - Gasket

1. Replace
2. Insert into manifold

17 - 13 Nm

18 - Panel bolt

19 - Vacuum unit

20 - Vacuum connection

1. To Intake manifold change-over valve -N156

21 - O-ring

1. Replace

22 - Bushing

Removing

Note. All cable ties which are released or cut open when removing must be replaced in the same position when installing.

1. With ignition switched off, disconnect ground cable (arrow) at battery in rear compartment under floor covering.

1. To remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).
2. Pull out oil dipstick.

Note. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, it can be damaged.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Unscrew upper securing bolt -2- for Generator.

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

1. Remove center sound insulation fasteners -1...3-.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).
2. Unbolt pulley for power steering pump (counterhold with mandrel).

1. Remove bolts (arrows) and remove power steering pump from bracket.
2. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- still attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wire clear.
3. Unscrew bracket -2- for coolant hose.
4. Unscrew bracket -3- for air filter for secondary air pump.

1. Remove bolts -1- and -2- and remove secondary air injection pump with bracket -A-.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Remove lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

1. Disconnect electrical connector -1- for air conditioning compressor clutch.

1. Unscrew bolt (arrow) for air conditioning compressor.

Note. The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To do so, press the engine simultaneously to the left side with an assembly lever (2nd technician required). If required, loosen all bolts of the assembly mounting 1 turn.

1. Tie up air conditioning compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).

1. Remove lower securing bolt -1- for Generator.
2. Remove Generator from bracket for ancillary units (electrical wires remain connected).

1. Unscrew clamp -3-.
2. Unscrew wire -1- at Generator.
3. Disconnect electrical connector -2-.
4. Remove Generator.

Scheme 254

1. Remove connector (arrow) for Engine speed (RPM) sensor -G28- from retainer on oil dipstick guide tube.

1. Remove bolt -3- and pull out guide tube for oil dipstick -2-.
2. Remove bolt -4- and disconnect vacuum reservoir from manifold.
3. Move vacuum reservoir to side (hoses still attached).

1. Remove bolt (arrow) at bracket for coolant pump for After-run coolant pump -V51-.
2. Remove bolts -1...5- and take off bracket for ancillary units.

1. Remove bolts (arrows) at front of intake manifold.

1. Disconnect electrical connectors at ignition coils by releasing tab (arrow) with assembly tool T10118 and carefully pulling connector.

1. Attach puller T10095A to ignition coils as shown in illustration (arrow) and remove ignition coils one at a time.

1. Remove body brace -1- (arrows).

1. Move electrical wire (arrow) clear.
2. Loosen hose clamps -1- and -2- and remove air hose between air cleaner housing and Throttle valve control module -J338-.

1. Disconnect electrical connectors -2- and -3-.
2. Disconnect crankcase breather hose -1-.

1. Remove bolts (arrows) for Throttle valve control module -J338- and move it clear to one side (coolant hoses remain attached).

1. Disconnect vacuum hoses -1...4- at rear of intake manifold.

Note. The other hoses remain attached on hose bracket.

1. Unbolt hose bracket from intake manifold (arrows).

1. Remove rear securing bolts (arrows) for intake manifold.

1. Protect intake manifold from damage with a clean cloth -1-.
2. Swing intake manifold forward (arrow).

Note. Cover or plug the intake ports in the cylinder head with a clean cloth or foam plastic to prevent small items from falling in.

1. Disconnect vacuum hose (arrow) at vacuum unit for intake manifold change-over.

Scheme 255

1. Unclip pipe guide -1- from fuel rail -2-.
2. Disconnect vacuum pipe -3- from fuel pressure regulator.
3. Remove bolts (arrows).
4. Remove fuel rail with fuel injectors from cylinder head and move clear to one side (fuel lines remain attached).

1. Swing intake manifold back to its installed position and remove.

Installing

Installation is performed in the reverse order. Note the following

Note. Replace seals and gaskets.

1. Install bracket for ancillary units. Refer to «Bracket for ancillary units, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
2. Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and air conditioning compressor.
3. Install Generator.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Install air conditioning compressor.

Refer to 87 AIR CONDITIONING

1. Install radiator cowl. Refer to «Radiator, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__radiator-removing-and-installing) .
2. Install secondary air injection pump. Refer to «Secondary air injection pump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__secondary-air-injection-pump-removing-and) .
3. Install power steering pump.

Refer to 48 STEERING

1. Install body brace and cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .
2. Connect Ground strap to battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Tightening torques

Cylinder head, removing

1. Engine in vehicle

Note. All cable ties which are released or cut open when removing must be replaced in the same position when installing. Heat insulation sleeves that have been removed are to be reinstalled in the original position. If engine oil is contaminated, perform oil change.

Refer to 01 MAINTENANCE

1. Drain coolant. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
2. Remove intake manifold. Refer to «Intake manifold, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
3. Remove timing chain from camshafts. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts) .

Note. To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°.

1. Unbolt front exhaust pipe from exhaust manifolds (arrows).

Scheme 256

1. Loosen and remove cylinder head bolts in sequence indicated.

Scheme 257

1. Attach lifting tackle 3033 as follows

1. Belt pulley end: position 3
2. Timing chain end: position 10

Note. The positions marked 1...12 on the lifting tackle 3033 face toward the timing chain end.

1. Carefully lift off cylinder head.
2. Place clean cloths in cylinders to prevent dirt from getting between cylinder wall and piston.

Cylinder head, installing

Special tools, testers and auxiliary items required

1. Camshaft bar T10068

Note. Replace cylinder head bolts. On assembly, replace self-locking nuts and bolts that are tightened by turning through to a specified angle, as well as oil seals and gaskets. Secure all hose connections with the correct type of hose clamps (same as original equipment). If repairing, carefully remove any remaining gasket material from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. Do not remove new cylinder head gasket from packaging until it is ready to be installed. Handle the gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks. No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.

1. Set camshafts to TDC for cylinder No. 1 before installing cylinder head.

1. It must be possible to insert camshaft plate T10068 in both camshaft grooves.

1. Check again whether crankshaft is positioned at TDC (arrow).

Scheme 258

1. Install new cylinder head gasket.
2. Pay attention to centering pins in cylinder block.
3. Check installed position of cylinder head gasket; Part No. must be visible from intake side.
4. Install cylinder head.

1. Insert cylinder head bolts and tighten by hand.

Note. The long cylinder head bolts are inserted in the middle bores in the cylinder head.

1. Tighten cylinder head in 4 stages in following sequence
2. Tighten using a torque wrench

1. 1st stage: 30 Nm
2. 2nd stage: 50 Nm

1. Tighten with a Torx key

1. 3rd stage: 90° (1/4 turn) further
2. 4th stage: 90° (1/4 turn) further

Note. Re-tightening of the cylinder head bolts is not necessary on completion of repair work.

1. Install camshaft timing chain. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts) .
2. Install cylinder head cover. Refer to «Cylinder head cover, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__cylinder-head-cover-removing-and-installing) .
3. Install intake manifold. Refer to «Intake manifold, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
4. Replace coolant. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

1. Connect Ground strap to battery

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Tightening torque

1) Replace nuts

Scheme 259

Special tools and equipment required

1. Spark plug socket 3122 B
2. Compression tester V.A.G 1763
3. Puller T10095 A
4. Assembly tool T10118

Conditions

1. Engine oil temperature at least 30° C
2. Battery voltage at least 12.7 V

Work sequence

1. Switch off ignition.

Scheme 260

1. Remove fuel pump fuse from slot No. 28.

1. Disconnect electrical connectors at ignition coils by releasing tab (arrow) with assembly tool T10118 and carefully pulling connector.

1. Attach puller T10095 A to ignition coils as shown in illustration (arrow) and remove ignition coils one at a time.
2. Remove spark plugs with spark plug wrench 3122 B.
3. Check compression pressure with compression tester V.A.G 1763.

Note. For use of compression tester. Refer to tester operating instructions.

1. Have a second technician press down accelerator pedal completely and simultaneously operate starter until pressure no longer increases on tester display.

Compression pressure

Installation is performed in the reverse order. Note the following

1. Upon completion of compression test, interrogate and erase engine control module fault memory. Faults will have been stored during fuse removal and connector separation. Use vehicle diagnostic, testing and information system VAS 5051 A.

Tightening torque

Valve gear, servicing

Note. The engine is not to be started for approx. 30 minutes after installing the camshafts. The hydraulic valve compensation elements have to settle (otherwise valves will strike pistons). After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. Replace seals and gaskets.

Scheme 261

1 - Camshaft adjuster - exhaust

1. Identification: 32A
2. Removing and installing. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

2 - 60 Nm + 90° (1/4 turn) further

1. Replace
2. To remove and install, counterhold with 32 mm open end wrench on camshaft. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

3 - Camshaft adjuster - intake

1. Identification: 24E
2. Removing and installing. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts)

4 - Valve timing housing

1. Removing and installing. Refer to «Camshafts, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshafts-removing-and-installing)
2. Check filter of valve timing housing for dirt before installing. Refer to «Checking filter of valve timing housing for dirt»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
3. When installing, lightly oil contact surfaces of oil seals
4. Disassembling and assembling. Refer to «Disassembling and assembling valve timing housing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

5 - Valve stem oil seal

6 - Valve spring

1. Installed position: larger diameter on bottom

7 - Valve spring plate

8 - Valve keepers

9 - Camshaft seals

1. 3 per camshaft
2. Replace all if leak detected
3. When installing valve timing housing, item -5-, lightly oil contact surfaces of oil seals
4. Offset gaps by 120° when installing

1. Do not stretch seals too wide when replacing

10 - 5 Nm + 45° (1/8 turn) further

11 - Bearing cap

1. Installed position. Refer to «Installed position of bearing caps for camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Installation sequence. Refer to «Camshafts, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshafts-removing-and-installing)

12 - Intake camshaft

1. Check radial clearance with Plastigage ®
2. Wear limit (radial clearance): 0.1 mm
3. Run-out: 0.01 mm (max.)
4. Checking axial clearance. Refer to «Camshaft axial clearance, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-axial-clearance-checking)

1. Removing and installing camshafts. Refer to «Camshafts, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshafts-removing-and-installing)
2. Identification. Refer to «Camshaft identification»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

13 - Exhaust camshaft

1. Check radial clearance with Plastigage ®
2. Wear limit (radial clearance): 0.1 mm
3. Run-out: 0.01 mm (max.)
4. Checking axial clearance. Refer to «Camshaft axial clearance, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-axial-clearance-checking)

1. Removing and installing camshafts. Refer to «Camshafts, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshafts-removing-and-installing)
2. Identification. Refer to «Camshaft identification»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

14 - Roller rocker finger

1. Do not interchange
2. Check roller bearing
3. Before installing, check camshaft axial clearance. Refer to «Camshaft axial clearance, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-axial-clearance-checking)
4. Lubricate contact surface

1. Assembly: attach to supporting element using securing clip, item -15

15 - Securing clip

1. Check for firm attachment

16 - Supporting element

1. With hydraulic valve clearance compensation
2. Do not interchange
3. Before installing, check camshaft axial clearance. Refer to «Camshaft axial clearance, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-axial-clearance-checking)
4. Lubricate contact surface

17 - Cylinder head

1. Checking valve guides. Refer to «Valve guides, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__valve-guides-checking)
2. Machining valve seats. Refer to «Valve seats, machining»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__valve-seats-machining)

18 - Valves

1. Must not be machined; only lapping is permissible
2. Valve dimensions. Refer to «Valve dimensions»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
3. Checking valve guides. Refer to «Valve guides, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__valve-guides-checking)
4. Machining valve seats. Refer to «Valve seats, machining»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__valve-seats-machining)

19 - 8 Nm

Scheme 262

The camshaft identification is located between the cam pairs for cylinder No. 4 and 5.

A - Exhaust camshaft; identification 022 - index 101

B - Intake camshaft; identification 022 - index 102

Coat surface of bearing caps 7 and 8 with lubricating paste

Scheme 263

1. Thinly coat contact surface (hatched surface in illustration) of bearing caps 7 and 8 with lubricating paste G 052 723 A2.

Scheme 264

1. Pointed section of bearing caps -A- for intake and exhaust camshafts faces outward.

Scheme 265

1 - Guide rail; clipped onto valve timing housing

2 - Valve timing housing

3 - Valve -1- for camshaft adjustment -N205

4 - Camshaft adjustment valve 1 (exhaust) -N318

5 - 8 Nm

Scheme 266

1. Unclip filter -2- on back of valve timing housing -1- and clean away any dirt or grime.

Scheme 267

Note. Intake and exhaust valves must not be machined. Only lapping is permitted.

Camshafts, removing and installing

Special tools, testers and auxiliary items required

1. Camshaft bar T10068
2. Adhesive lubricating paste G 052 723 A2

Removing

1. Engine in vehicle

Note. All cable ties which are released or cut open when removing must be replaced in the same position when installing. Heat insulation sleeves that have been removed are to be reinstalled in the original position.

1. Remove timing chain from camshafts. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts) .

Scheme 268

1. Unbolt valve timing housing (arrows).
2. Carefully separate valve timing housing from oil seals for camshafts.

Scheme 269

1. Remove intake camshaft -A- as follows

1 - Unbolt bearing caps 1 and 13.

2 - Unbolt bearing caps 3 and 11.

3 - Unbolt bearing cap 7.

4 - Loosen bearing caps 5 and 9 alternately in a diagonal sequence and remove.

1. Remove exhaust camshaft -B- as follows

1 - Unbolt bearing caps 2 and 14.

2 - Unbolt bearing caps 4 and 12.

3 - Unbolt bearing cap 8.

4 - Loosen bearing caps 6 and 10 alternately in a diagonal sequence and remove.

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

Installing

Note. The crankshaft must not be at TDC at any cylinder when the camshafts are installed. Otherwise, there is a risk of damage to the valves and piston crowns. The engine is not to be started for approx. 30 minutes after installing the camshafts. The hydraulic valve compensation elements have to settle (otherwise valves will strike pistons). After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.

1. Insert supporting elements into cylinder head.

Scheme 270

1. Install roller rocker fingers -1- so that they touch valve stems and are clipped onto supporting elements -2-.
2. Lubricate running surfaces of camshafts.
3. Insert respective camshaft in camshaft bearings of cylinder head.

1. Pay attention to camshaft identification located between cam pairs for cylinder No. 4 and 5.

A - Exhaust camshaft; identification 022 - index 101

B - Intake camshaft; identification 022 - index 102

1. Insert camshafts into cylinder head so that they are located at TDC for cylinder 1.

1. It must be possible to insert camshaft plate T10068 in both camshaft grooves.

1. Note installed position of bearing caps

1. Pointed section -A- of bearing caps for intake and exhaust camshafts faces outward.
2. Identification markings for bearing caps are legible from intake side.

1. Thinly coat contact surface (hatched surface in illustration) of bearing caps 7 and 8 with lubricating paste G052 723 A2.

1. Install intake camshaft as follows

1 - Tighten bearing caps 5 and 9 alternately in a diagonal sequence and then tighten to final torque.

2 - Tighten bearing caps 1 and 13.

3 - Tighten bearing cap 7.

4 - Tighten bearing caps 3 and 11.

1. Install exhaust camshaft as follows

1 - Tighten bearing caps 6 and 10 alternately in a diagonal sequence and then tighten to final torque.

2 - Tighten bearing caps 2 and 14.

3 - Tighten bearing cap 8.

4 - Tighten bearing caps 4 and 12.

1. Position camshafts in cylinder head to TDC for cylinder 1.

1. It must be possible to insert camshaft plate T10068 in both camshaft grooves.

1. Unclip filter -2- on back of valve timing housing -1- and clean away any dirt or grime.
2. Lightly oil contact surfaces for camshaft oil seals in valve timing housing.
3. Lightly oil contact surfaces of oil seals on camshafts and carefully push valve timing housing over camshaft oil seals.

1. Tighten valve timing housing (arrows).
2. Install camshaft timing chain (adjusting valve timing). Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts) .

Tightening torques

1) 45° equals 1/8 of a turn

Camshaft axial clearance, checking

Special tools and equipment required

Scheme 271

1. Universal dial gauge bracket VW 387
2. Dial gauge

Work sequence

1. Perform measurement with roller rocker fingers and supporting elements removed. Center bearing caps for respective camshaft remain tightened.

Scheme 272

1. Secure universal dial gauge bracket VW 387 with dial gauge to cylinder head.
2. Determine axial clearance.

1. Wear limit: (axial clearance): 0.10 mm

Scheme 273

Special tools and equipment required

1. Valve lever VW 541/1 A with press piece VW 541/6
2. Assembly device for valves 2036
3. Spark plug socket 3122 B
4. Puller for valve stem oil seal 3364

1. Press tool for valve stem oil seal 3365
2. Adapter T40012

Removing

1. Remove timing chain from camshafts. Refer to «Camshaft timing chain, removing from camshafts»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshaft-timing-chain-removing-from-camshafts) .
2. Remove camshafts. Refer to «Camshafts, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshafts-removing-and-installing) .
3. Remove roller rocker fingers together with supporting elements.
4. Place roller rocker fingers and supporting elements down on a clean surface in order that they were removed.

Note. The roller rocker fingers and the supporting elements must not be interchanged.

1. Remove spark plugs with spark plug wrench 3122 B.
2. Set piston of respective cylinder to "bottom dead center".

Scheme 274

1. Install assembly device for valves 2036 with adapter plates 2036/1 and adjust to correct position.
2. Screw adapter T40012 with seal finger-tight into corresponding spark plug thread, connect to compressed air hose and apply a steady pressure.

1. Air pressure: at least 6 bar

1. Remove valve springs using valve lever VW541/1 A with press piece VW 541/6.

Note. Tap assembly lever lightly with a hammer to loosen valve keepers that are stuck.

1. Remove valve stem oil seals using puller for valve stem oil seals 3364.

Installing

Scheme 275

1. Insert plastic sleeve -A- onto valve stem to prevent damage to new valve stem oil seal -B-.
2. Lubricate sealing lip of valve stem oil seal.
3. Insert valve stem oil seal into press piece for valve stem oil seal 3365 and push carefully onto valve guide.
4. Install camshafts. Refer to «Camshafts, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__camshafts-removing-and-installing) .

Valve guides, checking

Special tools and equipment required

1. Universal dial gauge bracket VW 387
2. Dial gauge

Work sequence

Scheme 276

1. Insert valve into valve guide. Only insert intake valve into intake guide and exhaust valve into exhaust guide, as stem diameters are different.

1. End of valve stem must be flush with valve guide

1. Determine amount of sideways play.

1. Wear limit (sideways play): 0.8 mm

If the amount of sideways play is exceeded

1. Replace cylinder head.

Valve seats, machining

Note. If a good seating pattern cannot be obtained by grinding the valve seats (lapping), they must be refaced (machined).

Special tools and equipment required

1. Depth gauge
2. Valve seat machining tool

Note. When servicing engines with leaking valves, it is not sufficient to machine (reface) the valve seats and replace the valves. The valve guides must also be checked for wear. This is particularly important on high-mileage engines. Refer to Valve guides, checking Valve seats should only be machined to the extent required to give a proper seating pattern. The maximum permissible machining dimension must be calculated before starting work. If the machining dimension is exceeded, the function of the hydraulic valve play compensation can no longer be guaranteed and the cylinder head must be replaced.

Calculating maximum permissible machining dimension

1. Insert valve and press firmly against valve seat.

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

Scheme 277

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

Distance measured minus minimum dimension = maximum permissible machining dimension.

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

Scheme 278

Note. Calculating maximum permissible machining dimension. Refer to Calculating maximum permissible machining dimension .

Machining exhaust valve seat

Note. Calculating maximum permissible machining dimension. Refer to Calculating maximum permissible machining dimension .

Lubrication system components, removing and installing

Note. If large quantities of metal shavings or abraded material are found in the engine oil while servicing the engine, it may indicate damage to the crankshaft or connecting rod bearings. To prevent further damage, the following procedures must be performed after the completion of repair work: oil passages must be carefully cleaned, oil spray jets, oil filter and the oil cooler must be replaced. Oil level must not exceed max. marking - risk of catalytic converter damage!

Viscosity classes and oil specifications

Refer to Additional Information, Fluid Capacity Chart

Oil capacities

Refer to Additional Information, Fluid Capacity Chart

Scheme 279

1 - 5 Nm

1. Secured to intake manifold

2 - Oil dipstick

3 - Guide tube for oil dipstick

4 - Cylinder block

5 - Oil return valve

1. Removing and installing. Refer to «Removing and installing oil return valve»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Note installed position

6 - 8 Nm

7 - Cover for oil pump drive

8 - O-ring

1. Replace
2. Lubricate before installing

9 - Oil pump drive

10 - Intermediate shaft

11 - Thrust washer

12 - 10 Nm

1. Install using locking fluid

13 - Oil spray jet (for cooling of pistons)

1. For crankshaft bearings 2...7
2. Opening pressure: 2.0 bar
3. Removing and installing. Refer to «Removing and installing oil spray jet»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__removing-and-installing-oil-spray-jet)

14 - Input shaft for oil pump drive

15 - Oil pump

1. Disassembling and assembling. Refer to «Oil pump, component overview»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Coat oil pressure pipe at cylinder block and at oil pump housing with sealing paste

16 - 23 Nm

17 - Oil drain plug, 30 Nm

18 - Sump

1. Removing and installing. Refer to «Sump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__sump-removing-and-installing)

19 - Oil level/Oil level thermal sensor -G266

1. Removing and installing. Refer to «Removing and installing Oil level thermal sensor -G266»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

20 - 12 Nm

21 - Oil filter bracket

1. Overview of components. Refer to «Oil filter bracket, component overview»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Removing and installing. Refer to «Oil filter bracket, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__oil-filter-bracket-removing-and-installing)

Scheme 280

1. To remove, screw in M8 x 1.5 bolt approx. 4 turns into valve (arrow) and pull out.
2. To install, lubricate O-ring and press valve into oil chained by hand.

Removing and installing oil spray jet

Note. Oil spray jets are installed in crankshaft main bearings 2...7.

1. To remove, use a 4 mm drift to press out oil spray jet toward crankshaft bearing.

Scheme 281

1. To install, use a 6 mm drift to press in oil spray jet (arrow) by hand.

Scheme 282

1 - Bolt, 10 Nm; self-locking, replace

2 - Seal; replace

3 - Electrical connector

4 - Oil level thermal sensor -G266

Sump, removing and installing

Special tools and equipment required

1. Electric drill with plastic brush attachment
2. Safety goggles
3. Silicone sealant.

Removing

1. Remove fasteners -1...3- and remove center sound insulation.

1. Remove right sound insulation (arrows).
2. Drain engine oil.
3. Disconnect connector at Oil level thermal sensor -G266-.

1. Remove bolts -1- and -2- and remove secondary air injection pump with bracket -A-.
2. Unscrew sump/transmission bolts.
3. Unscrew securing bolts for sump in diagonal sequence.
4. Take off sump. If necessary, loosen sump by striking lightly with a rubber hammer.

Installing

Installation is performed in the reverse order. Note the following

Scheme 283

1. Carefully remove sealant residue form cylinder block.

1. Remove sealant residue from sump, e.g. with a rotating plastic brush or similar.
2. Clean sealing surfaces.
3. Cut off tube nozzle at front marking (nozzle approx. 3 mm diameter).

Scheme 284

1. Apply bead of silicone sealant onto clean sealing surface of sump as shown.

1. Width of sealing bead: 2 mm

Note. The bead of sealant must not be thicker than specified, otherwise excess sealant can enter to sump and obstruct the strainer in the oil intake pipe. Use extra care when applying sealant bead in the area around the cover for the timing chains (arrows). The sump must be installed within 5 minutes after applying silicone sealant.

1. Immediately install sump and tighten bolts in following sequence
2. Tighten securing bolts for sump in diagonal sequence initially to 5 Nm.
3. Tighten bolts for sump/transmission to 40 Nm. Use new bolts.
4. Tighten securing bolts for sump in diagonal sequence to 12 Nm.

Note. After installing the sump assembly, the sealant must dry for approx. 30 minutes. Only then fill the engine with oil.

1. Fill engine with oil and check oil level. Refer to «Oil pump, component overview»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Tightening torques

Scheme 285

1 - Sealing cap

1. Tighten to 25 Nm

2 - O-ring

1. Replace

3 - Oil filter element

1. Observe change intervals

Refer to 01 MAINTENANCE

4 - Oil filter bracket

1. With oil retention valve

5 - 23 Nm

6 - Screw plug, 15 Nm

7 - Oil seal

1. If seal is leaking, cut open and replace

8 - Oil seal

1. If seal is leaking, cut open and replace

9 - Oil pressure switch -F1-, 1.4 bar

1. Black insulation
2. Checking. Refer to «Oil pressure and oil pressure switch, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
3. Tighten to 25 Nm

10 - Oil seals

1. Replace

11 - Sealing cap

1. Tighten to 25 Nm

12 - Oil seal

1. Replace
2. Lubricate before installing

13 - Oil cooler

1. Ensure clearance from adjacent components
2. Diagram of coolant hose connections. Refer to «Cooling system, component overview»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
3. Read note if making repairs on engine. Refer to «Lubrication system components, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

14 - Oil seal

1. Installed position. Refer to «Installed position of oil seal and plastic element in oil cooler»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__installed-position-of-oil-seal-and)
2. Lubricate before installing
3. Press onto oil cooler with plastic element item -15

15 - Plastic element

1. Insert into oil cooler together with oil seal item -14
2. Installed position. Refer to «Installed position of oil seal and plastic element in oil cooler»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__installed-position-of-oil-seal-and)

Installed position of oil seal and plastic element in oil cooler

1. Insert oil seal (coat with oil) into oil cooler.
2. Insert plastic element into oil cooler.

Scheme 286

1. Side of plastic element without support must align with lug (arrow) of oil cooler.

Oil filter bracket, removing and installing

Special tools and equipment required

Scheme 287

1. Assembly tool T10118
2. Drip trap V.A.G 1306

Removing

1. Open filler cap on coolant expansion tank.

1. Remove screw -1- and remove cover over coolant expansion tank (arrow).

Note. Mark the rotation direction of the poly V-belt with chalk or a felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, breakage may result.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.

1. Disconnect secondary air injection air hose at position marked with an arrow.
2. Move air hose at bracket clear.

1. Remove fasteners -1...3- and remove center sound insulation.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).
2. Place drip tray V.A.G 1306 under engine.

Scheme 288

1. Turn drain plug (arrow) on radiator counter-clockwise. If necessary, install drain hose to connection.

1. In addition, remove lower coolant hose at After-run coolant pump -V51- (arrow) and drain remaining coolant.

1. Remove cross piece (arrows).
2. Unbolt pulley for power steering pump (counterhold with mandrel).

1. Remove bolts securing power steering pump to bracket (arrows).
2. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wire clear.
3. Remove bracket -2- for coolant hoses.
4. Remove bracket -3- for secondary air pump air filter.

1. Remove bolts -1- and -2- and remove secondary air pump with bracket -A-.

Scheme 289

1. Disconnect electrical connector -1- at oil pressure switch using assembly tool T10118.
2. Disconnect coolant hoses -2- and -3- at oil filter bracket.
3. Unscrew bolts (arrows) and remove oil filter bracket.

Installing

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

Note. Replace seals.

1. Install secondary air pump. Refer to «Secondary air injection pump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__secondary-air-injection-pump-removing-and) .
2. Install power steering pump

Refer to 48 STEERING

1. Install cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .
2. Fill cooling system. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Tightening torque

Scheme 290

1 - Input shaft for oil pump drive

2 - Oil pump housing

3 - 23 Nm

4 - Gears

1. Checking backlash. Refer to «Checking backlash»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
2. Checking axial clearance. Refer to «Checking axial clearance»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

5 - Oil pump cover

1. With pressure relief valve
2. Opening pressure: 5.3...5.7
3. Clean strainer if dirty

6 - 8 Nm

1. Install using locking fluid

7 - Oil pressure pipe

1. Apply sealing paste at cylinder block and at oil pump housing

Refer to Parts catalog

8 - 10 Nm

9 - Oil seal

1. Replace if damaged

Scheme 291

1. Use a feeler gauge to measure.

1. Wear limit (backlash): 0.20 mm

Scheme 292

1. Use a feeler gauge and straightedge to measure.

1. Wear limit (axial clearance): 0.10 mm

Scheme 293

Special tools and equipment required

1. Oil pressure tester V.A.G 1342
2. Adapter V.A.G 1342/14
3. Voltage tester V.A.G 1527 B
4. Adapter set V.A.G 1594 A

1. Assembly tool T10118

Conditions

1. Oil level OK
2. Engine oil temperature approx. 80° C
3. Message "OK" must light up in driver information display

Work sequence

1. Remove bolt -1- and remove cover over coolant expansion tank (arrow).

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.

Note. Mark the rotation direction of the poly V-belt with chalk or a felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, breakage may result.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

1. Remove fasteners -1...3- and remove sound insulation.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).
2. Unbolt pulley for power steering pump (counterhold with mandrel).

1. Remove bolts securing power steering pump to bracket (arrows).
2. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wire clear.
3. Remove bracket -2- for coolant hose.
4. Remove bracket -3- for secondary air pump air filter.

1. Remove bolts -1- and -2- and remove secondary air injection pump with bracket -A-.

Scheme 294

1. Disconnect electrical connector (arrow) at oil pressure switch using assembly tool T10118.
2. Unscrew oil pressure switch.

Scheme 295

1. Connect oil pressure tester V.A.G 1342 with adapter V.A.G 1342/14 to bore for oil pressure switch.
2. Screw oil pressure switch -2- into oil pressure tester V.A.G 1342.

Checking oil pressure switch

1. Connect brown wire -1- of oil pressure tester to Ground (-).
2. Connect voltage tester V.A.G 1527 B with test leads from adapter set V.A.G 1594 A to oil pressure switch and battery positive (+).

1. LED must not light up

If the LED lights up

1. Replace oil pressure switch.
2. Install power steering pump

Refer to 48 STEERING

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing)

Note. Observe oil pressure tester and LED while starting. Switching point of oil pressure switch may already be exceeded when starting.

1. Start engine.

1. Test lamp must light up at 1.2...1.6 bar

If the LED does not light up

1. Replace oil pressure switch.

Checking oil pressure

1. Install power steering pump

Refer to 48 STEERING

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .
2. Start engine.

1. Minimum oil pressure at idling speed: 2.0 bar
2. Minimum oil pressure at 2000 RPM: 3.0 bar
3. Oil pressure at higher engine speeds: max. 7.0 bar

The pressure relief valve or oil pump is faulty if the specifications are not attained.

1. Replace oil pump. Refer to «Oil pump, component overview»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Assembling

Assembly is performed in the reverse order. Note the following

1. Install secondary air injection pump. Refer to «Secondary air injection pump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__secondary-air-injection-pump-removing-and) .
2. Install power steering pump

Refer to 48 STEERING

1. Install cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .

Engine oil, general information

The engine is filled at the factory with a high quality multi-grade oil that can be used all year round, except in extremely cold climates.

Viscosity grades and oil specifications

Refer to Additional Information, Fluid Capacity Chart

Oil level, checking

1. Engine oil temperature at least 60° C
2. Vehicle must be level (horizontal)
3. Wait a few minutes after switching off the engine to allow the oil to flow back into the sump

Work sequence

1. Pull out oil dipstick, wipe off with a clean cloth and insert again as far as it will go.
2. Pull out dipstick again and read oil level.

Scheme 296

Markings on oil dipstick

a - Do not top up oil

b - Oil may be topped up. Oil level may rise as far as area -a- after topping up.

c - Oil must be topped up. It is sufficient if the oil level is somewhere in area -b- (grooved area on dipstick) after topping up.

Note. The oil level must not be above the MAX marking (arrow -1-) and not below the MIN marking (arrow -2-).

Cooling system components, removing and installing

Note. The cooling system is under pressure when the engine is warm. If necessary reduce pressure before repair. Secure all hose connections using hose clamps appropriate for the model type VAG 1921 hose clip pliers are recommended for installing spring-type clamps. Always replace gaskets, seals and O-rings. The arrows which are marked on coolant lines and hoses must face each other.

Scheme 297

Coolant hose connection diagram

1 - Radiator

1. Removing and installing. Refer to «Radiator, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__radiator-removing-and-installing)
2. After replacing, fill with new coolant

2 - Non-return valve

3 - After-run coolant pump -V51

1. Removing and installing. Refer to «After-run coolant pump -V51-, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__after-run-coolant-pump-v51-removing-and)

4 - Oil cooler

1. After replacing, fill with new coolant

5 - Coolant pump

1. Removing and installing. Refer to «Coolant pump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

6 - Cylinder head/cylinder block

1. After replacing, fill with new coolant

7 - Expansion tank

8 - Filler cap for expansion tank

1. With pressure relief valve
2. Checking pressure relief valve. Refer to «Pressure relief valve in filler cap, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

9 - Throttle valve control module -J338

10 - Heat exchanger

1. After replacing, fill with new coolant

11 - Thermostat

1. Removing and installing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing)
2. Checking. Refer to «Thermostat housing, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-checking)

12 - Non-return valve

13 - ATF cooler

1. After replacing, fill with new coolant

14 - Auxiliary radiator

1. After replacing, fill with new coolant

Scheme 298

Special tools and equipment required

1. Adapter for cooling system tester V.A.G 1274/8
2. Drip tray V.A.G 1306
3. Hose clamp pliers V.A.G 1921
4. Cooling system charge unit VAS 6096 with VAS 6096/1

1. Refractometer T10007

Draining

Note. Collect drained coolant in a clean container for re-use or disposal.

1. Open filler cap on expansion tank.

1. Remove fasteners -1...3- and remove center sound insulation.
2. Place drip tray V.A.G 1306 under engine.

1. Turn drain plug (arrow) on radiator counter-clockwise and, if necessary, fit a drain hose to connection.

1. In addition, remove lower coolant hose at After-run coolant pump -V51- (arrow) and drain remaining coolant.

Filling

Note. The cooling system must be filled year round with a mixture of water and frost and corrosion protection additives. Only use coolant additive Plus G 012 A8F A1 (also designated as "G12+") meeting specification TL VW 774 F. Other coolant additives could seriously impair in particular the anticorrosion properties. The resulting damage could lead to loss of coolant and consequently to serious engine damage. Coolant additive "G12+" may be mixed with additives "G11" and "G12". "G12+" and coolant additives marked with "Meets specification TL VW 774 F" prevent frost and corrosion damage as well as stop scale from forming. They also raise the boiling point. Therefore, cooling system must be filled year round with the correct antifreeze and corrosion protection additives. A higher boiling point improves engine reliability under heavy load particularly in countries with tropical climates. Frost protection must be ensured to about -25° C (about -35° C in countries with arctic climates). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%. If greater frost protection is required in very cold climates, the amount of "G12+" can be increased, but only up to 60% (this gives frost protection to about -40° C). If the antifreeze percentage exceeds 60%, frost protection decreases again and cooling efficiency is also impaired. Only use clean drinking water for mixing coolant. If the radiator, heat exchanger, cylinder head, cylinder head gasket or cylinder block have been replaced, do not re-use the old coolant. Contaminated or dirty coolant must not be used again. To check frost protection level of coolant additive "G12+" use refractometer T10007.

1. Close drain plug (arrow).

1. Connect coolant hose to After-run coolant pump -V51- (arrow).

Scheme 299

1. Fill reservoir VAS 6096/1 with at least 8 liters of premixed coolant (based on recommended ratio)

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

1. Screw adapter for cooling system tester V.A.G 1274/8 onto coolant expansion tank.
2. Mount cooling system charge unit VAS 6096 onto adapter V.A.G 1274/8.
3. Feed vent hose -1- into a small container -2-. (The vented air draws along a small amount of coolant, which should be collected.)
4. Close both valves -A- and -B- (turn lever perpendicular to direction of flow).

1. Connect hose -3- to compressed air.

1. Pressure: 6...10 bar

1. Open valve -B- (turn lever in direction of flow).

The suction jet pump generates a vacuum in the cooling system.

1. Needle on gauge must move into green zone

Scheme 300

1. Also briefly open valve -A- (turn lever in direction of flow) so that hose on coolant expansion tank, VAS 6096/1, can fill with coolant.
2. Close valve -A- again.
3. Leave valve -B- open for another 2 minutes.

1. Suction jet pump will continue generating a vacuum in the cooling system.
2. Needle on gauge must remain in green zone.

1. Close valve -B-.

1. Needle on gauge must stop in green zone. Vacuum level in cooling system is then sufficient for subsequent filling.

If the needle does not reach the green area, repeat the process.

If the vacuum level drops, there is a leak in the cooling system.

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

The vacuum in the cooling system causes the coolant to be drawn out of the cooling system charge unit VAS 6096/1; the cooling system is then filled.

Scheme 301

1. Check coolant level and top up coolant as far as MAX mark.
2. Start engine, run for maximum of 2 minutes at approx. 1500 RPM and fill coolant up to overflow hole on expansion tank.
3. Close expansion tank.
4. Run engine until coolant fan starts.

1. Check coolant level and top up if necessary.

1. When engine is at normal operating temperature, coolant level must be at MAX mark. When engine is cold coolant level must be between MIN and MAX marks.

1. Switch engine off.

Scheme 302

Special tools and equipment required

1. Support bracket 10-222 A
2. Shackle 10-222 A/12
3. Drip tray V.A.G 1306
4. Coolant pump spanner V.A.G 1590

1. Hose clamp pliers V.A.G 1921
2. Bolt M8 x 40

Removing

1. Open filler cap on coolant expansion tank.

1. Loosen hose clamp -1- and disconnect air hose at Throttle valve control module -J338-.
2. Move electrical wire (arrow) clear.

Note. Hose clamp -2- remains attached.

1. To remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).

Note. Before removing, mark direction of rotation of poly V-belt with chalk or a felt-tipped pen. If the belt runs in the opposite direction when it is re-installed, breakage may result.

1. To release tension of poly V-belt, screw an M8 x 40 bolt into bore on tensioning element.

Scheme 303

1. Attach shackle 10-222 A/12 to right rear engine lifting eye.
2. Place support bracket 10-222 A on surface of panel flange; spindle faces forward.
3. Attach spindle hook to shackle.
4. Pretension spindle slightly.

1. Remove securing bolt (arrow) for power steering reservoir.

1. Loosen bolts (arrows) of assembly mounting (left side) on engine.

1. Remove fasteners -1...3- and remove center sound insulation.

1. Remove right sound insulation (arrows).
2. Place drip tray V.A.G 1306 under engine.

1. Turn drain plug (arrow) on radiator counter-clockwise and, if necessary, install drain hose to connection.

1. In addition, remove lower coolant hose at After-run coolant pump -V51- (arrow) and drain remaining coolant.

1. Remove bolts (arrows -A-) for pendulum support at subframe.

Scheme 304

1. Remove pulley; counterhold using coolant pump spanner V.A.G 1590.

Note. The pulley must not be removed if the engine has been taken out. In this case, the securing bolts for the coolant pump are accessible through the holes of the pulley.

Scheme 305

1. Remove bolts -1- for coolant pump -2-.

1. Lower engine via spindle approx. 65 mm.
2. Swing coolant pump forward and remove.

Installing

Installation is performed in the reverse order. Note the following

Note. Replace the O-ring.

1. Clean and smooth surface for O-ring as required.
2. Moisten new O-ring with coolant "G12+".

1. Install coolant pump -2-.
2. Tighten bolts -1- for coolant pump.
3. Install coolant pump pulley.
4. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__poly-v-belt-removing-and-installing) .

1. Adjust engine mountings. Refer to «Engine mountings, checking and adjusting»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__engine-mountings-checking-and-adjusting) .

Tightening torques

Scheme 306

1 - O-ring

1. Replace

2 - Retaining clip

3 - Thermostat housing

1. Removing and installing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing)

4 - Bracket

5 - 10 Nm

6 - Thermostat

1. Removing and installing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing)
2. Checking. Refer to «Thermostat housing, checking»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-checking)

7 - Connection

8 - Gasket

1. Replace

9 - Engine Coolant Temperature (ECT) sensor -G62

1. With ECT sensor -G2
2. Dissipate cooling system pressure before removal if necessary

10 - Sealing plug

1. Dissipate cooling system pressure before removal if necessary

Thermostat housing, removing and installing

Special tools and equipment required

Scheme 307

1. Drip tray V.A.G 1306

Scheme 308

1. Hose clamp pliers V.A.G 1921

Removing

Note. Collect drained coolant in a clean container for re-use or disposal.

1. With ignition switched off, disconnect Ground cable (arrow) at battery (in luggage compartment, under floor cover).

1. Open filler cap on coolant expansion tank.

1. Remove fasteners -1...3- and remove center sound insulation.
2. Place drip tray V.A.G 1306 under engine.

1. Turn drain plug (arrow) on radiator counter-clockwise. If necessary, install drain hose to connection.

1. In addition, remove lower coolant hose at After-run coolant pump -V51- (arrow) and drain remaining coolant.

1. To remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

1. Disconnect air hose -2- at Throttle valve control module -J338-.
2. Disconnect electrical connector for Mass Air Flow (MAF) sensor -G70-, item -3-.
3. Remove bolts -1- and -4-.
4. Move electrical wire clear.

1. Take out air cleaner housing.

1. Unclip protective cover -1- for electrical cables.
2. Fold bracket for fuse box upward (arrows).

1. Remove fuse box by releasing tabs (arrow).

Note. The wires remain connected.

1. Remove carrier (arrows).

1. Disconnect vacuum hose (arrow) at actuator for intake manifold change-over.
2. Remove bolts -1- and -2- and remove actuator from intake manifold.

Scheme 309

1. Disconnect electrical connector (arrow) at Engine Coolant Temperature (ECT) sensor -G62-.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose at bracket clear.

1. Disconnect coolant hoses at connections indicated (arrows).

1. Remove bolts (arrows).
2. Swing bracket for secondary air hose forward.

1. Remove bolt (arrow) on bracket for wiring harness.

1. Remove thermostat housing -2-. When doing so, press coolant pipe -1- toward coolant pump with an assembly lever.

Installing

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

Note. Replace the seals and gaskets.

1. Connect battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

1. Fill cooling system. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Tightening torques

Thermostat housing, checking

Note. Collect drained coolant in a clean container for re-use or disposal.

1. Remove thermostat housing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing) .

Scheme 310

1. Remove bolts (arrows) and remove connection -1-.

Scheme 311

1. Remove O-ring -3- with thermostat -2- from thermostat housing -1-.
2. Heat thermostat in container of water.

1) Cannot be tested

1. Install thermostat housing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing) .
2. Fill cooling system. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Tightening torque

Coolant pipe, removing and installing

Removing

Note. Collect drained coolant in a clean container for re-use or disposal.

1. Remove thermostat housing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing) .
2. Remove bracket for ancillary units. Refer to «Bracket for ancillary units, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
3. Unclip bracket for wiring on right from coolant pipe.
4. Remove wiring harness from retainer on left.

1. Pull off coolant hose to oil cooler.
2. Pull coolant pipe out of cylinder block.

Installing

Note. Always replace seals and gaskets.

1. Before installing, clean and smoothen sealing surfaces for O-ring.

Scheme 312

1. Lubricate new O-ring -1- with "G 12+" and push onto coolant pipe -2-.
2. Slide coolant pipe into bore in cylinder block.
3. Install bracket for ancillary units. Refer to «Bracket for ancillary units, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .
4. Install thermostat housing. Refer to «Thermostat housing, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__thermostat-housing-removing-and-installing) .

1. Fill cooling system. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

After-run coolant pump -V51-, removing and installing

Special tools and equipment required

1. Drip tray V.A.G 1306

1. Hose clip pliers V.A.G 1921

Removing

1. Open filler cap on coolant expansion tank.

1. Remove fasteners -1...3- and center sound insulation.
2. Place drip tray V.A.G 1306 under engine.

1. Turn drain plug (arrow) on radiator counter-clockwise. If necessary install a drain hose to connection.

Scheme 313

1. In addition, remove lower coolant hose at After-run coolant pump -V51- (arrow) and drain remaining coolant.

Scheme 314

1. Disconnect electrical connector -1-.
2. Disconnect coolant hose -2-.
3. Pull After-run coolant pump -V51- downward out of rubber retainers. If necessary, spray with silicone-free lubricant.

Installing

Installation is performed in the reverse order. Note the following

1. Fill cooling system. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Scheme 315

1 - Coolant fan -V7

1. Removing and installing. Refer to «Coolant fan -V7- and Coolant fan -2- -V177-, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__coolant-fan-v7-and-coolant-fan)

2 - Retaining clips

1. For electrical wiring going to fans
2. Check for firm attachment

3 - Coolant Fan Control (FC) thermal switch -F18

1. Tighten to 35 Nm

4 - Seal

1. Replace

5 - Coolant hose

1. To disconnect, release retaining clip

6 - O-ring

1. Replace

7 - Radiator

1. Removing and installing. Refer to «Radiator, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__radiator-removing-and-installing)
2. After replacing, fill with new coolant

8 - 15 Nm

9 - Bracket for radiator

1. Note installed position

10 - 10 Nm

11 - 10 Nm

12 - Radiator cowl

13 - Coolant fan -2- -V177

1. Removing and installing. Refer to «Coolant fan -V7- and Coolant fan -2- -V177-, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__coolant-fan-v7-and-coolant-fan)

Radiator, removing and installing

Special tools and equipment required

1. Hose clip pliers V.A.G 1921
2. Drip tray V.A.G 1306

1. Open filler cap on coolant expansion tank.

1. Remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Release tension of poly V-belt by screwing an M8 x 40 bolt (arrow) into bore on tensioning element.

Note. Mark the rotation direction of the poly V-belt with chalk or a felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, breakage can result.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

1. Remove fasteners -1...3- and remove sound insulation.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).

1. Remove power steering pump pulley (counterhold with mandrel).
2. Remove bolts (arrows) and remove power steering pump from bracket.
3. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wiring clear.
3. Remove bolt -2- for coolant hose bracket.
4. Remove bolt -3- for secondary air pump air filter.

1. Remove bolts -1- and -2- and remove secondary air pump with bracket -A-.

1. Turn drain plug -1- on radiator counter-clockwise and drain coolant. If necessary, fit auxiliary hose to connection.
2. Release retaining clip -2- for lower coolant hose and disconnect coolant hose from radiator.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Unscrew lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

Scheme 316

1. Disconnect connector -2- at Coolant Fan Control (FC) thermal switch -F18-.

1. Remove refrigerant line -1- at radiator.

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

Scheme 317

1. Remove upper coolant hose -1- at radiator.
2. Remove front bumper cover.

Refer to 63 BUMPERS .

Scheme 318

1. Remove securing bolts -1- for condenser.
2. Remove securing bolts -2- for radiator.
3. Remove Coolant Fan Control (FC) module -J293- at longitudinal member (left side) in front of battery.
4. Remove bolts for lock carrier at front.

1. Loosen upper bolts for lock carrier 2 turns.

Installing

Installation is performed in the reverse order. Note the following

Scheme 319

1. Install brackets -3- and -4- on radiator as shown.
2. Install radiator.
3. Fit securing bolts for radiator (help of a second technician is required).
4. Install secondary air injection pump. Refer to «Secondary air injection pump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__secondary-air-injection-pump-removing-and) .

1. Install power steering pump

Refer to 48 STEERING

1. Install cross piece.

Refer to 40 FRONT SUSPENSION

1. Install front bumper cover.

Refer to 63 BUMPERS

1. Replace O-rings in connections for radiator hoses.
2. Fill cooling system. Refer to «Cooling system, draining and filling»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Tightening torques

Scheme 320

Special Tools and Equipment

1. VAG1274 Cooling system tester
2. VAG1274/8 Adapter
3. VAG1274/9 Adapter

Requirement

1. Engine at operating temperature.

Work sequence

1. Open cap of coolant expansion tank.

Scheme 321

1. Attach VAG1274 Cooling System Tester together with VAG1274/8 adapter to coolant expansion tank.
2. Use tester hand pump to create a pressure of approx. 1.0 bar.

If pressure drops

1. Detect leak and repair malfunction.

Scheme 322

1. Attach VAG1274 cooling system tester together with VAG1274/9 adapter to filler cap.
2. Pump using hand pump.

1. Pressure release valve must open at a positive pressure of 1.4 to 1.6 bar.

If the pressure relief valve does not open as described

1. Replace filler cap.

Coolant fan -V7- and Coolant fan -2- -V177-, removing and installing

1. Open filler cap on coolant expansion tank.

1. Remove fasteners -1- at lock carrier by pressing in pin -2- approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Release tension of poly V-belt by screwing an M8 x 40 bolt (arrow) into bore on tensioning element.

Note. Mark the rotation direction of the poly V-belt with chalk or a felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, this can cause breakage.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

1. Remove fasteners -1...3- and remove sound insulation.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).
2. Remove power steering pump pulley (counterhold with mandrel).

1. Remove bolts (arrows) and remove power steering pump from bracket.
2. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wiring clear.
3. Remove bolt -2- for coolant hose bracket.
4. Remove bolt -3- for secondary air pump air filter.

1. Remove bolts -1- and -2- and remove secondary air pump with bracket -A-.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Unscrew lower securing bolts (lower arrows) for radiator cowl.

Scheme 323

1. Disconnect electrical connector -1-.
2. Move wiring clear.
3. Remove nuts (arrows) and remove fans.

Installing

Installation is performed in the reverse order. Note the following

1. Install secondary air pump. Refer to «Secondary air injection pump, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__secondary-air-injection-pump-removing-and) .
2. Install power steering pump.

Refer to 48 STEERING

1. Install cross piece.

Refer to 40 FRONT SUSPENSION

1. Install poly V-belt.

Tightening torques

Exhaust system, servicing

Note. Always replace gaskets and self-locking nuts. After exhaust system repairs, make sure the exhaust system is not under stress and is far enough from the body. If necessary, loosen clamps and align mufflers and exhaust pipes so that there is adequate distance to the vehicle body, and weight is evenly distributed among the exhaust hangers. Use a screwdriver to unfasten and tighten lock washers for heat shields. Tightening torque: 2 Nm. The flex joint in the front exhaust pipe must not be bent more than 10° , otherwise it may be damaged.

Scheme 324

1 - 23 Nm

2 - Mounting

1. Replace if damaged

3 - 40 Nm

4 - Rear clamp

1. For separate replacement of center and rear mufflers
2. Installed position. Refer to «Installed position of rear clamp»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)
3. Before tightening, adjust exhaust system free of stress. Refer to «Exhaust system, aligning free of stress»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__exhaust-system-aligning-free-of-stress)
4. Tighten bolt connections evenly

5 - Center muffler

1. Center and rear muffler are one unit as original equipment and can be replaced individually for repair purposes
2. Cutting location. Refer to «Center and rear muffler, separating»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__center-and-rear-muffler-separating)
3. Align exhaust system so it is free of stress before tightening clamp. Refer to «Exhaust system, aligning free of stress»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__exhaust-system-aligning-free-of-stress)

6 - Rubber mounting

1. Replace if damaged

7 - 23 Nm

8 - Bracket

1. For exhaust system mounting in driveshaft tunnel.

9 - 23 Nm

1. Replace

10 - Front exhaust pipe with flexible joint

1. Do not bend flexible joint more than 10° otherwise it can be damaged
2. Removing and installing. Refer to «Front exhaust pipe, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__front-exhaust-pipe-removing-and-installing)
3. Align exhaust system so it is free of stress before tightening clamp. Refer to «Exhaust system, aligning free of stress»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__exhaust-system-aligning-free-of-stress)

11 - 40 Nm

1. Replace

12 - Gasket

1. Replace

13 - Exhaust manifold

1. Removing and installing. Refer to «Exhaust manifold, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__exhaust-manifold-removing-and-installing)

14 - 23 Nm

1. Replace

15 - Heated oxygen sensor

1. 2x
2. Threads of new oxygen sensors are already greased with assembly paste. Paste must not get into slots on sensor body
3. When reusing old oxygen sensor, grease threads lightly with hot bolt paste
4. Removing and installing

Refer to 24 MULTIPORT FUEL INJECTION (MFI)

16 - Gasket

17 - Oxygen sensor behind catalytic converter

1. 2x
2. Threads of new oxygen sensors are already greased with assembly paste. Paste must not get into slots on sensor body
3. When reusing old oxygen sensor, grease threads lightly with hot bolt paste
4. Removing and installing

18 - Catalytic converter

1. Protect from damage due to impact
2. Aligning. Refer to «Aligning catalytic converter»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe)

19 - Front clamp

1. Align exhaust system so it is free of stress before tightening clamp. Refer to «Exhaust system, aligning free of stress»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__exhaust-system-aligning-free-of-stress)

20 - 40 Nm

21 - Rubber mounting

1. Replace if damaged

22 - Mounting

1. Replace if damaged

23 - 23 Nm

24 - Rear muffler

1. Rear and center muffler are one unit as original equipment. Can be replaced individually for repair purposes
2. Cutting location. Refer to «Center and rear muffler, separating»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__center-and-rear-muffler-separating)
3. Align exhaust system so it is free of stress before tightening clamp. Refer to «Exhaust system, aligning free of stress»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__exhaust-system-aligning-free-of-stress)

Scheme 325

1. Install clamps so that bolt ends do not project beyond lower edge of clamp (arrow).

1. Threaded connections face to right

Scheme 326

1. Install clamp so that bolt end does not project over lower edge of double clamp.

1. Bolt connection faces to left

Scheme 327

1. Align catalytic converter horizontally.

Distance to heat shield on right and on left in tunnel should be same on both sides.

1. Distance x = x

Center and rear muffler, separating

1. A separating point has been provided in the separating pipe for individual replacement of the center or rear muffler.
2. Separating point is marked by a depression around the circumference of the exhaust pipe.

Special tools and equipment

Scheme 328

1. Cutting chain VAS 6524
2. Protective glasses

Work sequence

Scheme 329

1. Using VAS 6524, cut exhaust pipe at separating point (arrow) at right angle.

Scheme 330

1. When installing, center clamp -1- on separation point.

1. Install clamp so that bolt ends do not protrude beyond bottom of clamp.

Bolt connection faces to left

1. Align exhaust system free of stress. Refer to «Exhaust system, aligning free of stress»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe__exhaust-system-aligning-free-of-stress) .
2. Tighten bolts on clamp evenly to 40 Nm.

Exhaust manifold, removing and installing

Special tools and equipment

Scheme 331

1. Puller T10095 A

1. Installation tool T10118

Note. All cable ties which are released or cut open when removing must be reinstalled in the same position.

1. With ignition switched off, disconnect Ground cable (arrow) at battery (in luggage compartment, under floor cover).

1. Remove fasteners -1- at lock carrier by pressing pin -2- approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).
2. Pull out oil dipstick.

Note. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, breakage can result.

1. Release tension of poly V-belt by screwing an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Remove upper securing bolt -2- for Generator.

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose at bracket clear.

1. Open filler cap on coolant expansion tank.

1. Remove fasteners -1...3- and remove center sound insulation.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).

1. Place drip tray V.A.G 1306 under engine.
2. Turn drain plug (arrow) on radiator counter-clockwise. If necessary, install a drain hose to connection.

1. Additionally, remove lower coolant hose at After-run coolant pump -V51- (arrow) and drain remaining coolant.

1. Remove pulley for power steering pump (counterhold with mandrel).
2. Remove bolts (arrows) and remove power steering pump from bracket.
3. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wiring clear.
3. Remove bolt -2- for coolant hose bracket.
4. Remove bolt -3- for secondary air pump filter bracket.

1. Remove bolts -1- and -2- and remove secondary air pump with bracket -A-.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Unscrew lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

1. Disconnect electrical connector -1- for magnetic clutch of air conditioning compressor.

Note. The air conditioning compressor can only be removed from the bracket with the upper securing bolt still inserted. To do so, press the engine simultaneously to the left side with an assembly lever (second technician required). If required, loosen all bolts of the assembly mounting 1 turn.

1. Remove bolts (arrow) for air conditioning compressor.
2. Tie up air conditioning compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).
3. Remove lower securing bolt -1- for Generator.
4. Remove Generator from bracket for ancillary units (electrical wires remain connected).

1. Unscrew clamp -3-.
2. Remove nut and disconnect wire -1- at Generator.
3. Disconnect electrical connector -2-.
4. Remove Generator.

1. Remove bolt -3- and pull out guide tube for oil dipstick -2-.
2. Remove bolt -4- and remove vacuum reservoir -1- from manifold.
3. Move vacuum reservoir to side (hoses remain attached).

1. Remove bolt (arrow) at bracket for After-run coolant pump -V51-.
2. Remove bolts -1...5- and remove bracket for ancillary units.

Note. To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°.

1. Unbolt front exhaust pipe from exhaust manifolds (arrows).

1. Remove bolts (arrows) at front of intake manifold.

1. Disconnect electrical connectors at ignition coils by releasing tab (arrow) with assembly tool T10118 and carefully pulling connector.

1. Attach puller T10095 A to ignition coils as shown in illustration (arrow) and remove ignition coils one at a time.

1. Remove body brace -1- (arrows).

1. Move electrical wire (arrow) clear.
2. Loosen hose clips -1- and -2- and remove air hose between air cleaner housing and Throttle valve control module -J338-.

1. Disconnect electrical connectors -2- and -3-.
2. Disconnect crankcase breather hose -1-.

1. Remove bolts (arrows) and remove Throttle valve control module -J338- from intake manifold.

1. Disconnect vacuum hoses -1...4- at rear of intake manifold.

Note. The other hoses remain connected in the hose bracket.

1. Unbolt hose bracket (arrows) and remove.
2. Unscrew securing bolts at right and at rear (arrows) for intake manifold.

Note. Illustration shows view from the rear with engine removed.

1. Protect intake manifold from damage with a clean cloth -1-.
2. Swing intake manifold forward (arrow).

Note. Cover or plug the intake ports in the cylinder head with a clean cloth or foam plastic to prevent small items from falling in.

1. Remove both bolts from heat shield and remove shield.

Scheme 332

1. Unscrew 7 nuts (arrows) on both exhaust manifolds and remove together with washers.
2. Pull exhaust manifolds to rear and remove.

Installing

Installation is performed in the reverse order. Note the following

Note. Replace gaskets and self-locking nuts.

1. Install intake manifold. Refer to «Intake manifold, removing and installing»(/audi/tt/8n-2003-2006/remont/cooling-system-mechanical/#32l-v6-4v-engine-mechanical-engine-codes-bhe) .

Tightening torques

1) Replace nuts

Front exhaust pipe, removing and installing

Special tools and equipment required