Audi 2.9-3.0L V6 PDF

Service
Workshop Manual
Audi A4 2015 ➤ , Audi A5 2016 ➤ ,
Audi A6 2019 ➤ , Audi A6 China 2019 ➤ ,
Audi A7 Sportback 2018 ➤ ,
Audi A8 2018 ➤ , Audi Q5 2017 ➤ ,
Audi Q5 China 2019 ➤ , Audi Q7 2016 ➤ ,
Audi Q8 2018 ➤
Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve
TFSI EA 839
Engine ID
CWG DEC CZS DLZA DKM CZS DCB DCB
D A E B A D E
Edition 02.2019
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Audi AG, Ingolstadt D4B80641D39

Audi A4 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2019 ➤ , Audi A6 China 2019 ➤ ...
Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI EA 839 - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on the high-voltage system . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 3
2.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 4
2.5 Safety precautions when using testers and measuring instruments during a road test . . . . 4
2.6 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.8 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.9 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Exploded view - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Removing and installing poly V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.8 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.9 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.6 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.7 Checking sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.8 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Contents i
4.1 Exploded view - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3 Renewing roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.3 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.5 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Exploded view - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.1 Exploded view - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.2 Exploded view - drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.3 Removing camshaft timing chain from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.4 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.5 Removing and installing chain tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.2 Exploded view - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.3 Measuring radial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.5 Removing and installing cam actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.6 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.7 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.4 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.5 Removing and installing oil baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.6 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.7 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 189
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.1 Exploded view - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.3 Removing and installing spray nozzle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.1 Exploded view - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.2 Removing and installing crankcase breather module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
ii Contents
4 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.1 Exploded view - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 198
4.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.4 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.5 Removing and installing oil temperature sender G8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.6 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.7 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.8 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 207
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2.1 Exploded view - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.3 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.6 Removing and installing map-controlled engine cooling system thermostat F265 . . . . . . 217
2.7 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 220
2.8 Removing and installing engine outlet coolant temperature sender G82 . . . . . . . . . . . . . . 222
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 224
2.10 Removing and installing temperature sender for engine temperature regulation G694 . . 225
2.11 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4 Radiators/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1 Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.3 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.4 Removing and installing temperature sender for engine cover panel G765 . . . . . . . . . . . . 258
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2.3 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.4 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
2.6 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
2.7 Removing and installing charge air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . 276
2.8 Removing and installing overrun air recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
2.9 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Contents iii
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.4 Cleaning throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.1 Exploded view - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
5.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
5.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.1 Exploded view - actuator for structure-borne sound and control unit for structure-borne
sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.2 Exploded view - pressure differential sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.3 Removing and installing actuator for structure-borne sound R214 . . . . . . . . . . . . . . . . . . 304
6.4 Removing and installing control unit for structure-borne sound J869 . . . . . . . . . . . . . . . . 304
6.5 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
6.6 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
6.7 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 305
6.8 Removing and installing pressure differential sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
7.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
7.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
8.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
1.2 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
1.3 Removing and installing front silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
1.5 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3.2 Removing and installing parts of exhaust gas temperature control . . . . . . . . . . . . . . . . . . 334
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.1 Exploded view - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.2 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
1.4 Removing and installing Hall senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
iv Contents
00 – Technical data
1 Identification
(ARL006256; Edition 02.2019)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

Engine number
♦ Pull off engine cover panel and heat shield to make engine
number visible.
♦ The engine number is located at the top rear of the cylinder
block.
1- Serial number
2- Engine code
♦ There is also a sticker on the timing chain cover (top) showing
the engine code and the serial number.
♦ In addition, the engine code is listed on the vehicle data stick‐
ers.
Engine data
For allocation of engine code, refer to ⇒ Technical data for en‐
gines; Rep. gr. 00 ; Overview of engines .
1. Identification 1
2 Safety precautions
⇒ “2.1 Safety precautions when working on the high-voltage sys‐
tem”, page 2
⇒ “2.2 Safety precautions when working in the vicinity of high-
voltage components”, page 3
⇒ “2.3 Safety precautions when working on the fuel supply sys‐
tem”, page 3
⇒ “2.4 Safety precautions when working on vehicles with start/
stop system”, page 4
⇒ “2.5 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
⇒ “2.6 Safety precautions when working on the subframe”,
page 4
⇒ “2.7 Safety precautions when working on the ignition system”,
page 4
⇒ “2.8 Safety precautions when working on the cooling system”,
page 5
⇒ “2.9 Safety precautions when working on the exhaust system”,
page 5
2.1 Safety precautions when working on the high-voltage system

High voltage can cause fatal injury.
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock.
– Persons with life-sustaining or other electronic medical devi‐
ces in or on their body must not perform any work on the high-
voltage system. Such medical devices include internal anal‐
gesic pumps, implanted defibrillators, pacemakers, insulin
pumps and hearing aids.
– The high-voltage system must be de-energised by a suitably
qualified person.
Risk of injury - engine may start unexpectedly

It is difficult to determine whether the drive system of an electric
vehicle or hybrid vehicle is active. Moving parts can trap or draw
in parts of the body.
– Switch off ignition.
– Deposit the ignition key outside of the vehicle.
Risk of damage to high-voltage wiring

Incorrect handling may result in damage to the insulation of high-
voltage wires or high-voltage connectors.
– Never use high-voltage wiring or high-voltage connectors as
a support.
– Never support tools or equipment on high-voltage wires and
high-voltage connectors.
– High-voltage cables must not be excessively bent or kinked.
2 Rep. gr.00 - Technical data

– Pay attention to coding when connecting high-voltage con‐

nections.
Risk of injury if auxiliary air conditioner is activated

On electric and hybrid vehicles, the auxiliary air conditioner can
switch itself on if it has been activated. The radiator fans can start
up automatically and trap or draw in parts of the body.
– Deactivate auxiliary air conditioner.
2.2 Safety precautions when working in the vicinity of high-voltage components

High voltage can cause fatal injury.
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock if
high-voltage components or high-voltage wiring are damaged.
– Carry out a visual check of high-voltage components and high-
voltage wiring.
– Never use cutting/forming tools or other sharp-edged imple‐
ments.
– Never perform work using welding, brazing, thermal bonding
or hot air.
2.3 Safety precautions when working on the fuel supply system

Risk of injury - fuel system operates under high pressure
The fuel system is pressurised. There is a risk of injury as fuel
may spray out.
Before opening the fuel system:
– Put on safety goggles.
– Put on protective gloves.
– Release pressure (wrap a clean cloth around connection and
open connection carefully).
Risk of fire due to escaping fuel

If the battery is connected, the door contact switch activates the
fuel pump when the driver's door is opened. Escaping fuel may
ignite, causing a fire.
– Before opening the fuel system, disconnect power supply to
fuel pump.
2. Safety precautions 3
2.4 Safety precautions when working on vehicles with start/stop system

Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.
2.5 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or:
– Have a second mechanic operate test equipment on the rear
seat.
2.6 Safety precautions when working on the subframe

Risk of damage to components
Lowering the vehicle onto its wheels can damage components if
the assembly mountings, steering rack or subframe cross brace
are not properly fitted.
– Never lower vehicle onto its wheels with suspension compo‐
nents unfastened or detached.
– Never support weight of vehicle on subframe or subframe
cross brace with suspension components unfastened or de‐
tached.
2.7 Safety precautions when working on the ignition system

Risk of injury due to electric shock
When the engine is running, there are high voltage levels in the
ignition system. There is a risk of electric shock when touching
the ignition system!
– Never touch or disconnect ignition wiring when the engine is
running or being turned at cranking speed.
Risk of damage to components

Washing the engine or connecting/disconnecting electrical wiring
may result in components being damaged if the engine is running.

– Switch off ignition before connecting/disconnecting electrical

wiring.
– Switch off ignition before cleaning engine.
2.8 Safety precautions when working on the cooling system

Risk of scalding as hot coolant can escape
The cooling system is under pressure when the power unit is hot.
Risk of scalding due to hot steam and hot coolant.
– Put on safety goggles.
– Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
2.9 Safety precautions when working on the exhaust system

Risk of damage to flexible joint
The flexible joint can be damaged or develop leaks if it is handled
incorrectly.
– Do not bend flexible joint more than 10°.
– Install flexible joint so that it is not under tension.
Risk of injury caused by components of the exhaust system

Danger of injury to hands and other parts of the body due to hot
or sharp parts of the exhaust system.
– Allow exhaust system to cool down.
2. Safety precautions 5
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 6
⇒ “3.2 Foreign particles in engine”, page 6
⇒ “3.3 Contact corrosion”, page 6
⇒ “3.4 Routing and attachment of pipes, hoses and wiring”, page
7
⇒ “3.5 Installing radiators and condensers”, page 7
⇒ “3.6 Checking fuel system for leaks”, page 7
3.1 Rules for cleanliness

Even small quantities of dirt can lead to defects. For this reason,
please observe the following rules when working on the fuel sup‐
ply system, turbocharger and injection system:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Before removing injectors, clean surrounding area and blow
out with compressed air if necessary. Wear safety goggles to
do this.
♦ Seal off open pipes and connections immediately with clean
plugs, e.g. from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them. Use
only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
3.2 Foreign particles in engine

♦ When performing assembly work on the engine, all open pas‐
sages in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set - VAS 6122- ) to
prevent foreign particles from entering the engine.
♦ In the event of mechanical damage to one of the cylinder
banks, the intake and exhaust systems and combustion cham‐
bers of the opposite cylinder bank must always be examined
for foreign particles to prevent further damage occurring later.
♦ If the turbocharger has suffered mechanical damage
⇒ page 242
3.3 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.

Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.
3.4 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.
♦ To avoid damaging pipes, hoses and wiring, ensure sufficient
clearance from all moving or hot components in engine com‐
partment (limited space in engine compartment).
♦ After attaching, check the routing of the fuel lines and refrig‐
erant lines. They must be inserted in the retainers provided
and should not make contact with other components.
3.5 Installing radiators and condensers

Even when the radiator, condenser and charge air cooler are cor‐
rectly installed, slight impressions may be visible on the fins of
these components. This does not mean that the components are
damaged. If the fins are only very slightly distorted, this does not
justify renewal of the radiator, condenser or charge air cooler.
3.6 Checking fuel system for leaks

– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.

– Then check high-pressure system again for leaks.
3. Repair instructions 7
10 – Removing and installing engine

1 Removing and installing engine
All procedures are described in ⇒ 6-cylinder direct injection en‐
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and
installing engine .
8 Rep. gr.10 - Removing and installing engine

2 Assembly mountings
All procedures and components are described in ⇒ 6-cylinder
direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 10 ;
Assembly mountings .
2. Assembly mountings 9
3 Engine cover panel

⇒ “3.1 Removing and installing engine cover panel”, page 10
3.1 Removing and installing engine cover

panel
Removing engine cover panel (version 1)
– Carefully pull engine cover panel off retaining pins one after
another -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
Removing engine cover panel (version 2)

– Carefully pull engine cover panel off retaining pins one after
another -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
10 Rep. gr.10 - Removing and installing engine

Removing heat shield

– Remove ball studs and bolts -arrows- and detach heat shield
-1-.
Installing
WARNING
Danger of fire and damage if the heat shield/engine cover pan‐

el is not fitted.
♦ The heat shield and the engine cover panel must always
be fitted before the bonnet is closed.
♦ If the heat shield and engine cover panel are not fitted, it
is not permissible to start the vehicle with the bonnet
closed or drive the vehicle.
– To avoid damage, do not strike the engine cover panel with

your fist or with any kind of tool.
– Position engine cover panel, paying attention to oil filler neck
and dipstick.
– Press engine cover panel into rubber grommets first on left
side, then on right side.
Tightening torques
♦ ⇒ “3.1 Exploded view - cylinder head”, page 118
3. Engine cover panel 11

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 12
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 23
⇒ “1.3 Removing and installing poly V-belts”, page 24
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 30
⇒ “1.5 Removing and installing vibration damper”, page 33
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 38
⇒ “1.7 Removing and installing engine support”, page 41
⇒ “1.8 Renewing crankshaft oil seal (pulley end)”, page 42
⇒ “1.9 Removing and installing sealing flange (pulley end)”, page
43
1.1 Exploded view - cylinder block (pulley

end)
⇒ “1.1.1 Exploded view - cylinder block (pulley end), alternator
belt drive, vehicles with 2.9 ltr./3.0 ltr. engine”, page 12
⇒ “1.1.2 Exploded view - cylinder block (pulley end), starter-al‐
ternator belt drive, vehicles with 3.0 ltr. engine”, page 15
⇒ “1.1.3 Exploded view - cylinder block (pulley end), air condi‐
tioner compressor belt drive, vehicles with 2.9 ltr. engine without
electric compressor”, page 17
tioner compressor belt drive, vehicles with 2.9 ltr. engine with
electric compressor”, page 18
tioner compressor belt drive, vehicles with 3.0 ltr. engine”,
page 19
⇒ “1.1.6 Exploded view - cylinder block (pulley end), vehicles with
high-voltage system”, page 21
1.1.1 Exploded view - cylinder block (pulley end), alternator belt drive, vehicles
with 2.9 ltr./3.0 ltr. engine
12 Rep. gr.13 - Crankshaft group

1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing
⇒ Fig. ““Belt routing for
alternator”“ , page 14
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
❑ Removing and installing
⇒ “1.3 Removing and in‐
stalling poly V-belts”,
page 24
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ 25 Nm
3 - Cover
❑ For idler roller
4 - Idler roller
❑ For poly V-belt
5 - Bolt
❑ Tightening torque
⇒ Item 4 (page 215)
6 - Bolt
❑ Renew after removing
❑ 8 Nm +45°
7 - Tensioner
❑ For poly V-belt
⇒ “1.4.1 Removing and
installing poly V-belt tensioner for alternator - vehicles with 2.9 ltr./3.0 ltr. engine”, page 30
8 - Bolt
❑ Tightening torques ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
9 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
10 - Bracket
❑ For alternator
❑ Removing and installing ⇒ “1.6.1 Removing and installing bracket for alternator”, page 38
11 - Bolt
❑ Tightening torques and sequence
⇒ Fig. ““Bracket for alternator - tightening torques and sequence”“ , page 14
12 - Dowel sleeves
13 - Pulley
❑ For coolant pump
14 - Vibration damper
❑ Removing and installing ⇒ “1.5 Removing and installing vibration damper”, page 33
15 - Bolt
1. Cylinder block (pulley end) 13

❑ 150 Nm +90°
Belt routing for alternator

1- Alternator
2- Idler roller
3- Coolant pump
4- Vibration damper
5- Tensioner for poly V-belt
Bracket for alternator - tightening torques and sequence

• After removing, renew bolts tightened with specified tightening
angle.
– Tighten bolts in stages as follows:
Stage Bolts Tightening torques/angle specifica‐
tion
1. -arrows- 8 Nm in diagonal sequence
2. -arrows- Turn 90° further in diagonal sequence

1.1.2 Exploded view - cylinder block (pulley end), starter-alternator belt drive, ve‐
hicles with 3.0 ltr. engine
1 - Bolt
❑ 40 Nm
2 - Tensioner
❑ For poly V-belt
installing poly V-belt
tensioner for starter-al‐
ternator - vehicles with
2.9 ltr./3.0 ltr. engine”,
page 31
3 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing
starter-alternator”“ ,
page 16
installing poly V-belt for
starter-alternator - vehi‐
cles with 2.9 ltr. engine”,
page 26
on pulleys.
4 - Pulley
5 - Bolt
❑ Tightening torques ⇒
Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
6 - Nut
7 - Threaded pin
8 - Starter-alternator - C29-
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
9 - Bracket
❑ For starter-alternator
❑ Removing and installing ⇒ “1.6.2 Removing and installing bracket for starter-alternator”, page 39
10 - Bolt
❑ Tightening torque and sequence
⇒ Fig. ““Bracket -1- for starter-alternator - tightening torque and tightening sequence”“ , page 16
11 - Dowel sleeves
12 - Bracket

13 - Bolt
❑ 25 Nm
14 - Idler roller
❑ For poly V-belt
15 - Bolt
❑ 40 Nm
16 - Cover
18 - Bolt
❑ 150 Nm +90°
Belt routing for starter-alternator

1- Starter-alternator
2- Tensioning roller (top)
3- Idler roller
4- Coolant pump
5- Vibration damper
6- Tensioning roller (bottom)
Bracket -1- for starter-alternator - tightening torque and tightening

sequence
Stage Bolts Tightening torques

1.1.3 Exploded view - cylinder block (pulley end), air conditioner compressor belt
drive, vehicles with 2.9 ltr. engine without electric compressor
1 - Bolt
❑ Tightening torques ⇒
Heating, air condition‐
ing; Rep. gr. 87 ; Air
conditioner compressor;
Exploded view - air con‐
ditioner compressor
drive unit
2 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing
air conditioner compres‐
sor, vehicles with 2.9 ltr.
engine”“ , page 18
sor - vehicles with 2.9 ltr.
engine”, page 28
on pulleys.
3 - Bolt
❑ 25 Nm
4 - Idler roller
❑ For poly V-belt
5 - Bolt
❑ 40 Nm
6 - Tensioner
❑ For poly V-belt
⇒ “1.4.3 Removing and installing poly V-belt tensioner for air conditioner compressor - vehicles with 2.9
ltr. engine”, page 31
7 - Bolt
❑ Tightening torque ⇒ Item 15 (page 13)
9 - Bolt
⇒ Fig. ““Bracket for air conditioner compressor - tightening torques and sequence, vehicles with 2.9 ltr.

10 - Dowel sleeves
11 - Bolt
12 - Bracket
❑ For air conditioner compressor
⇒ “1.6.3 Removing and installing bracket for air conditioner compressor - vehicles with 2.9 ltr. engine
without electric compressor”, page 39
13 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
Belt routing for air conditioner compressor, vehicles with 2.9 ltr.
engine
1- Vibration damper
3- Air conditioner compressor
4- Idler roller
Bracket for air conditioner compressor - tightening torques and

sequence, vehicles with 2.9 ltr. engine
tion
1. -2, 3- Screw in by hand until contact is made
2. -2, 3- 22 Nm
1.1.4 Exploded view - cylinder block (pulley

end), air conditioner compressor belt
drive, vehicles with 2.9 ltr. engine with
electric compressor
All components are described in ⇒ 6-cylinder direct injection en‐
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block
(pulley end); Exploded view - cylinder block (pulley end) .

1.1.5 Exploded view - cylinder block (pulley end), air conditioner compressor belt
drive, vehicles with 3.0 ltr. engine
1 - Cover
2 - Bolt
❑ 25 Nm
3 - Idler roller
❑ For poly V-belt
4 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing
sor, vehicles with 3.0 ltr.
sor - vehicles with 3.0 ltr.
engine”, page 28
on pulleys.
5 - Cover
❑ For tensioner
6 - Bolt
❑ 25 Nm
7 - Tensioner
❑ For poly V-belt
⇒ “1.4.4 Removing and installing poly V-belt tensioner for air conditioner compressor - vehicles with 3.0
8 - Bolt
10 - Dowel sleeve
❑ 2x
11 - Bracket
❑ For air conditioner compressor
⇒ “1.6.5 Removing and installing bracket for air conditioner compressor - vehicles with 3.0 ltr. engine”,
page 40
12 - Bolt


❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
14 - Bolt
❑ Tightening torques ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
15 - Dowel sleeves
16 - Bolt
Belt routing for air conditioner compressor, vehicles with 3.0 ltr.
engine
1- Vibration damper
3- Air conditioner compressor
4- Idler roller
Bracket for air conditioner compressor - tightening torques and

sequence, vehicles with 3.0 ltr. engine
angle.
tion
1. -2, 3- Screw in by hand until contact is made
2. -2, 3- 8 Nm
3. -2- Turn 90° further

1.1.6 Exploded view - cylinder block (pulley end), vehicles with high-voltage sys‐
tem
1 - Bracket
2 - Bolt
❑ 8 Nm +90°
3 - Pulley
4 - Dowel sleeve
5 - Bracket
❑ For air conditioner com‐
pressor
installing bracket for air
conditioner compressor
- vehicles with high-volt‐
age system”, page 41
6 - Bolt
❑ 22 Nm
7 - Bolt
❑ 22 Nm
8 - Bolt
❑ Tightening torques: Ex‐
ploded view - drive unit
for electrically driven air
conditioner compressor
⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Air
conditioner compressor;
Exploded view - air con‐
ditioner compressor
drive unit
❑ Removing and installing electrically driven air conditioner compressor ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air conditioner compressor; Removing and installing air conditioner compressor
10 - Bolt
11 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing ⇒ Fig. ““Belt routing for coolant pump - vehicles with high-voltage system”“ , page 22
❑ Before removing, mark direction of rotation with chalk or felt-tip pen
⇒ “1.3.7 Removing and installing poly V-belt for coolant pump - vehicles with high-voltage system”, page
29
❑ When installing, make sure it is properly seated on pulleys.
⇒ “1.5.3 Removing and installing vibration damper - vehicles with high-voltage system”, page 36

13 - Bolt
14 - Bolt
❑ 40 Nm
15 - Tensioner
❑ For poly V-belt
⇒ “1.4.5 Removing and installing tensioner for poly V-belt for coolant pump - vehicles with high-voltage
system”, page 32
Belt routing for coolant pump - vehicles with high-voltage system

2- Coolant pump
3- Vibration damper

1.2 Exploded view - sealing flange (pulley end)
1 - Oil seal
❑ For crankshaft (pulley
end)
❑ Renewing
⇒ “1.8 Renewing crank‐
shaft oil seal (pulley
end)”, page 42
2 - Sealing flange (pulley end)
stalling sealing flange
(pulley end)”, page 43
3 - Bolt
❑ Tightening torques and
sequence
⇒ Fig. ““Sealing flange
(pulley end) - tightening
torques and se‐
quence”“ , page 23
4 - Dowel sleeve
5 - Bolt
❑ 9 Nm
6 - Dipstick guide tube
7 - Seals
8 - Dowel sleeve
9 - O-ring
Sealing flange (pulley end) - tightening torques and sequence

angle.
– Tighten bolts in stages in the sequence shown:
tion
1. -1 … 17- 3 Nm
2. -1 … 17- Turn 90° further

1.3 Removing and installing poly V-belts

⇒ “1.3.1 Removing and installing poly V-belt for alternator - vehi‐
cles with 2.9 ltr. engine”, page 24
⇒ “1.3.2 Removing and installing poly V-belt for alternator - vehi‐
⇒ “1.3.3 Removing and installing poly V-belt for starter-alternator
- vehicles with 2.9 ltr. engine”, page 26
⇒ “1.3.4 Removing and installing poly V-belt for starter-alternator
⇒ “1.3.5 Removing and installing poly V-belt for air conditioner
compressor - vehicles with 2.9 ltr. engine”, page 28
compressor - vehicles with 3.0 ltr. engine”, page 28
⇒ “1.3.7 Removing and installing poly V-belt for coolant pump -
vehicles with high-voltage system”, page 29
1.3.1 Removing and installing poly V-belt for

alternator - vehicles with 2.9 ltr. engine
Special tools and workshop equipment required
♦ Locking pin - T10060A-
Removing
Preparatory work may be necessary depending on model ⇒ 6-
cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep.
gr. 13 ; Cylinder block (pulley end); Removing and installing poly
V-belts .
– Detach poly V-belt from air conditioner compressor ⇒ 6-cyl‐
inder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep.
gr. 13 ; Cylinder block (pulley end); Removing and installing
poly V-belts .

Caution
Running a used poly V-belt in the opposite direction could

cause irreparable damage.
♦ Before removing the poly V-belt, mark the direction of ro‐
tation with chalk or a felt-tip pen for re-installation.
– To slacken poly V-belt turn tensioner in anti-clockwise direc‐

tion -arrow- using ring spanner.
– Lock tensioner with locking pin - T10060A- and take off poly
V-belt.
Installing
Installation is carried out in reverse order; note the following:
– Fit poly V-belt ⇒ Fig. ““Belt routing for alternator”“ , page 14 .
– Turn tensioner of poly V-belt for alternator slightly anti-clock‐
wise -arrow- using a ring spanner and pull out locking pin -
T10060A- .
– Release tensioner to slacken poly V-belt.
– Check that poly V-belt is properly seated.
– Install poly V-belt for air conditioner compressor ⇒ 6-cylinder
direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr.
13 ; Cylinder block (pulley end); Removing and installing poly
V-belts .
– Start engine and check that poly V-belt(s) run properly.

alternator - vehicles with 3.0 ltr. engine
Removing
V-belts .

Caution


– Lock tensioner with locking pin - T10060A- and take off poly
V-belt.
Installing
– Fit poly V-belt ⇒ Fig. ““Belt routing for alternator”“ , page 14 .
wise -arrow- using a ring spanner and pull out locking pin -
T10060A- .

starter-alternator - vehicles with 2.9 ltr.
engine
♦ Locking tool - T40098-
Removing
V-belts .
– Detach poly V-belt from air conditioner compressor ⇒ 6-cyl‐
poly V-belts .

Caution


– Lock tensioner with locking tool - T40098- and take off poly V-
belt.
Installing
– Fit poly V-belt
⇒ Fig. ““Belt routing for starter-alternator”“ , page 16 .

wise -arrow- using a ring spanner and pull out locking tool -
T40098- .
– Install poly V-belt for air conditioner compressor ⇒ 6-cylinder
13 ; Cylinder block (pulley end); Removing and installing poly
V-belts .
Additional work depending on model ⇒ 6-cylinder direct injection
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing poly V-belts .

starter-alternator - vehicles with 3.0 ltr.
engine
♦ Locking tool - T40098-
Removing
V-belts .

Caution


– Lock tensioner with locking tool - T40098- and take off poly V-
belt.
Installing
– Fit poly V-belt
⇒ Fig. ““Belt routing for starter-alternator”“ , page 16 .

wise -arrow- using a ring spanner and pull out locking tool -
T40098- .

air conditioner compressor - vehicles
with 2.9 ltr. engine

air conditioner compressor - vehicles
Removing
– Remove poly V-belt for alternator
⇒ “1.3.2 Removing and installing poly V-belt for alternator -
vehicles with 3.0 ltr. engine”, page 25 /
⇒ “1.3.3 Removing and installing poly V-belt for starter-alter‐
nator - vehicles with 2.9 ltr. engine”, page 26 .
– Remove cover.

– Loosen bolt -1- by 1/2 a turn.
Caution

– To slacken poly V-belt, turn tensioner clockwise -arrow A- us‐

ing special wrench Torx T55. Then remove poly V-belt.
Installing
– Fit poly V-belt
⇒ Fig. ““Belt routing for air conditioner compressor, vehicles
with 3.0 ltr. engine”“ , page 20 .
– To tension poly V-belt for air conditioner compressor, turn ten‐

sioner anti-clockwise using special wrench Torx T55
-arrow B- as far as stop (tensioner should remain under ten‐
sion).
– Tighten bolt -1-.
– Install poly V-belt for alternator
vehicles with 3.0 ltr. engine”, page 25 /
Tightening torques
♦ ⇒ “1.1.5 Exploded view - cylinder block (pulley end), air con‐
ditioner compressor belt drive, vehicles with 3.0 ltr. engine”,
page 19

coolant pump - vehicles with high-volt‐
age system
Removing


V-belts .
Caution

– To slacken poly V-belt, turn tensioner -3- in clockwise direction

-arrow- using ring spanner -2-.
– Lock tensioner with locking pin - T10060A- -item 1- and take
off poly V-belt.
Installing
– Fit poly V-belt

⇒ Fig. ““Belt routing for coolant pump - vehicles with high-volt‐
age system”“ , page 22 .
– Turn tensioner -3- of poly V-belt for alternator slightly clock‐
wise -arrow- using a ring spanner -2- and pull out locking pin
- T10060A- -item 1-.
– To tension poly V-belt, release tensioner by turning in anti-
clockwise direction.
1.4 Removing and installing tensioner for

poly V-belt
⇒ “1.4.1 Removing and installing poly V-belt tensioner for alter‐
nator - vehicles with 2.9 ltr./3.0 ltr. engine”, page 30
⇒ “1.4.2 Removing and installing poly V-belt tensioner for starter-
alternator - vehicles with 2.9 ltr./3.0 ltr. engine”, page 31
⇒ “1.4.3 Removing and installing poly V-belt tensioner for air con‐
ditioner compressor - vehicles with 2.9 ltr. engine”, page 31
⇒ “1.4.4 Removing and installing poly V-belt tensioner for air con‐
ditioner compressor - vehicles with 3.0 ltr. engine”, page 32
⇒ “1.4.5 Removing and installing tensioner for poly V-belt for
coolant pump - vehicles with high-voltage system”, page 32
1.4.1 Removing and installing poly V-belt ten‐

sioner for alternator - vehicles with 2.9
ltr./3.0 ltr. engine
Removing
– Slacken poly V-belt
⇒ “1.3 Removing and installing poly V-belts”, page 24 .

– Remove bolts -arrows- and detach tensioner -1-.

Installing
– Install poly V-belt
⇒ “1.3 Removing and installing poly V-belts”, page 24 .
Tightening torques
♦ ⇒ “1.1.1 Exploded view - cylinder block (pulley end), alternator
belt drive, vehicles with 2.9 ltr./3.0 ltr. engine”, page 12

sioner for starter-alternator - vehicles
with 2.9 ltr./3.0 ltr. engine
Removing
– Remove bolt -2- and detach tensioner -1-.
Installing
Tightening torques
♦ ⇒ “1.1.2 Exploded view - cylinder block (pulley end), starter-
alternator belt drive, vehicles with 3.0 ltr. engine”, page 15

sioner for air conditioner compressor -
vehicles with 2.9 ltr. engine
Removing
V-belt tensioner .
– Slacken poly V-belt ⇒ 6-cylinder direct injection engine (2.9
ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block (pulley
end); Removing and installing poly V-belts .

– Unscrew bolt -arrow-, push coolant hose slightly to one side

and detach tensioner -1- (illustration shows engine without
electric compressor).
Installing
– Install poly V-belt ⇒ 6-cylinder direct injection engine (2.9 ltr.,
3.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing poly V-belts .
Tightening torques
ditioner compressor belt drive, vehicles with 2.9 ltr. engine
without electric compressor”, page 17

sioner for air conditioner compressor -
Removing
compressor - vehicles with 3.0 ltr. engine”, page 28 .
– Remove bolt -1- and detach tensioner.
Installing
Tightening torques
ditioner compressor belt drive, vehicles with 3.0 ltr. engine”,
page 19
1.4.5 Removing and installing tensioner for

poly V-belt for coolant pump - vehicles
with high-voltage system
Removing
⇒ “1.3.7 Removing and installing poly V-belt for coolant pump
- vehicles with high-voltage system”, page 29 .
– Remove bolt -1- and detach tensioner -1-.
– If bracket -2- is to be removed, unscrew bolts -3- and detach
bracket -2-.
Installing
Tightening torques
♦ ⇒ “1.1.6 Exploded view - cylinder block (pulley end), vehicles
with high-voltage system”, page 21

1.5 Removing and installing vibration damp‐

er
⇒ “1.5.1 Removing and installing vibration damper - vehicles with
2.9 ltr. engine”, page 33
high-voltage system”, page 36
1.5.1 Removing and installing vibration damp‐

er - vehicles with 2.9 ltr. engine
♦ Hose clip pliers - VAS 6362-
♦ Counterhold tool - T40330-
Preparing tool
– Secure adapter -T40330/6- to counterhold tool -T40330/1- us‐
ing bolts -arrows-.
Removing
gr. 13 ; Cylinder block (pulley end); Removing and installing vi‐
bration damper .
– Remove poly V-belt for alternator
vehicles with 2.9 ltr. engine”, page 24 .
– Remove poly V-belt tensioner for air conditioner compressor
⇒ “1.4.3 Removing and installing poly V-belt tensioner for air
conditioner compressor - vehicles with 2.9 ltr. engine”,
page 31 .

– Remove bolt -arrow-.

– Release hose clip -1-, disconnect coolant hose and push front
coolant pipe (bottom left) slightly to one side.
– Remove cover.
– Unscrew bolt -arrow- and remove idler roller.
– Position adapter -T40330/4- with counterhold tool -T40330/1-

against vibration damper and secure with bolt -arrow- (tighten
to 23 Nm and fit spacer sleeves -T40330/7- in between).
– Remove bolt -1-.
– Unscrew bolt -arrow- and remove counterhold tool and vibra‐
tion damper.
Installing
angle.
– Position vibration damper -1- on crankshaft -2- and secure
with a new bolt (pay attention to dowel sleeve -arrow-).


– Tighten bolt -1- for vibration damper.
– Remove bolt -arrow- and detach counterhold tool.
– Install poly V-belt tensioner for air conditioner compressor
page 31 .
– Install poly V-belt for alternator
(pulley end); Removing and installing vibration damper .
Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 12
♦ ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve
TFSI); Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes

er - vehicles with 3.0 ltr. engine
Preparing tool
ing bolts -arrows-.
Removing
bration damper .
– Remove poly V-belt for air conditioner compressor
page 32 .

– Remove cover.
– Unscrew bolt -arrow- and remove idler roller.

tion damper.
Installing
angle.

page 32 .
Tightening torques

er - vehicles with high-voltage system

Preparing tool
ing bolts -arrows-.
Removing
bration damper .
– Remove poly V-belt for coolant pump

tion damper.
Installing
angle.


– Fit poly V-belt for coolant pump
Tightening torques
1.6 Removing and installing bracket for an‐

cillaries
⇒ “1.6.1 Removing and installing bracket for alternator”,
page 38
⇒ “1.6.2 Removing and installing bracket for starter-alternator”,
page 39
⇒ “1.6.3 Removing and installing bracket for air conditioner com‐
pressor - vehicles with 2.9 ltr. engine without electric compressor”,
page 39
pressor - vehicles with 2.9 ltr. engine with electric compressor”,
page 40
pressor - vehicles with 3.0 ltr. engine”, page 40
pressor - vehicles with high-voltage system”, page 41
1.6.1 Removing and installing bracket for al‐

ternator
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Unscrew bolts -arrows- and detach bracket -1-.
Installing
angle.
Tightening torques
♦ ⇒ Fig. ““Bracket for alternator - tightening torques and se‐
♦ ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view
- alternator

1.6.2 Removing and installing bracket for

starter-alternator
Removing
– Remove starter-alternator ⇒ Electrical system; Rep. gr. 27 ;
Alternator; Removing and installing alternator .
– Unscrew bolts -arrows- and detach bracket -1-.
Installing
angle.
Tightening torques
♦ ⇒ Fig. ““Bracket -1- for starter-alternator - tightening torque
and tightening sequence”“ , page 16
- alternator
1.6.3 Removing and installing bracket for air

conditioner compressor - vehicles with
2.9 ltr. engine without electric compres‐
sor
Removing
– Remove air conditioner compressor from bracket and tie up to
left side ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor; Detaching and attaching air conditioner
compressor at bracket .
page 31 .
– Remove bolt -1- and loosen nut -2-.

– Unscrew bolts -2, 3- and remove bracket -1- for air conditioner
compressor.
Installing
page 31 .
Tightening torques
♦ ⇒ Fig. ““Bracket for air conditioner compressor - tightening
torques and sequence, vehicles with 2.9 ltr. engine”“ ,
page 18
♦ ⇒ “2.1 Exploded view - charge air system”, page 259
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Exploded view - air conditioner compressor drive unit

2.9 ltr. engine with electric compressor
(pulley end); Removing and installing bracket for ancillaries .

3.0 ltr. engine
Removing
bracket for ancillaries .
page 32 .
– All models except A8: Remove air conditioner compressor
from bracket and tie up to left side ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
– A8: Remove air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor .

compressor.
Installing
angle.
page 32 .
(pulley end); Removing and installing bracket for ancillaries
Tightening torques
♦ ⇒ Fig. ““Bracket for air conditioner compressor - tightening
torques and sequence, vehicles with 3.0 ltr. engine”“ ,
page 20
- alternator
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Exploded view - air conditioner compressor drive unit

high-voltage system
Removing
bracket for ancillaries .
compressor.
Installing
angle.
(pulley end); Removing and installing bracket for ancillaries
Tightening torques
♦ ⇒ “1.1.6 Exploded view - cylinder block (pulley end), vehicles
with high-voltage system”, page 21
♦ Exploded view - drive unit for electrically driven air conditioner
compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air con‐
ditioner compressor; Exploded view - air conditioner compres‐
sor drive unit
1.7 Removing and installing engine support

(pulley end); Removing and installing engine support .

1.8 Renewing crankshaft oil seal (pulley

end)
♦ Oil seal extractor - T40019-
♦ Assembly tool - T40320-
Procedure
– Remove vibration damper
⇒ “1.5 Removing and installing vibration damper”, page 33 .
– Adjust inner part of oil seal extractor -T40019- so it is flush with
the outer part and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
seal.
– Clean contact surface and sealing surface.
– Fit guide sleeve -T40320/2- on crankshaft and slide oil seal

-1- into sealing flange (pulley end).
• Open side of oil seal faces engine.
• Leave guide sleeve -T40320/2- in position on crankshaft for
pressing in oil seal.

– Fit press tool -T40320/1- on crankshaft using bolt -1- for vi‐
bration damper.
– Press oil seal -2- in as far as stop.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install vibration damper
1.9 Removing and installing sealing flange

(pulley end)
♦ Electric drill with plastic brush
♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
♦ Bolt, M6x30 (2x)
Removing
gr. 13 ; Cylinder block (pulley end); Removing and installing seal‐
ing flange (pulley end) .
– Remove vibration damper
– Remove bracket for air conditioner compressor
page 38 .
– Remove oil pressure sender - G10-
⇒ “4.6 Removing and installing oil pressure sender G10 ”,
page 205 .
– Remove sump (bottom section)
⇒ “1.3 Removing and installing sump (bottom section)”,
page 175 .
– Unscrew bolt -arrow- and detach intake connecting pipe -1-.

– Remove bolt -2-, pull guide tube -1- for oil dipstick off sealing
flange (front) and detach guide tube.
– Unplug electrical connector -3- and detach change-over valve

from bracket -2-.
– Unplug electrical connector -1-.
– Remove bolts -arrows- and tie up bracket to one side.
– Slacken and remove bolts in the sequence: -17 ... 1-.

– To loosen sealing flange (front) -1-, screw in two M6x30 bolts

-arrows- as far as stop.
– Screw bolts in 1/2 turn each (one after the other) until sealing
flange (front) is released.
– Remove bolts, detach sealing flange and press out oil seal for
crankshaft.
Installing
angle.
• Renew intake connecting pipe with bolt, gaskets, seals, oil
seal for crankshaft and O-rings after removal.
– Pull dowel sleeves -arrows- off cylinder block.

– Drive dowel sleeves into corresponding holes on sealing
flange (pulley end) -1- (as shown) so that they are flush with
sealing surface.
Caution
Protect lubrication system against contamination.

♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.

♦ Put on safety goggles.
– Remove sealant residue from cylinder block and sump (top

section) -1- using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
• Note expiry date of sealant.

– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5
mm).

– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump (top section) -arrows-.
– Fit seals -3-.
Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The sealant bead must not be thicker than specified.
• The bead of sealant -2- must project 3.0 mm above the sealing
surface.
• Install sealing flange within 5 minutes of applying the sealant.
– Apply a thin coat of sealant to bottom sealing surface -1- on
sealing flange.
– Carefully position sealing flange (pulley end) by guiding it to‐
wards sealing surface on cylinder block and sump (top sec‐
tion) at an angle from above, but do not press it on yet.
• Sealant must not be allowed to get into threaded holes.
– Screw in all bolts by hand and drive dowel sleeves into cylinder
block.
– Tighten sealing flange bolts (pulley end).
– Install crankshaft oil seal (pulley end)
⇒ “1.8 Renewing crankshaft oil seal (pulley end)”, page 42 .
– Install sump (bottom section)
page 175 .
– Install oil pressure sender - G10-
page 205 .
– Install bracket for air conditioner compressor
page 38 .
– Install vibration damper
(pulley end); Removing and installing sealing flange (pulley end)
Tightening torques
♦ ⇒ Fig. ““Sealing flange (pulley end) - tightening torques and
sequence”“ , page 23
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 23
♦ ⇒ “1.1 Exploded view - sump/oil pump”, page 171

2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 47
⇒ “2.2 Removing and installing drive plate”, page 47
⇒ “3.6 Removing and installing sender wheel”, page 56
⇒ “3.7 Checking sender wheel”, page 56
⇒ “2.3 Renewing crankshaft oil seal (gearbox end)”, page 48
2.1 Exploded view - cylinder block (gearbox end)

• When carrying out repairs, secure engine to engine and gear‐
box support ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and installing en‐
gine; Securing engine to engine and gearbox support .
1 - Bolt
❑ 60 Nm +90°
2 - Drive plate
❑ With bearing flange
❑ Check running surface
on bearing flange and
holes for torque convert‐
er for cracks and scoring
stalling drive plate”,
page 47
3 - Sender wheel
❑ For engine speed send‐
er - G28-
stalling sender wheel”,
page 56
❑ Checking
⇒ “3.7 Checking sender
wheel”, page 56
4 - Oil seal
❑ For crankshaft (gearbox
end)
❑ Renewing
shaft oil seal (gearbox
end)”, page 48
5 - Dowel pin
6 - Crankshaft
❑ Exploded view
⇒ “3.1 Exploded view - crankshaft”, page 51
2.2 Removing and installing drive plate

2. Cylinder block (gearbox end) 47

♦ Counterhold tool - 10-201-
Removing
• Gearbox removed ⇒ Gearbox; Rep. gr. 37 ; Removing and
installing gearbox; Removing gearbox .
– Insert counterhold tool - 10-201- to slacken bolts.
Caution
Take care not to damage outer surface of bearing flange on

drive plate.
♦ Use a multi-point socket bit with a length of at least 40 mm
to slacken and tighten the drive plate bolts.
– Remove bolts and take off drive plate -1- and sender wheel.
Installing
• If the drive plate has been removed or renewed, check that the
sender wheel is operating correctly before installation
⇒ “3.7 Checking sender wheel”, page 56 .
angle.
– Pay attention to dowel pin when installing drive plate.
– Fit counterhold tool - 10-201- the other way round to tighten
bolts.
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 47
2.3 Renewing crankshaft oil seal (gearbox

end)

♦ Fitting tool - T10122B-
♦ Extractor tool - T20143/2-
Procedure
– Remove drive plate
⇒ “2.2 Removing and installing drive plate”, page 47 .
– Remove sender wheel
⇒ “3.6 Removing and installing sender wheel”, page 56 .
– Pry out oil seal using extractor tool -T20143/2- .
– Clean contact surface and sealing surface.

– Fit assembly aid -T10122/1- onto guide piece - T10122/6- and
slide oil seal -A- onto guide piece (closed side first).
– Detach assembly aid -T10122/1- .
2. Cylinder block (gearbox end) 49

– Fit guide piece - T10122/6- onto crankshaft.

– Use bolts -arrows- to secure guide piece to crankshaft through
securing points -A-.
Caution
Risk of leaks if installed incorrectly.

♦ Slide oil seal onto crankshaft by hand to prevent sealing
lip on oil seal from folding over.
– Slide oil seal over guide piece - T10122/6- onto crankshaft by

hand.
– Press in oil seal evenly all round using thrust piece -

T10122/5- .
– Remove guide piece - T10122/6- .
– Check that oil seal and its sealing lip are correctly seated. If
sealing lip is partially folded over, repeat procedure with a new
oil seal.
– Install sender wheel
– Install drive plate

3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 51
⇒ “3.2 Crankshaft dimensions”, page 54
⇒ “3.3 Allocation of main bearing shells”, page 54
⇒ “3.4 Measuring axial clearance of crankshaft”, page 54
⇒ “3.5 Measuring radial clearance of crankshaft”, page 55
⇒ “3.6 Removing and installing sender wheel”, page 56
⇒ “3.7 Checking sender wheel”, page 56
⇒ “3.8 Removing and installing crankshaft”, page 57
3.1 Exploded view - crankshaft

• When carrying out repairs, secure engine to engine and gear‐
box support ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and installing en‐
gine; Securing engine to engine and gearbox support .
1 - Cylinder block
2 - Bracket
❑ For vacuum reservoir
3 - Plug
❑ For “TDC” bore
❑ Different versions; allo‐
cation and tightening
torques ⇒ page 53
4 - O-ring
❑ For plug version A
⇒ page 53
5 - Bolt
sequence
⇒ Fig. ““Bearing caps -
tightening torques and
6 - Bearing shell
❑ For cylinder block (with
oil groove)
❑ Renew used bearing
shells
❑ Install new bearing
shells for the bearing
caps with the correct
coloured markings
⇒ “3.3 Allocation of main
bearing shells”,
page 54
❑ Lubricate with engine oil
7 - Dowel sleeve
8 - Crankshaft
❑ Measuring axial clearance ⇒ “3.4 Measuring axial clearance of crankshaft”, page 54
3. Crankshaft 51
❑ Measuring radial clearance ⇒ “3.5 Measuring radial clearance of crankshaft”, page 55

❑ Crankshaft dimensions ⇒ “3.2 Crankshaft dimensions”, page 54
❑ Removing and installing ⇒ “3.8 Removing and installing crankshaft”, page 57
❑ Renew dowel sleeve ⇒ Item 7 (page 51) and dowel pin ⇒ Item 14 (page 52) when installing a new
crankshaft
❑ Note installation position in relation to balance shaft
9 - Bearing shell
❑ For bearing cap (without oil groove)
❑ Renew used bearing shells
❑ Install new bearing shells for the bearing caps with the correct coloured markings
❑ Lubricate with engine oil
10 - Dowel sleeve
❑ 2x per bearing cap
11 - Bearing caps
❑ Allocation ⇒ Fig. ““Allocation of bearing cap”“ , page 53
❑ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
12 - Bolt
❑ Use old bolts when measuring radial clearance
⇒ Fig. ““Bearing caps - tightening torques and sequence”“ , page 53
13 - Thrust washers
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil grooves face outwards
❑ Make sure it engages in retaining frame
14 - Dowel pin
15 - Thrust washers
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil grooves face outwards
16 - Bolt
⇒ Fig. ““Bearing caps - tightening torques and sequence”“ , page 53

Plug for “TDC” drilling - allocation and tightening torques

– Clean threaded hole in cylinder block.
Plug version A:
– Renew O-ring after removal.
– Clean plug, fit with new O-ring and tighten to 25 Nm.
Plug version B:
– Renew plug after removal.
– Tighten plug to 40 Nm.
Allocation of bearing cap

– Allocate bearing caps -1 ... 4- as shown.
Bearing caps - tightening torques and sequence

angle.
Stage Bolts Tightening torque/angle specification
1. -1 … 8- Screw in by hand until contact is made
2. -1 … 8- 30 Nm
3. -1 … 8- 50 Nm
4. -1 … 8- Turn 90° further
5. -arrows- 20 Nm
6. -arrows- Turn 90° further
3. Crankshaft 53
3.2 Crankshaft dimensions

Crankshaft main bearing Crankshaft main bearing Crankshaft conrod journal
journal ∅ journal ∅ ∅
2.9 ltr. engine 3.0 ltr. engine All engines
mm mm mm
Basic dimension 67.000 – 0.022 65.000 – 0.022 56.000 – 0.022
– 0.042 – 0.042 – 0.042
3.3 Allocation of main bearing shells

Allocation of crankshaft bearing shells for cylinder block
♦ Bearing shells of the correct thickness are matched to the
bearings in the cylinder block at the factory. Coloured dots on
the side of the bearing shells are used to identify the bearing
shell thickness.
♦ The allocation of the bearing shells to the cylinder block is in‐
dicated by letters on the right of the cylinder block, as shown.
Letter on cylinder block Colour coding of bearing
R = Red
S = Black
G = Yellow
U = Green
B = Blue
Allocation of crankshaft bearing shells for bearing caps

♦ Bearing shells of the correct thickness are assigned to the
bearing caps at the factory. Coloured dots on the side of the
bearing shells are used to identify the bearing shell thickness.
♦ The allocation of the bearing shells to the bearing caps is in‐
dicated by letters on the rear crankshaft flange, as shown in
the illustration.
♦ The row of letters begins with crankshaft bearing “1” (pulley
end) and ends with crankshaft bearing “4” (gearbox end).
Letter on crankshaft flange Colour coding of bearing
R = Red
S = Black
G = Yellow
U = Green
B = Blue
3.4 Measuring axial clearance of crankshaft


♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
– Bolt dial gauge - VAS 6079- with dial gauge bracket - VW 387-
to cylinder block.
– Apply dial gauge to crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
• Axial clearance: 0.013 ... 0.251 mm
3.5 Measuring radial clearance of crank‐

shaft
♦ Plastigauge
Procedure
• Use old bolts when measuring radial clearance.
– Remove bearing cap and clean bearing journal.
– Place a length of Plastigauge corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
• The Plastigauge must be positioned in the centre of the bear‐
ing shell.
– Fit bearing caps and tighten through specified angle
⇒ Fig. ““Bearing caps - tightening torques and sequence”“ ,
page 53 without rotating crankshaft.
– Remove bearing cap again.
3. Crankshaft 55
– Compare width of Plastigauge with measurement scale.

Radial clearance:
• New: 0.021 ... 0.036 mm.
• Wear limit: 0.08 mm.
– When carrying out final assembly, renew bolts.
3.6 Removing and installing sender wheel

Removing
Caution
Risk of magnetic fields causing irreparable damage to sender

wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation
⇒ “3.7 Checking sender wheel”, page 56 .
– Detach sender wheel -arrow-.

Installing
– If sender wheel has been renewed, perform corresponding
adaptions listed in Guided Function “01 - Functions, engine
mechanics” / “0001 - Work steps after component replace‐
ment” ⇒ Vehicle diagnostic tester.
3.7 Checking sender wheel
Caution
Risk of magnetic fields causing irreparable damage to sender

wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation.

♦ Sensor gauge - T10473-
Procedure
• Sender wheel removed
– Check entire circumference of sender wheel using sensor
gauge - T10473- , as shown in illustration.
Inspection image of sender wheel

A - Sender wheel OK
B - Sender wheel defective
3.8 Removing and installing crankshaft

3. Crankshaft 57
♦ Puller - T10055-
♦ Screwdriver Torx T25 - T10248- (not illustrated)

♦ Locking pin - T40011-
♦ Puller -T40332-
♦ Adjustment pin -T40362- (not illustrated)

Preparing extractor -T40332-

– Secure tensioning bolts -1- to crosspiece of puller -T40332-
using bolts -arrows-, as shown.
– Unscrew threaded pins -2- for assembling tool later.
Removing
• Engine secured to engine and gearbox support ⇒ 6-cylinder
10 ; Removing and installing engine; Securing engine to en‐
gine and gearbox support .
– Remove piston
⇒ “5.2 Removing and installing pistons”, page 72 .
– Remove sealing flange (pulley end)
⇒ “1.9 Removing and installing sealing flange (pulley end)”,
page 43 .
– If not yet removed, remove timing chain cover (bottom)
⇒ “1.2.2 Removing and installing timing chain cover (bottom)”,
page 84 .
– Press tensioning rail in direction of -arrow- and lock in place

using locking pin - T40011- .
– Unscrew bolts -2- and detach guide rail -1-.
– Remove oil pump together with chain sprocket
⇒ “1.6 Removing and installing oil pump”, page 187 .
– Lock backlash compensation assembly at gear by inserting

adjustment pin -T40362- into sprocket as far as stop and turn‐
ing it 180° clockwise -arrow-.
3. Crankshaft 59
– Remove bolts -arrows- and -1 … 8-.
– Remove plug (front left) -arrow-.
– Apply and secure extractor -T40332- (prepared previously) at

grooves -arrows- on corresponding bearing cap; to do so,
screw in threaded pins -1- on left and right as far as stop using
screwdriver Torx T25 - T10248- .
– Secure puller - T10055- to extractor -T40332- and pull off
bearing cap.
– Pull off remaining bearing caps and remove crankshaft.

Installing
angle.
• Backlash compensation assembly locked at balance shaft
gear with adjustment pin -T40362-
– Ensure correct version:
♦ Bearing caps ⇒ Fig. ““Allocation of bearing cap”“ , page 53
♦ Bearing shells
– Oil running surface of bearing shells with engine oil.
– Move crankshaft into installation position and press it on; pay

attention to markings:
• Marking -A- for crankshaft -1- must be between the two mark‐
ings -B- on balance shaft gear -2-.
Tightening torques
♦ ⇒ Fig. ““Bearing caps - tightening torques and sequence”“ ,
page 53
3. Crankshaft 61
4 Balance shaft
⇒ “4.1 Exploded view - balance shaft”, page 62
⇒ “4.2 Removing and installing balance shaft”, page 62
4.1 Exploded view - balance shaft
1 - Bolt
❑ 40 Nm +45°
2 - Gear
❑ With sprockets for cam‐
shaft timing chains
3 - Bolt
❑ 9 Nm
4 - Balance shaft
stalling balance shaft”,
page 62
5 - Roller bearing
❑ Renewing
⇒ “4.3 Renewing roller
bearing”, page 66
6 - Balance weight
❑ Can only be fitted on
balance shaft in one po‐
sition.
7 - Bolt
❑ 40 Nm +90°
8 - Roller bearing
❑ Renewing
⇒ “4.3 Renewing roller
bearing”, page 66
9 - Thrust washer
10 - Gasket
11 - Bearing plate
4.2 Removing and installing balance shaft


♦ Key - T40049-
♦ Camshaft clamp - T40264- (not illustrated)

Removing
– Remove timing chains
⇒ “2.4 Removing and installing camshaft timing chain”,
page 113 .
– Secure key - T40049- to crankshaft using bolts -1, 2-.
– Remove sealing flange (pulley end)
page 43 .
Caution
Risk of damage to valves and piston crowns.

♦ Do NOT turn crankshaft.
– Unscrew bolts -arrows- and remove guide rail -1-.
4. Balance shaft 63
– Unscrew guide pins -arrows- and remove guide rail -1-.
– Remove bolt -arrow- on pulley end, using key - T40049- to

counterhold crankshaft (balance weight -1- is removed later).
– Lock backlash compensation assembly at gear by inserting

adjustment pin -T40362- into sprocket as far as stop and turn‐
ing it 180° clockwise -arrow-.
– Remove bolt -arrow- (counterhold crankshaft with key -

T40049- ).
– Remove gear -1-.

– Remove bolts -arrows- and detach bearing plate -1- for bal‐
ance shaft.
– Remove balance shaft -2- from cylinder block towards gear‐
box end and, at the same time, detach balance weight on
pulley end.
Installing
angle.
• Renew gasket after removing.
• Backlash compensation assembly locked at gear with adjust‐
ment pin -T40362- .
• A new gear is supplied with an assembly aid which is inserted
in place of the adjustment pin -T40362- .
– Move balance shaft -1- into installation position.

– Fit balance weight -2- onto balance shaft at pulley end.
• Machined surface -arrow- of balance weight must be posi‐
tioned over machined surface of balance shaft.
– Move gear -1- into installation position; marking -2- must align
with dual toothing of balance shaft -arrow-.
4. Balance shaft 65
– Fully slide gear onto balance shaft, noting marking:

• Marking -A- for crankshaft -1- must be between the two mark‐
ings -B- on balance shaft gear -2-.
– Counterhold crankshaft with key - T40049- and tighten bolt for
gear and balance weight.
– Install sealing flange (pulley end)
page 43 .
– Adjust crankshaft so that notch -1- on vibration damper aligns

with cast projection -2- on sealing flange (pulley end).
– Screw camshaft clamp - T40264/3- through bore in vibration
damper into sealing flange (pulley end) by hand until it makes
contact. If necessary, turn crankshaft back and forth slightly.
– Install camshaft timing chains
page 113 .
Tightening torques
♦ ⇒ “2.1 Exploded view - camshaft timing chains”, page 89
♦ ⇒ “4.1 Exploded view - balance shaft”, page 62
4.3 Renewing roller bearing

♦ Special tool -T40395-
Pulling out
– Remove crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 51 .
– Remove balance shaft
⇒ “4.2 Removing and installing balance shaft”, page 62 .

– Position special tool correctly on roller bearing:

• The chamfer -arrow- faces towards the roller bearing.
– Align adapter -T40395/3- .

• The side without the chamfer -arrows- faces downwards.
– Pull roller bearings (front -1- and rear -2-) out inwards using
spindle -T40395/1- and adapters -T40395/2- / -T40395/3- ; to
do so, turn nut -T40395/4- .
– Detach special tool and remove roller bearing.
Installing
– Position adapter correctly on roller bearing:
• Chamfer -arrow- must face roller bearing; chamfer determines
installation depth.
4. Balance shaft 67
– Align adapter -T40395/3- .

• The side without the chamfer -arrows- faces downwards.
– Pull roller bearings (front -1- and rear -2-) in as far as stop
using spindle -T40395/1- and adapters -T40395/2- / -
T40395/3- ; to do so, turn nut -T40395/4- .
• The sides of the roller bearings with identification lettering face
outwards.
– Install balance shaft
⇒ “4.2 Removing and installing balance shaft”, page 62 .
– Install crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 51 .

5 Pistons and conrods

⇒ “5.1 Exploded view - pistons and conrods”, page 69
⇒ “5.2 Removing and installing pistons”, page 72
⇒ “5.3 Removing and installing oil spray jets”, page 76
⇒ “5.4 Checking pistons and cylinder bores”, page 77
⇒ “5.5 Checking radial clearance of conrod bearings”,
page 78
5.1 Exploded view - pistons and conrods
1 - Bolts
❑ Use old bolts when
measuring radial clear‐
ance
❑ Lubricate thread and
contact surface with oil
❑ 50 Nm +90°
2 - Conrod bearing cap
❑ Mark cylinder and con‐
rod allocation in colour
⇒ Fig. ““Marking con‐
rods”“ , page 72
❑ Installation position of
conrod pairs
⇒ Fig. ““Installation po‐
sition of conrods”“ ,
page 72
3 - Bearing shells
❑ Ensure that retaining
lugs are securely seat‐
ed.
❑ Renew used bearing
shells
4 - Conrod
❑ Only renew as a com‐
plete set
❑ Mark cylinder and con‐
rod bearing cap alloca‐
tion in colour
⇒ Fig. ““Marking con‐
rods”“ , page 72
❑ Installation position of
conrod pairs
⇒ Fig. ““Installation po‐
sition of conrods”“ , page 72
❑ Axial clearance for each conrod pair (when new): 0.30 … 0.54 mm
❑ Measuring radial clearance ⇒ “5.5 Checking radial clearance of conrod bearings”, page 78
5 - Circlip
6 - Piston pin
❑ Removing and installing ⇒ “5.2 Removing and installing pistons”, page 72
5. Pistons and conrods 69

7 - Piston
❑ Mark installation position and cylinder number ⇒ Fig. ““Installation position of pistons”“ , page 72
❑ Renew piston if cracking is visible on piston crown or piston skirt
❑ Install with piston installation sleeve -T40369-
❑ Removing and installing ⇒ “5.2 Removing and installing pistons”, page 72
❑ Checking pistons and cylinder bores ⇒ “5.4 Checking pistons and cylinder bores”, page 77
8 - Circlip
9 - Compression ring
❑ Install using piston ring pliers -VAS 211 003- ⇒ Fig. ““Installing compression rings”“ , page 71
❑ Measuring ring gap ⇒ Fig. ““Measuring piston ring gap”“ , page 77
❑ Measuring ring-to-groove clearance ⇒ Fig. ““Measuring ring-to-groove clearance”“ , page 78
❑ Allocation and installation position ⇒ Fig. ““Allocation of piston rings”“ , page 71
❑ Offset gaps by 120° to ⇒ Item 10 (page 70)
10 - Compression ring
❑ Install using piston ring pliers -VAS 211 003- ⇒ Fig. ““Installing compression rings”“ , page 71
❑ Measuring ring gap ⇒ Fig. ““Measuring piston ring gap”“ , page 77
❑ Measuring ring-to-groove clearance ⇒ Fig. ““Measuring ring-to-groove clearance”“ , page 78
❑ Allocation and installation position ⇒ Fig. ““Allocation of piston rings”“ , page 71
❑ Offset gaps by 120°
11 - Oil scraper ring
❑ Remove and install 3-part oil scraper ring carefully by hand
❑ Installation position ⇒ Fig. ““Installing oil scraper ring”“ , page 71
❑ Gap cannot be measured
❑ Ring-to-groove clearance cannot be checked
❑ Allocation ⇒ Fig. ““Allocation of piston rings”“ , page 71
12 - Oil spray jet
❑ With spray nozzle valve
❑ Do not bend
❑ Removing and installing ⇒ “5.3 Removing and installing oil spray jets”, page 76
13 - Banjo bolt
❑ 10 Nm +45°

Allocation of piston rings

1- Compression ring with chamfer -arrow A- (inner side, top)
2- Compression ring with shoulder -arrow B- (outer side, bot‐
tom)
3- Three-part oil scraper ring
Installing compression rings

• Open up compression ring -2- using piston ring pliers -VAS
211 003- just far enough to be able to slide it over piston -1-.
Installing oil scraper ring

– Note installation position of spring:
• Ends of fins -2, 3- and spring -1- must be offset from one an‐
other by at least 90°.
– Install by hand.
Installation sequence:
1. Insert spring -1- in groove.
2. Insert bottom fin -3- in groove.
3. Insert top fin -2- in groove.
• Offset top gap of 3-part oil scraper ring by 120° to next com‐
pression ring.

Installation position of pistons
Caution
Do not damage the coating of the piston crown.

♦ If you intend to re-install used pistons, mark the cylinder
number on the piston crown using paint. Do not mark pis‐
ton crown by means of centre punch, notch or the like.
Installation position:
Pfeil - points to pulley end
x - Cylinder bank identification: L = left, R = right
Marking conrods
– Use a coloured pen to mark matching conrods and conrod
bearing caps with cylinder numbers -arrow- for re-installation.
Installation position of conrods

• The cast lugs on the ground surfaces -arrows- of the conrod
pairs must face each other.
5.2 Removing and installing pistons


♦ Pin - VW 222A-
♦ Wrench, 21 mm - T40263-
♦ Adapter - T40314-
♦ Piston installation sleeve -T40369- (not illustrated)

♦ Piston ring pliers -VAS 211 003- (not illustrated)
Removing
– Remove corresponding cylinder head
⇒ “3.3 Removing and installing cylinder head”, page 124 .
– Remove oil baffle plate
⇒ “1.5 Removing and installing oil baffle plate”, page 185 .
– Mark installation position and matching of:
• Conrod bearing caps to cylinders and to conrods
⇒ Fig. ““Marking conrods”“ , page 72
• Pistons to cylinders
⇒ Fig. ““Installation position of pistons”“ , page 72
• Conrods to cylinders ⇒ Item 4 (page 69)

– If necessary, unscrew camshaft clamp -T40264/3- and turn

crankshaft as appropriate.
Caution
Irreparable engine damage can be caused if the camshaft tim‐

ing chains slip.
♦ Only turn crankshaft in direction of engine rotation.
– Turn crankshaft using wrench, 21 mm - T40263- and adapter

- T40314- -arrow-, paying attention to camshaft timing chain
or guiding camshaft timing chain.
– Unscrew relevant bolts -arrows- and detach conrod bearing

cap.
Caution
Risk of damage to oil spray jets due to deformation.

• Never bend oil spray jets.
– Detach piston, paying attention to oil spray jets.
– Take circlip -2- out of piston pin boss.

– Use drift - VW 222A- to drive out piston pin -3-.
Note:
If piston pin is difficult to remove, heat piston to approx. 60 °C.
– Detach piston -1- from conrod -4-.
Installing
angle.
Installation positions:
• Piston rings ⇒ Fig. ““Allocation of piston rings”“ , page 71
• Pistons ⇒ Fig. ““Installation position of pistons”“ , page 72
• Conrods ⇒ Fig. ““Installation position of conrods”“ , page 72
– Install compression rings
⇒ Fig. ““Installing compression rings”“ , page 71 .
– Install oil scraper ring
⇒ Fig. ““Installing oil scraper ring”“ , page 71 .

– Oil running surfaces of bearing shells and cylinder wall.

– Carefully push piston -1- into cylinder by hand -arrow- using
piston installation sleeve -T40369- .
Caution
Risk of damage to oil spray jets due to deformation.

• Never bend oil spray jets.
– Check that oil spray jets have adequate clearance after instal‐
ling pistons.
– Install conrod bearing caps according to markings.
• If pistons are only removed on one cylinder bank, “TDC” po‐

sition of crankshafts must be checked with camshaft housing
fitted.
Caution
Risk of damage to engine.

♦ Camshafts must be at “TDC” position, as described below.
– Unscrew bolt -3- and detach cover -2-.

• Exhaust camshaft -1- has an asymmetrically positioned pair
of grooves -arrows-. In TDC position, the asymmetrically posi‐
tioned pair of grooves must be above the imaginary horizontal
centre line, as shown. (Shown on exhaust camshaft, cylinder
bank 2)
• Notch -1- on vibration damper must align with cast projection

-2- on sealing flange (pulley end).
– Screw locking pin - T40069- into hole and tighten to 20 Nm. If

necessary, turn crankshaft back and forth slightly. The locking
pin will engage in the crank web hole.
– Install oil baffle plate
– Install cylinder head
⇒ “3.3.6 Installing cylinder head - vehicles with 3.0 ltr. engine”,
page 137 .
Tightening torques
♦ ⇒ “5.1 Exploded view - pistons and conrods”, page 69

5.3 Removing and installing oil spray jets

Removing
– Remove oil baffle plate
Caution
Irreparable damage can be caused if the camshaft timing chain

slips.
– Use wrench, 21 mm - T40263- and adapter - T40314- to turn

crankshaft -arrow- until corresponding oil spray jet is accessi‐
ble.
– Mark installation position and matching of conrod bearing caps

to cylinder and to conrods for re-installation ⇒ page 72 .
– Unscrew relevant bolts -arrows- and detach conrod bearing
cap.
– Unscrew banjo bolt -2- and remove oil spray jet -1-.
– Repeat procedure for each oil spray jet if necessary.
Installing
• Renew banjo bolts after removal.
angle.
• Do not bend oil spray jets.
• Check clearance of oil spray jets.
– Install oil baffle plate
Tightening torques
♦ ⇒ “5.1 Exploded view - pistons and conrods”, page 69

5.4 Checking pistons and cylinder bores

Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 10 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.017 mm.
Piston ∅ mm
2.9 ltr. 3.0l
Nominal dimension 84.471) 84.451)
• 1)Dimensions including coating (thickness 0.018 mm). The
coating will wear down in service.
Measuring cylinder bore

– Use a cylinder gauge - VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore ∅ mm
Nominal dimension 84.510 + 0.005 1)
• 1) Measure at 50 mm into cylinder bore.
Measuring piston ring gap

– 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.
2.9 ltr. engine
Piston ring new Wear limit
mm mm
1st compression ring 0.20 … 0.35 0.45
2nd compression ring 0.50 … 0.70 0.80
Oil scraper ring (3 parts) Cannot be measured
3.0 ltr. engine
mm mm

Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
2.9 ltr. engine
mm mm
3.0 ltr. engine
mm mm
5.5 Checking radial clearance of conrod

bearings
♦ Plastigauge
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing caps and tighten through specified angle
⇒ Item 1 (page 69) without rotating crankshaft.
– Remove conrod bearing cap again.
Radial clearance:
• New: 0.027 ... 0.072 mm.

15 – Cylinder head, valve gear

1 Timing chain cover
⇒ “1.1 Exploded view - timing chain cover”, page 79
⇒ “1.2 Removing and installing timing chain cover”, page 81
1.1 Exploded view - timing chain cover
1 - Bolt
sequence
⇒ Fig. ““Timing chain
cover (bottom) - tighten‐
ing torques and tighten‐
ing sequence”“ ,
page 81
2 - Oil seal
❑ For crankshaft (gearbox
end)
❑ Renewing
shaft oil seal (gearbox
end)”, page 48
3 - Dowel sleeve
❑ 2x
4 - Timing chain cover (bottom)
installing timing chain
cover (bottom)”,
page 84
5 - Cylinder head gasket, bank
2 (left-side)
6 - Centre hex stud
sequence
⇒ Fig. ““Timing chain
cover for cylinder bank 2
(left-side) - tightening
torques and se‐
7 - Bolt
⇒ Fig. ““Timing chain cover for cylinder bank 2 (left-side) - tightening torques and sequence”“ ,
page 80
8 - Timing chain cover (top) for cylinder bank 2 (left-side)
❑ Removing and installing ⇒ “1.2.1 Removing and installing timing chain covers (top)”, page 81
9 - Dowel sleeve
❑ 2x
10 - Bolt
❑ 9 Nm
1. Timing chain cover 79

11 - Heat shield
12 - Exhaust camshaft control valve 1 - N318-
❑ Cylinder bank 2 (left-side): exhaust camshaft control valve 2 - N319-
❑ Removing and installing ⇒ “4.6 Removing and installing camshaft control valve 1 N205 ”, page 157
13 - Seal
14 - Dowel sleeve
❑ 2x
15 - Timing chain cover (top) for cylinder bank 1 (right-side)
❑ Removing and installing ⇒ “1.2.1 Removing and installing timing chain covers (top)”, page 81
16 - Bolt
⇒ Fig. ““Timing chain cover for cylinder bank 1 (right-side) - tightening torques and sequence”“ ,
page 80
17 - Seal
18 - Camshaft control valve 1 - N205-
❑ Cylinder bank 2 (left-side): camshaft control valve 2 - N208-
❑ Removing and installing ⇒ “4.6 Removing and installing camshaft control valve 1 N205 ”, page 157
19 - Bolt
❑ 9 Nm
20 - Cylinder head gasket, bank 1 (right-side)
21 - Dowel sleeve
❑ 2x
Timing chain cover for cylinder bank 1 (right-side) - tightening

torques and sequence
– Tighten bolts -1 ... 8- to 9 Nm in the sequence shown.
Timing chain cover for cylinder bank 2 (left-side) - tightening tor‐

ques and sequence
– Tighten bolts -1 ... 8- to 9 Nm in the sequence shown.
80 Rep. gr.15 - Cylinder head, valve gear

Timing chain cover (bottom) - tightening torques and tightening

sequence
angle.
1. -arrows- 3 Nm
2. -1 … 6- 3 Nm
3. -arrows- 8 Nm
1.2 Removing and installing timing chain

cover
⇒ “1.2.1 Removing and installing timing chain covers (top)”, page
81
page 84
1.2.1 Removing and installing timing chain

covers (top)
♦ Electric drill with plastic brush
♦ Safety goggles
Removing
• Reinstall heat insulation sleeves in the same locations when
installing.
– Remove high-pressure pipe (rear)
⇒ “7.3 Removing and installing high-pressure pipe”,
page 315 .
Cylinder bank 1 (right-side):
– If fitted, remove coolant circulation pump - V50- ⇒ 6-cylinder
19 ; Coolant pump/thermostat assembly; Removing and in‐
stalling electric coolant pump .
– Unplug electrical connector -2- for camshaft control valve 1 -
N205- and move electrical wiring clear.

– Remove centre hex studs -2- and bolts -1-, then detach brack‐
et for continued coolant circulation pump - V51- .
Cylinder bank 2 (left-side):

– If fitted, unclip bracket -arrow- from timing chain cover and
press it to side with vacuum hose still attached.
– Open heat insulation sleeve and unplug electrical connector

-arrow- on oil pressure switch - F22- . (Shown on vehicle with
3.0 ltr. engine.)

– Unplug electrical connector -1- at oil temperature sender -

G8- . (Shown on vehicle with 3.0 ltr. engine.)
– Move wiring harness clear at timing chain cover.

Both sides (continued):
– Carefully release and detach timing chain cover from bonded
joints.
Caution
Risk of irreparable damage to engine.

♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine when the timing chain cover (top) is removed.
Installing
angle.
• Renew O-rings after removing.
• Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
– Remove old sealant from sealing surfaces.
Caution

WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover -1- and cyl‐

inder head using rotating plastic brush or similar.


– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2
mm).
Caution

• Width of sealant bead: 3.0 mm.
– Apply sealant bead -arrow- onto clean sealing surface of tim‐

ing chain cover for cylinder bank 1 (right-side).
– Apply sealant bead -arrow- onto clean sealing surface of tim‐

ing chain cover for cylinder bank 2 (left-side).
• Install timing chain cover within 5 minutes of applying sealant.
– Slide timing chain cover carefully onto dowel sleeves on cyl‐
inder head but do not press sealant bead on yet.
– First, screw all bolts for timing chain cover in by hand and then
tighten.
note the following:
– Install high-pressure pipe (rear)
page 315 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover for cylinder bank 1 (right-side) -
tightening torques and sequence”“ , page 80
♦ ⇒ Fig. ““Timing chain cover for cylinder bank 2 (left-side) -
tightening torques and sequence”“ , page 80
♦ ⇒ “2.2 Exploded view - electric coolant pump”, page 216
1.2.2 Removing and installing timing chain

cover (bottom)

♦ Socket Torx T30 - T10405-
♦ Bolt, M6x20 (3x)

♦ Electric drill with plastic brush attachment
♦ Safety goggles
Removing
– Remove timing chain covers (top)
⇒ “1.2.1 Removing and installing timing chain covers (top)”,
page 81 .
– Unplug electrical connector -2- for engine speed sender -
G28- .

– Remove bolts -arrows- and -1 … 6-.
– To loosen cover (bottom) -1- for timing chains, tighten 3 bolts

M6x20 -arrows- as far as stop.
– Tighten bolts one after the other by 1/2 each until timing chain
cover (bottom) is loosened.
– Remove bolts again, detach timing chain cover (bottom) and
press out crankshaft oil seal (gearbox end).
Installing
angle.
– Pull dowel sleeve at top right out of cylinder block.
– Bevel the dowel sleeve with a file, as shown.
• Dimension -x- = 6.5 mm
• Dimension -y- = 8 mm
– Fit dowel sleeve on cylinder block in such a way that the bev‐
elled side points upwards. Bevelling the dowel sleeve makes
it easier to fit the timing chain cover (bottom) with the cylinder
head installed.
Caution


WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover (bottom)

-1-, cylinder block and cylinder head using rotating plastic
brush or similar.
– The old sealing compound must not be removed from the

groove -arrow- in the cylinder head gaskets. With the cylinder
head installed, the groove is only half visible.
Caution
Avoid damage to cylinder head gasket.

♦ Only bend the ends of the cylinder head gaskets slightly
and do not kink.
• The cylinder head gasket must be renewed if it is bent or

kinked.
– Carefully bend the cylinder head gasket -1- down very slightly
-arrows- on both sides, just far enough to be able to clean the
upper sealing surface between the gasket and the cylinder
head.
– Clean cylinder head gaskets (top and bottom); they must be
free of oil and grease.

mm).

– Apply a small amount of sealant to sealing surfaces of cylinder

head gasket -1- (top and bottom) on both sides. To do so, bend
cylinder head gasket down again very slightly -arrows-.
– Use a flat object (e.g. a feeler gauge) to apply sealant to the
area between cylinder head and gasket.
Caution

– Apply sealant beads -1, 2, 3- onto the clean sealing surfaces

of the timing chain cover (bottom).
• Width of sealant beads: 3.0 mm.
• Install timing chain cover within 5 minutes of applying sealant.
• Take care not to damage the cylinder head gaskets when fit‐
ting the timing chain cover (bottom).
– Fit timing chain cover (bottom), guiding it towards sealing sur‐
face on cylinder block and cylinder head at an angle from
below, but do not press sealant bead on yet.
– First, screw all bolts in by hand and then tighten.
note the following:
– Install crankshaft oil seal (gearbox end)
⇒ “2.3 Renewing crankshaft oil seal (gearbox end)”,
page 48 .
– Install timing chain covers (top)
⇒ “1.2 Removing and installing timing chain cover”, page 81 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (bottom) - tightening torques and
tightening sequence”“ , page 81

2 Chain drive
⇒ “2.1 Exploded view - camshaft timing chains”, page 89
⇒ “2.2 Exploded view - drive chain for oil pump”, page 92
⇒ “2.3 Removing camshaft timing chain from camshafts”,
page 93
page 113
⇒ “2.5 Removing and installing chain tensioner”, page 114
2.1 Exploded view - camshaft timing chains

Camshaft timing chain for cylinder bank 1 (right-side)
1 - Guide pin
❑ 5 Nm +45°
2 - Guide rail
3 - Gear
❑ With sprockets for cam‐
shaft timing chains
4 - Camshaft timing chain
❑ Removing from cam‐
shafts
⇒ “2.3 Removing cam‐
shaft timing chain from
camshafts”, page 93
❑ Do not separate from
tensioning rail
stalling camshaft timing
chain”, page 113
5 - Tensioning rail
❑ Do not separate from
camshaft timing chain
6 - Pivot pin
❑ 23 Nm
7 - Bolt
❑ 9 Nm
8 - Chain tensioner
stalling chain tension‐
er”, page 114
9 - Seal
10 - Timing valve
❑ For camshaft adjuster
❑ Tightening torques and sequence ⇒ page 99
2. Chain drive 89
11 - O-ring
12 - Camshaft adjuster
❑ For exhaust camshaft
❑ Allocation ⇒ Electronic parts catalogue
❑ After removing, renew friction washer (diamond-coated washer) ⇒ Item 13 (page 90)
❑ Removing and installing ⇒ “2.3 Removing camshaft timing chain from camshafts”, page 93
13 - Friction washer (diamond-coated washer)
❑ To ensure secure fit between camshaft adjuster and end of camshaft
❑ Bring new friction washer (diamond-coated washer) into installation position carefully without bending it
❑ For inlet camshaft
16 - O-ring
17 - Timing valve
18 - Slide
19 - Guide pin
❑ 5 Nm +45°
20 - Guide pin
❑ 5 Nm +45°
Camshaft timing chain for cylinder bank 2 (left-side)

1 - Pivot pin
❑ 23 Nm
2 - Tensioning rail
3 - Camshaft timing chain
❑ Mark direction of rota‐
tion for re-installation
with a paint marker
❑ Removing from cam‐
shafts
⇒ “2.3 Removing cam‐
shaft timing chain from
camshafts”, page 93
stalling camshaft timing
chain”, page 113
4 - Chain tensioner
stalling chain tension‐
er”, page 114
5 - Bolt
❑ 9 Nm
6 - Gasket
7 - Slide
8 - Timing valve
sequence ⇒ page 99
9 - O-ring
❑ For exhaust camshaft
2. Chain drive 91
14 - O-ring
15 - Timing valve
16 - Guide rail
17 - Bolt
❑ 9 Nm
18 - Gear
❑ With sprockets for camshaft timing chains
2.2 Exploded view - drive chain for oil pump
1 - Guide rail
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Drive chain
❑ For oil pump
5 - Guide pin
❑ 5 Nm +45°
6 - Guide pin
❑ 5 Nm +45°
7 - Crankshaft
❑ With drive chain sprock‐
et for oil pump
8 - Tensioning rail
9 - Oil pump
stalling oil pump”,
page 187
10 - Chain sprocket
❑ For oil pump
11 - Bolt

2.3 Removing camshaft timing chain from

camshafts
⇒ “2.3.1 Removing camshaft timing chain from camshafts - cyl‐
inder bank 1 (right-side)”, page 93
⇒ “2.3.2 Removing camshaft timing chain from camshafts - cyl‐
inder bank 2 (left-side)”, page 102
2.3.1 Removing camshaft timing chain from

camshafts - cylinder bank 1 (right-side)
In the following procedure the camshaft timing chain remains on
the engine.
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - VAS 6583-
2. Chain drive 93
♦ Locking pin - T40069- (with engine removed)
♦ Wrench, 21 mm - T40263-
♦ Camshaft clamp - T40264/3-

♦ Socket E24 - T90000- (not illustrated)
♦ Counterhold tool - T90001- (not illustrated)
♦ Socket -VAS 261 001- (not illustrated)

Preparing camshaft clamp - T40331-

• Lettering “A” on camshaft clamp - T40331/1- faces forwards.
• Camshaft clamps - T40331/4- and -T40331/5- and washers
on bolts -T40331/9- must be positioned using dowel pins
-arrows-.
– Tighten bolts hand tight.
Removing
For the preparatory work required before removing camshaft tim‐
ing chain from camshafts (with engine installed), refer to ⇒ 6-
gr. 15 ; Chain drive; Removing camshaft timing chain from cam‐
shafts .
Caution

♦ The crankshaft and camshafts must only be turned with
the chain drive mechanism fully installed.
– Remove timing chain cover (top) for cylinder bank 1 (right-

side)
page 81 .
– Remove air pipe (top) ⇒ 6-cylinder direct injection engine (2.9
ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;
Removing and installing air pipe .
Caution

slips.

crankshaft -arrow- until vibration damper is at “TDC” position.
(Shown on vehicle with 3.0 ltr. engine.)
2. Chain drive 95
• The marking -1-/-2- on the camshaft adjusters must be oppo‐

site the corresponding projections -arrows- on the camshaft
housing. Turn crankshaft one turn if necessary.
– Unscrew bolts -arrows- and remove sealing plugs -1, 2-.
– Tighten adapter -T40331/2- on camshaft housing to 9 Nm.

• It should be possible to insert the camshaft clamp -T40331/1-

easily.
• Do not knock camshaft clamp into place with any kind of tool.
– Insert camshaft clamp -T40331/1- prepared previously into
camshafts as far as stop. Turn crankshaft slightly if necessary.
• Camshaft clamp -T40331/4- engages in flat surface -1- on inlet
camshaft, as shown.
• Camshaft clamp -T40331/5- engages in asymmetrically posi‐
tioned groove (top) -2- on exhaust camshaft, as shown.
– Tighten bolts -arrows- to 9 Nm.
Note:
Counterhold tool - T90001- can only be fitted in one position;
notch -1- and marking -2- on camshaft adjuster must align.
Caution
Risk of damage to camshafts.

♦ Do NOT use camshaft clamps -T40331- to counterhold
when loosening timing valves for camshaft adjusters.
– Fit socket -VAS 261 001- with counterhold tool - T90001- to

counterhold on corresponding camshaft adjuster and loosen
timing valve -1- with socket E24 - T90000- .
– Mark position of camshaft adjusters in relation to camshafts
with paint for re-installation.

Procedure if engine has NOT been removed during preparatory
work:
contact. If necessary, turn crankshaft backwards and forwards
slightly to fully centralise locking pin.
2. Chain drive 97
Procedure if engine has been removed during preparatory work:

– If still fitted, unscrew plug.
necessary, turn crankshaft back and forth slightly.
Continued:
– Press piston of chain tensioner -2- back as far as stop
-arrow- using a screwdriver -1-. Then lock chain tensioner by
inserting locking pin - T03006- .
Note:
The piston is oil-damped and can therefore only be pressed back
slowly by applying constant pressure.
– Unscrew timing valves -1, 2- and detach both camshaft ad‐

justers.
Installing
• Crankshaft locked in “TDC” position with camshaft clamp -
T40264/3- / locking pin - T40069- .
• Camshaft clamp -T40331/1- screwed on to camshaft housing
(9 Nm)
• Renew friction washers (diamond-coated washers)
⇒ Item 13 (page 90) and ⇒ Item 15 (page 90) after removal.
Caution
Risk of damage to engine if camshaft adjusters are loosened.

♦ When installing, it is very important to ensure that the re‐
quired friction washer (diamond-coated washer) is fitted.
This is necessary to ensure a secure fit between the cam‐
shaft adjuster and the stub on the camshaft.
♦ Bring new friction washer (diamond-coated washer) into
installation position carefully without bending it.
♦ The camshaft adjusters MUST be installed as described
in the following work steps:
• The markings -1, 2- on the camshaft adjusters must be oppo‐

housing.

– With camshaft timing chain fitted, bring camshaft adjusters in‐

to installation position described previously (note marks ap‐
plied when removing).
– Oil timing valves -1, 2- on thread and bolt head contact surface
and screw in without tightening.
• It should still be possible to turn both camshaft adjusters on
the camshaft.
– Remove locking pin - T03006- .
• A second mechanic is required for the following step.

– Have a second mechanic use torque wrench - VAS 6583- with
socket -VAS 261 001- and counterhold tool - T90001- to apply
30 Nm of torque at exhaust camshaft adjuster in anti-clockwise
direction -arrow- and maintain this torque.
– Tighten timing valves as follows using socket E24 - T90000- ,
while keeping camshaft adjuster under tension:
♦ Timing valve -2- on inlet camshaft: 30 Nm
♦ Timing valve -1- on exhaust camshaft: 30 Nm
Checking valve timing
– Remove camshaft clamp -T40331/1- .
– Remove camshaft clamp - T40264/3- / locking pin - T40069- .
Caution


crankshaft two turns -arrow- until vibration damper is back at
“TDC” position.
2. Chain drive 99
• The markings -1, 2- on the camshaft adjusters must be oppo‐

housing.

work:

Continued:
30 Nm of torque at exhaust camshaft adjuster in anti-clockwise


easily.
camshaft as far as stop.
camshaft, as shown.
If it is NOT possible to insert the camshaft clamp -T40331/1- :

camshafts as far as stop, as described previously. To do so,
turn crankshaft slightly.
– Loosen timing valves -1, 2- half a turn using socket E24 -
T90000- .

work:

Continued:
– Repeat adjustment ⇒ page 99 .
2. Chain drive 101

If it is possible to insert the camshaft clamp -T40331/1- :

– Apply counterhold tool - T90001- and counterhold tool -
T90002- to exhaust camshaft adjuster.
– Support counterhold tool at timing valve -2- for inlet camshaft.
If necessary, turn crankshaft clockwise slightly (only clock‐
wise).
– Turn timing valve -1- 35° further using socket E24 - T90000- .

T90002- to inlet camshaft adjuster.
– Support counterhold tool at timing valve -1- for exhaust cam‐
shaft. If necessary, turn crankshaft clockwise slightly (only
clockwise).
– Remove counterhold tool - T90001- and counterhold tool -
T90002- .
– Install air pipe (top) ⇒ 6-cylinder direct injection engine (2.9
– Install timing chain cover (top) for cylinder bank 1
page 81 .
Additional work ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 15 ; Chain drive; Removing camshaft
timing chain from camshafts
– If changes have been made to timing chain drive and/or com‐
ponents have been renewed, perform corresponding adap‐
tions listed in Guided Function “0001 - Functions, engine
mechanics” ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ “3.2 Exploded view - camshaft housing”, page 121
2.3.2 Removing camshaft timing chain from

camshafts - cylinder bank 2 (left-side)
In the following procedure the camshaft timing chain remains on
the engine.

♦ Torque wrench - VAS 6583-
♦ Locking pin - T40069- (with engine removed)
2. Chain drive 103

♦ Wrench, 21 mm - T40263-
♦ Camshaft clamp - T40264/3-

♦ Socket E24 - T90000- (not illustrated)
♦ Socket -VAS 261 001- (not illustrated)

Preparing camshaft clamp - T40331-

• Lettering “B” on camshaft clamp - T40331/1- faces forwards.
• Camshaft clamps - T40331/5- and -T40331/6- and washers
on bolts -T40331/9- must be positioned using dowel pins
-arrows-.
– Tighten bolts hand tight.
Removing
For the preparatory work required before removing camshaft tim‐
ing chain from camshafts (with engine installed), refer to ⇒ 6-
gr. 15 ; Chain drive; Removing camshaft timing chain from cam‐
shafts .
Caution

– Remove timing chain cover (top) for cylinder bank 2 (right-

side)
page 81 .
– Remove air pipe (top) ⇒ 6-cylinder direct injection engine (2.9
– Remove vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vac‐
uum system; Removing and installing vacuum pump .
Caution

slips.

crankshaft -arrow- until vibration damper is at “TDC” position.
2. Chain drive 105

• The marking -1, 2- on the camshaft adjusters must be opposite

the corresponding projections -arrows- on the camshaft hous‐
ing. Turn crankshaft one turn if necessary.
– Unscrew bolts -arrows- and remove sealing plugs -2-.

– Press guide tube for oil dipstick -1- slightly to one side.
– Tighten adapter -T40331/2- on camshaft housing to 9 Nm.


easily.
camshafts as far as stop. Turn crankshaft slightly if necessary.
camshaft, as shown.
– Tighten bolts -arrows- to 9 Nm.
Note:
Counterhold tool - T90001- can only be fitted in one position;
notch -1- and marking -2- on camshaft adjuster must align.
Caution
Risk of damage to camshafts.

♦ Do NOT use camshaft clamps -T40331- to counterhold
when loosening timing valves for camshaft adjusters or
camshaft chain sprocket.
– Fit counterhold tool - T90001- with socket -VAS 261 001- to

counterhold on corresponding camshaft adjuster and loosen
timing valve -1- with socket E24 - T90000- .
– Mark position of camshaft adjusters in relation to camshafts
with paint for re-installation.
2. Chain drive 107


work:

– If still fitted, unscrew plug.
Continued:
– Press guide rail -2- back -arrow- and lock piston of chain ten‐
sioner -1- using locking pin - T03006- .
Note:
– Unscrew timing valves -1, 2- and detach both camshaft ad‐

justers.
Installing
T40264/3- / locking pin - T40069- .
• Camshaft clamp -T40331/1- screwed on to camshaft housing
(9 Nm)
• Renew friction washers (diamond-coated washers)
⇒ Item 11 (page 91) and ⇒ Item 12 (page 91) after removal.

Caution
Risk of damage to engine if camshaft adjusters are loosened.

♦ When installing, it is very important to ensure that the re‐
quired friction washer (diamond-coated washer) is fitted.
This is necessary to ensure a secure fit between the cam‐
shaft adjuster and the stub on the camshaft.
♦ Bring new friction washer (diamond-coated washer) into
installation position carefully without bending it.
♦ The camshaft adjusters MUST be installed as described
in the following work steps:

ing.
– With camshaft timing chain fitted, bring camshaft adjusters in‐

to installation position described previously (note marks ap‐
plied when removing).
– Oil timing valves -1, 2- on thread and bolt head contact surface
and screw in without tightening.
• It should still be possible to turn both camshaft adjusters on
the camshaft.
– Remove locking pin - T03006- .

30 Nm of torque at inlet camshaft adjuster in anti-clockwise
– Tighten timing valves as follows using socket E24 - T90000- ,
while keeping camshaft adjuster under tension:
♦ Timing valve -2- on exhaust camshaft: 30 Nm
♦ Timing valve -1- on inlet camshaft: 30 Nm
Checking valve timing
– Remove camshaft clamp - T40331/1- .
Caution

2. Chain drive 109


crankshaft two turns -arrow- until vibration damper is back at
“TDC” position.

ing.

work:


Continued:
30 Nm of torque at inlet camshaft adjuster in anti-clockwise

easily.
camshaft as far as stop.
camshaft, as shown.
If it is NOT possible to insert the camshaft clamp -T40331/1- :
camshafts as far as stop, as described previously. To do so,
turn crankshaft slightly.
– Loosen timing valves -1, 2- half a turn using socket E24 -

T90000- .

work:
2. Chain drive 111


Continued:
– Repeat adjustment ⇒ page 109 .
If it is possible to insert the camshaft clamp -T40331/1- :

T90002- to inlet camshaft adjuster.
– Support counterhold tool at timing valve -2- for exhaust cam‐
shaft. Turn crankshaft slightly if necessary.

T90002- to exhaust camshaft adjuster.
– Support counterhold tool at timing valve -1- for inlet camshaft.
Turn crankshaft slightly if necessary.
– Install vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vacuum
system; Removing and installing vacuum pump .
– Install timing chain cover (top) for cylinder bank 2
page 81 .
Additional work ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 15 ; Chain drive; Removing camshaft
timing chain from camshafts
Tightening torques
♦ ⇒ “3.2 Exploded view - camshaft housing”, page 121
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 23

2.4 Removing and installing camshaft tim‐

ing chain
Removing
– Remove timing chain cover (bottom)
page 84 .
Camshaft timing chain for cylinder bank 2 (left-side):
Caution
If a used timing chain rotates in the opposite direction when it

is refitted, this can cause breakage.
♦ Paint an arrow on timing chain (left-side) to mark running
direction and allocation for re-installation.
– Remove camshaft timing chain from camshafts for cylinder

bank 2 (left-side)
⇒ “2.3 Removing camshaft timing chain from camshafts”, page
93 .
– Unscrew guide pins -arrow- and detach guide rail -1- down‐
wards.
– Lift off timing chain -2-.
2. Chain drive 113

Camshaft timing chain for cylinder bank 1 (right-side):

• Camshaft timing chain for cylinder bank 2 (left-side) removed.
– Remove camshaft timing chain from camshafts for cylinder
bank 1 (right-side)
93 .
– Unscrew bolts -arrows- and detach chain tensioner -4-.
– Unscrew mounting pin -2- and remove camshaft timing chain
-3- with tensioning rail -1-.
• Camshaft timing chain must not be separated from tensioning
rail.
Installing
note the following:
– Fit timing chains on camshafts
93 .
– Install timing chain cover (bottom)
page 84 .
Tightening torques
2.5 Removing and installing chain tensioner


♦ Wrench, 21 mm - T40263-
Removing
– Remove relevant timing chain cover (top)
page 81 .
Caution

slips.

crankshaft -arrow- until vibration damper is at “BDC” position.
2. Chain drive 115

Chain tensioner for cylinder bank 1 (right-side):

• The markings -1- on the camshaft adjusters must be opposite
– Press piston of chain tensioner -3- back as far as stop

-arrow- using a screwdriver -1-. Then lock chain tensioner by
inserting locking pin - T03006- .
Note:
– Remove bolts -2 and 4- and take off chain tensioner.
Caution

Chain tensioner for cylinder bank 2 (left-side):

• The markings -1- on the camshaft adjusters must be opposite

– Press guide rail -3- back -arrow- and lock piston of chain ten‐
sioner -1- using locking pin - T03006- .
Note:
– Remove bolts -2 and 4- and take off chain tensioner.
Caution

Installing
– Install timing chain cover (top)
page 81 .
Tightening torques
2. Chain drive 117

3 Cylinder head
⇒ “3.1 Exploded view - cylinder head”, page 118
⇒ “3.2 Exploded view - camshaft housing”, page 121
⇒ “3.3 Removing and installing cylinder head”, page 124
⇒ “3.4 Removing and installing camshaft housing”, page 141
⇒ “3.5 Checking compression”, page 149
3.1 Exploded view - cylinder head
1 - Non-return valve
❑ For coolant
2 - Cylinder head
❑ Shown for cylinder bank
2 (left-side)
stalling cylinder head”,
page 124
❑ Checking for distortion
⇒ Fig. ““Checking cylin‐
der head for distortion”“ ,
page 121
❑ Machining limit
⇒ Fig. ““Cylinder head
machining limit”“ ,
page 121
❑ If renewed, change
coolant and engine oil
3 - Bolt
❑ Loosening sequence:
♦ Cylinder bank 1 (right-side)
⇒ page 126
♦ Cylinder bank 2 (left-side)
⇒ page 136
sequence:
⇒ Fig. ““Cylinder head,
bank 1 (right-side) - tighten‐
ing torques and se‐
⇒ Fig. ““Cylinder head, bank 2 (left-side) - tightening torques and sequence”“ , page 120
4 - Engine lifting eye
5 - Bolt
❑ 22 Nm
6 - Ball stud
❑ For engine cover panel
❑ 5 Nm +45°

7 - Bolt
❑ 22 Nm
8 - Engine lifting eye
9 - Bolt
♦ Cylinder bank 1 (right-side) ⇒ page 126
♦ Cylinder bank 2 (left-side) ⇒ page 136
❑ Tightening torques and sequence:
⇒ Fig. ““Cylinder head, bank 1 (right-side) - tightening torques and sequence”“ , page 119
10 - Cylinder head gasket
❑ Renewing ⇒ “3.3 Removing and installing cylinder head”, page 124
❑ Installation position: part number must face cylinder head
❑ If renewed, change coolant and engine oil
11 - Bolt
♦ Cylinder bank 1 (right-side) ⇒ page 126
♦ Cylinder bank 2 (left-side) ⇒ page 136
⇒ Fig. ““Cylinder head, bank 1 (right-side) - tightening torques and sequence”“ , page 119
Cylinder head, bank 1 (right-side) - tightening torques and se‐

quence
angle.
2. -1 … 8- 30 Nm
3. -1 … 8- 50 Nm
6. -9- 10 Nm
7. -arrows- 8 Nm
3. Cylinder head 119

Cylinder head, bank 2 (left-side) - tightening torques and se‐

quence
angle.
2. -1 … 8- 30 Nm
3. -1 … 8- 50 Nm
6. -9- 10 Nm
7. -arrows- 8 Nm
Installing coolant bleeder line, cylinder bank 1 (right-side)

• Renew O-ring after removal.
– Tighten bolt -1- to 9 Nm.
Installing coolant bleeder line, cylinder bank 2 (left-side)

– Tighten bolt -arrow- for coolant bleeder line -3- to 9 Nm.

Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.1 mm.
Cylinder head machining limit

Machining of the cylinder head (surface grinding) is only permis‐
sible down to the minimum dimension -a-.
• Minimum dimension -a- = 138.0 ± 0.1 mm
3.2 Exploded view - camshaft housing

1 - Bolt
❑ 9 Nm
2 - Bearing caps
stalling camshaft”,
page 154
❑ Note installation posi‐
tion
3 - Dowel sleeves
4 - Exhaust camshaft
stalling camshaft”,
page 154
❑ Measuring axial clear‐
ance
⇒ “4.2 Measuring axial
clearance of camshaft”,
page 153
❑ Measuring radial clear‐
ance
⇒ “4.3 Measuring radial
clearance of camshaft”,
page 154
❑ Runout: max. 0.04 mm
5 - Retention valve
❑ For oil separator
6 - O-ring
7 - Gasket
8 - Bolt
❑ 9 Nm
9 - Sealing plug
10 - O-ring
11 - Camshaft housing
❑ Shown for cylinder bank 2 (left-side)
❑ Removing and installing ⇒ “3.4 Removing and installing camshaft housing”, page 141
12 - Bolt
⇒ Fig. ““Camshaft housing, cylinder bank 1 (right-side) - tightening torques and sequence”“ , page 124
⇒ Fig. ““Camshaft housing, cylinder bank 2 (left-side) - tightening torques and sequence”“ , page 124
13 - Plug
❑ 5 Nm +90°

14 - Seal
15 - Restrictor
❑ Cylinder bank I: 20 Nm
❑ Cylinder bank II: 15 Nm
16 - O-ring
17 - Plug
❑ 25 Nm
18 - Bolt
❑ 3 Nm +90°
19 - Cam actuator
❑ Removing and installing ⇒ “4.5 Removing and installing cam actuators”, page 156
20 - O-ring
❑ Supplied with ⇒ Item 19 (page 123) ; not available separately
❑ Lubricate lightly with engine oil
❑ Check for damage
21 - Plug
❑ 5 Nm +90°
22 - Seal
23 - Rectangular section seals
24 - Sleeve bearing
❑ Removing and installing ⇒ “4.4 Removing and installing camshaft”, page 154
25 - Rectangular section seals
26 - Axial bearing
27 - Inlet camshaft
❑ Removing and installing ⇒ “4.4 Removing and installing camshaft”, page 154
❑ Measuring axial clearance ⇒ “4.2 Measuring axial clearance of camshaft”, page 153
❑ Measuring radial clearance ⇒ “4.3 Measuring radial clearance of camshaft”, page 154
❑ Runout: max. 0.04 mm

Camshaft housing, cylinder bank 1 (right-side) - tightening tor‐

ques and sequence
angle.
• The camshaft housing should
make contact with the cylinder
head over the full surface.
2. -1 … 20- 8 Nm
3. -1 … 20- Turn 90° further
Camshaft housing, cylinder bank 2 (left-side) - tightening torques

and sequence
angle.
• The camshaft housing should
make contact with the cylinder
head over the full surface.
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further
3.3 Removing and installing cylinder head

⇒ “3.3.1 Removing cylinder head, bank 1 (right-side) - vehicles
with 2.9 ltr. engine”, page 124
⇒ “3.3.2 Removing cylinder head, bank 2 (left-side) - vehicles with
page 129
⇒ “3.3.4 Removing cylinder head, bank 1 (right-side) - vehicles
⇒ “3.3.5 Removing cylinder head, bank 2 (left-side) - vehicles with
page 137
3.3.1 Removing cylinder head, bank 1 (right-

side) - vehicles with 2.9 ltr. engine

♦ Engine bung set - VAS 6122-
Procedure
– Remove camshaft housing for cylinder bank 1 (right-side)
⇒ “3.4.1 Removing and installing camshaft housing - cylinder
bank 1 (right-side)”, page 141 .
– Remove turbocharger (right-side)
⇒ “1.2.1 Removing turbocharger, cylinder bank 1 (right-side) -
– Remove coolant pipe (front) ⇒ 6-cylinder direct injection en‐
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pipes;
Removing and installing coolant pipes .
– Remove intake manifold (right-side)
⇒ “4.2 Removing and installing intake manifold”, page 288 .
– Bring engine support and engine mounting into installation po‐
sition and screw in bolts until they make contact.
– Remove support bracket ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 10 ; Assembly mount‐
ings; Supporting engine in installation position .
– Remove bolt -1- and detach breather line -2- from cylinder
head.

– Unplug electrical connector -1- for Lambda probe after cata‐

lytic converter - G130- and move wiring clear.
– Detach Lambda probe.
– Remove bolts -2- and detach chain tensioner -1-.

– Remove guide pin -5-.
– If cylinder head is being removed with engine installed: Press
guide rail -4- upwards and secure it to camshaft timing chain
-3- using cable tie, as shown.
– Remove bolts -arrows- and -9-.

– Slacken cylinder head bolts in the sequence -1 ... 8-.
– Remove bolts and carefully take off cylinder head.
– Place cylinder head onto soft surface (foam plastic).
– Seal off all open passages in the intake and exhaust system
with clean cloths or plugs (thoroughly cleaned) from engine
bung set - VAS 6122- .
3.3.2 Removing cylinder head, bank 2 (left-


Procedure
cylinder direct injection engine (3.0 ltr. 4-valve TFSI); Rep. gr.
15 ; Cylinder head; Removing and installing cylinder head .
– Remove camshaft housing (left-side)
bank 2 (left-side)”, page 145 .
– Remove turbocharger (left-side)
⇒ “1.2.2 Removing turbocharger, cylinder bank 2 (left-side) -
Audi A6/A7 without electric compressor:
– Bring engine mounting into installation position and screw in
bolts until they make contact.
Audi A6/A7 with electric compressor:
– Bring subframe into installation position and tighten bolts to
115 Nm.
All vehicles (continued):
– Lower engine onto engine mounting.
– Remove coolant pipes ⇒ 6-cylinder direct injection engine (2.9
ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pipes; Re‐
moving and installing coolant pipes .
♦ Coolant pipe (front)
♦ Coolant pipe (front left)

– Pull guide tube -2- for oil dipstick off sealing flange (pulley end)
and detach guide tube.
– Remove bolt -arrow- and detach breather line -3- from cylinder
head.
– Disconnect vacuum hose -1-, taking care not to damage it.
– Take electrical connector -1- for Lambda probe 2 after catalytic

converter - G131- out of bracket, unplug and move wiring
clear.
– Detach catalytic converter (left-side).

– Remove bolt -5- for guide rail.
tensioning rail -2- upwards -arrow- and secure it to camshaft
timing chain -1- using cable tie, as shown.


3.3.3 Installing cylinder head - vehicles with

2.9 ltr. engine
♦ Blade scraper; blade width at least 40 mm (commercially avail‐
able)
Procedure
Note
♦ Risk of damage to sealing surfaces if handled incorrectly.

♦ Carefully remove sealant residue from cylinder head and cyl‐
inder block.
♦ Do NOT use abrasive materials (sandpaper, sanding discs,
sanding pads, abrasive web, wire wool, etc.).
♦ When removing sealant residue, make sure none of the resi‐
due enters the open channels of the engine.
♦ Ensure that nearby workspaces are kept clean and that the
abrasive materials listed above are not being used there.
♦ Use of impermissible abrasive materials can lead to subse‐
quent damage to the turbocharger, conrod bearings, etc.
Caution
Risk of eye injury due to sealant residue.

– Sealant residue may only be removed from the cylinder head

and cylinder block using a commercially available blade scra‐
per (blade width at least 40 mm).
– Remove loose residue with a lint-free cloth.
– Clean blind holes for cylinder head bolts in cylinder block so
that they are free of oil and coolant residue.
• Carefully remove sealant residue from cylinder head and cyl‐
inder block.
• Ensure that no long scores or scratches are made on the sur‐
faces.
• No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
• When installing an exchange cylinder head, the plastic pro‐
tectors fitted to protect the open valves should not be removed
until the cylinder head is ready to be fitted.
angle.

• Renew self-locking nuts, as well as seals, gaskets and O-rings

after removing.
• The gaskets for the left and right cylinder heads have different
shapes and cannot be interchanged.
• When installing an exchange cylinder head, the contact sur‐
faces between roller rocker finger and cam must be oiled
before installing the cylinder head cover.
• Before fitting, check vacuum hoses for damage and renew if
necessary.
• After fitting a new cylinder head or cylinder head gasket,
change engine oil and coolant in entire cooling system.
– Check if non-return valve for coolant -arrow- is fitted in cylinder
head (shown on cylinder bank 2).
– Check that dowel sleeves -arrows- are fitted in cylinder block

(shown on cylinder block, bank 2).

– Cut off nozzle of tube at front marking (nozzle ∅ approx.
2.0 mm).
Caution

♦ The sealant beads must not be thicker than specified.


– Apply beads of sealant -1, 2- onto clean sealing surfaces of
cylinder block and timing chain cover (bottom) as shown.
• Width of sealant bead: 2 mm.


– Fit cylinder head gasket onto dowel sleeves in cylinder block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Fit cylinder head.
– Screw in cylinder head bolts by hand until they make contact.
– Tighten cylinder head bolts.
Note:
Cylinder head bolts do not have to be torqued down again later
after repair work.
note the following:
– Install coolant pipes ⇒ 6-cylinder direct injection engine (2.9
– Install turbocharger
⇒ “1.2 Removing and installing turbocharger”, page 238 .
– Install camshaft housing
⇒ “3.4 Removing and installing camshaft housing”,
page 141 .
– Change engine oil ⇒ “1.2 Engine oil”, page 175 .
– Fill cooling system with fresh coolant
⇒ “1.3 Draining and filling cooling system”, page 213 .
engine (3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head; Re‐
moving and installing cylinder head
Tightening torques
♦ ⇒ Fig. ““Cylinder head, bank 1 (right-side) - tightening torques
and sequence”“ , page 119
♦ ⇒ Fig. ““Cylinder head, bank 2 (left-side) - tightening torques
♦ ⇒ Fig. ““Installing coolant bleeder line, cylinder bank 1 (right-
side)”“ , page 120
♦ ⇒ Fig. ““Installing coolant bleeder line, cylinder bank 2 (left-
♦ ⇒ “1.1 Exploded view - turbocharger”, page 231
3.3.4 Removing cylinder head, bank 1 (right-


Procedure
– Remove turbocharger
⇒ “1.2.4 Removing and installing turbocharger - vehicles with
3.0 ltr. engine”, page 242 .
– Remove camshaft housing for cylinder bank 1 (right-side)
bank 1 (right-side)”, page 141 .
– Remove intake manifold (right-side)
⇒ “4.2 Removing and installing intake manifold”, page 288 .
– If fitted, remove coolant pipe (right-side) ⇒ 6-cylinder direct
injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ;
Coolant pipes; Removing and installing coolant pipes .

– Remove bolt -1- and detach breather line -2- from cylinder
head.

– Remove guide pin -5-.
guide rail -4- upwards and secure it to camshaft timing chain
-3- using cable tie, as shown.

3.3.5 Removing cylinder head, bank 2 (left-


Procedure
cylinder direct injection engine (3.0 ltr. 4-valve TFSI); Rep. gr.
15 ; Cylinder head; Removing and installing cylinder head .
– Remove camshaft housing (left-side)
bank 2 (left-side)”, page 145 .
Audi A6/A7:
– Bring engine mounting into installation position and screw in
bolts until they make contact.
– Lower engine onto engine mounting.

– Pull guide tube -2- for oil dipstick off sealing flange (pulley end)
and detach guide tube.
– Remove bolt -arrow- and detach breather line -3- from cylinder
head.
– Disconnect vacuum hose -1-, taking care not to damage it.
– Unplug electrical connector -4- for coolant temperature sender

- G62- .
– Unscrew bolt -5- and move coolant line -6- clear to one side.
– Release screw-type clip -1- and remove nuts -3-.
– Unscrew threaded pins -arrows- and detach flexible joint -2-.

– Remove bolt -5- for guide rail.
tensioning rail -2- upwards -arrow- and secure it to camshaft
timing chain -1- using cable tie, as shown.


3.3.6 Installing cylinder head - vehicles with

3.0 ltr. engine
♦ Blade scraper; blade width at least 40 mm (commercially avail‐
able)
Procedure
Note
♦ Risk of damage to sealing surfaces if handled incorrectly.

♦ Carefully remove sealant residue from cylinder head and cyl‐
inder block.
♦ Do NOT use abrasive materials (sandpaper, sanding discs,
sanding pads, abrasive web, wire wool, etc.).
♦ When removing sealant residue, make sure none of the resi‐
due enters the open channels of the engine.
♦ Ensure that nearby workspaces are kept clean and that the
abrasive materials listed above are not being used there.
♦ Use of impermissible abrasive materials can lead to subse‐
quent damage to the turbocharger, conrod bearings, etc.
Caution
Risk of eye injury due to sealant residue.

– Sealant residue may only be removed from the cylinder head

and cylinder block using a commercially available blade scra‐
per (blade width at least 40 mm).
– Remove loose residue with a lint-free cloth.
– Clean blind holes for cylinder head bolts in cylinder block so
that they are free of oil and coolant residue.
• Carefully remove sealant residue from cylinder head and cyl‐
inder block.
• Ensure that no long scores or scratches are made on the sur‐
faces.
• No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
• When installing an exchange cylinder head, the plastic pro‐
tectors fitted to protect the open valves should not be removed
until the cylinder head is ready to be fitted.
angle.

• Renew self-locking nuts, as well as seals, gaskets and O-rings

after removing.
• The gaskets for the left and right cylinder heads have different
shapes and cannot be interchanged.
• When installing an exchange cylinder head, the contact sur‐
faces between roller rocker finger and cam must be oiled
before installing the cylinder head cover.
• 3.0 ltr. engine: Renew flexible joint after removing
⇒ Item 19 (page 237) .
necessary.
• After fitting a new cylinder head or cylinder head gasket,
change engine oil and coolant in entire cooling system.
– Check if non-return valve for coolant -arrow- is fitted in cylinder
head (shown on cylinder bank 2).
– Check that dowel sleeves -arrows- are fitted in cylinder block

(shown on cylinder block, bank 2).


– Cut off nozzle of tube at front marking (nozzle ∅ approx.
2.0 mm).
Caution

♦ The sealant beads must not be thicker than specified.


– Fit cylinder head gasket onto dowel sleeves in cylinder block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Fit cylinder head.
– Screw in cylinder head bolts by hand until they make contact.
– Tighten cylinder head bolts.
Note:
Cylinder head bolts do not have to be torqued down again later
after repair work.
note the following:
page 141 .
– Cylinder head, bank 1 (right-side): Install turbocharger
⇒ “1.2.4 Removing and installing turbocharger - vehicles with
3.0 ltr. engine”, page 242 .

– Cylinder head, bank 2 (left-side): Fit flexible joint -2- with

screw-type clip -1-. Fit and tighten studs -arrows-.
– Tighten nuts -3-.
– Press flexible joint in direction of -arrow- by hand while tight‐

ening screw-type clip.
• Pressure must be applied at right angle -arrow- to flexible joint.
– When tightening, ensure that flange contour of flexible joint

-1- is positioned flush with contour on turbine housing of tur‐
bocharger.
Note
It is possible to check the correct installation -arrow- of the flexible

joint -1- by examining the screw-type clip from above.
– Change engine oil ⇒ “1.2 Engine oil”, page 175 .

– Fill cooling system with fresh coolant
⇒ “1.3 Draining and filling cooling system”, page 213 .
engine (3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head; Re‐
moving and installing cylinder head
Tightening torques
♦ ⇒ Fig. ““Cylinder head, bank 1 (right-side) - tightening torques
♦ ⇒ Fig. ““Cylinder head, bank 2 (left-side) - tightening torques
♦ ⇒ Fig. ““Installing coolant bleeder line, cylinder bank 1 (right-
♦ ⇒ Fig. ““Installing coolant bleeder line, cylinder bank 2 (left-
♦ ⇒ “1.1 Exploded view - turbocharger”, page 231

3.4 Removing and installing camshaft hous‐

ing
bank 1 (right-side)”, page 141
bank 2 (left-side)”, page 145
3.4.1 Removing and installing camshaft hous‐

ing - cylinder bank 1 (right-side)
♦ Impact extractor attachment -T10133/3- from tool set for FSI
engines - T10133 C-
♦ Locating pins - T40116-

♦ Safety goggles
♦ Bolt, M8x25 (2x)
Removing
gr. 15 ; Cylinder head; Removing and installing camshaft hous‐
ing .
– Remove high-pressure pump
⇒ “7.2 Removing and installing high-pressure pump”,
page 313 .
– Remove timing chain from camshafts
93 .
– Remove injectors
⇒ “5.3 Removing and installing injectors”, page 295 .

2.9 ltr. engine:

– Unplug electrical connectors:
1- For continued coolant circulation pump - V51-
2- For activated charcoal filter solenoid valve 1 - N80-
3- For tank breather pressure sensor 1 - G950-
4- For temperature sender for engine cover panel - G765-
5- For overrun air recirculation valve for bank 1 - N625-
6- For switch valve for mechanical coolant pump - N649-
7- For Hall sender 3 - G300-
8- For charge pressure control solenoid valve - N75-
– Detach wiring harness and move clear to the side.
– Detach activated charcoal filter solenoid valve 1 - N80- from
bracket and press to side.
3.0 ltr. engine:

1- For continued coolant circulation pump - V51-
2- For activated charcoal filter solenoid valve 1 - N80-
3- For tank breather pressure sensor 1 - G950-
4- For temperature sender for engine cover panel - G765-
5- For overrun air recirculation valve for bank 1 - N625-
6- For switch valve for mechanical coolant pump - N649-
8- For charge pressure control solenoid valve - N75-
– Detach wiring harness and move clear to the side.
– Detach activated charcoal filter solenoid valve 1 - N80- from
bracket and press to side.

– Remove nuts -arrows- and detach bracket -1- for solenoid
valves.

– Detach noise insulation (bottom section).

– Loosen and remove bolts for camshaft housing in the se‐
quence -20 ... 1-.
– To loosen camshaft housing -1-, screw in two M8x25 bolts

– Screw bolts in 1/2 turn each (one after the other) until camshaft
housing is released.
– Remove bolts and detach camshaft housing.
Installing
angle.
• Hydraulic compensation elements and roller rocker fingers in‐
stalled.
If only one of the camshaft housings was removed, “TDC” position
of crankshafts must be checked with camshaft housing fitted.
Caution

– Unscrew bolt -3- and remove sealing plug -2-.

centre line, as shown. Turn crankshaft one turn if necessary.
(Shown on exhaust camshaft, cylinder bank 2)
T40264/3- / locking pin - T40069- .
• Camshaft clamp -T40331/1- screwed into camshaft housing
(right-side)
Caution


WARNING
Risk of eye injury.

– Remove remaining sealant from camshaft housing -1- and

cylinder head using rotating plastic brush or similar.
– Oil running surfaces of both camshafts.

mm).
– Fit gasket -4-.
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
– Apply sealant beads -1, 2, 3- to the clean sealing surfaces of

the camshaft housing.
• Install camshaft housing within 5 minutes after applying the
sealant.
– Place camshaft housing -1- on cylinder head but do not press

sealant beads on yet.
– Insert locating pins - T40116- in camshaft housing and cylinder
head.
– Screw in all bolts for camshaft housing by hand initially and
then tighten.

– Use impact extractor attachment -T10133/3- to pull out locat‐

ing pins - T40116- .
note the following:
– Insert noise insulation (bottom section).
– Install injectors
– Fit camshaft timing chain (adjust valve timing)
93 .
– Install high-pressure pump
⇒ “7.2 Removing and installing high-pressure pump”,
page 313 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head;
Removing and installing camshaft housing
Tightening torques
♦ ⇒ Fig. ““Camshaft housing, cylinder bank 1 (right-side) - tight‐
ening torques and sequence”“ , page 124
3.4.2 Removing and installing camshaft hous‐

ing - cylinder bank 2 (left-side)
♦ Impact extractor attachment -T10133/3- from tool set for FSI
engines - T10133 C-
♦ Adjusting pin - T40060- (with engine installed)

♦ Locating pins - T40116-

♦ Safety goggles
♦ Bolt, M8x25 (2x)
Removing
– Remove timing chain from camshafts
93 .
– Remove crankcase breather module
⇒ “3.2 Removing and installing crankcase breather module”,
page 195 .
– Detach noise insulation (bottom section).
– Loosen and remove bolts for camshaft housing in the se‐
quence -19 ... 1-.

– To loosen camshaft housing -1-, screw in two M8x25 bolts

– Screw bolts in 1/2 turn each (one after the other) until camshaft
housing is released.
– Remove bolts and detach camshaft housing.
Installing
angle.
• Hydraulic compensation elements and roller rocker fingers in‐
stalled.
If only one of the camshaft housings was removed, “TDC” position
of crankshafts must be checked with camshaft housing fitted.
Caution

– Unscrew bolt -3- and remove sealing plug -2-.

centre line, as shown. Turn crankshaft one turn if necessary.
T40264/3- / locking pin - T40069- .
• Camshaft clamp -T40331/1- screwed into camshaft housing
(left-side)
Caution

WARNING
Risk of eye injury.

– Remove remaining sealant from camshaft housing -1- and

cylinder head using rotating plastic brush or similar.
– Oil running surfaces of both camshafts.


mm).
– Check whether retention valve -5- is fitted.

– Fit gasket -4-.
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
– Apply sealant beads -1, 2, 3- to the clean sealing surfaces of

the camshaft housing.
• Install camshaft housing within 5 minutes after applying the
sealant.

– Insert locating pins - T40116- in camshaft housing and cylinder
head.

work:
gr. 15 ; Cylinder head; Removing and installing camshaft hous‐
ing .
– Insert locating pin - T40116- at front of camshaft housing and
cylinder head.
– Insert adjusting pin - T40060- at rear of camshaft housing and
cylinder head.

Continued:
– Screw in all bolts for camshaft housing by hand initially and
then tighten.
– Use impact extractor attachment -T10133/3- to pull out locat‐
ing pin - T40116- .
– If necessary, pull adjusting pin - T40060- out with pliers.
note the following:
– Insert noise insulation (bottom section).
– Install injectors
– Fit camshaft timing chain (adjust valve timing)
93 .
– Install crankcase breather module
⇒ “3.2 Removing and installing crankcase breather module”,
page 195 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head;
Removing and installing camshaft housing
Tightening torques
♦ ⇒ Fig. ““Camshaft housing, cylinder bank 2 (left-side) - tight‐
ening torques and sequence”“ , page 124
3.5 Checking compression

♦ Compression tester - V.A.G 1763-
♦ Spark plug socket, 3/8" - VAS 6919-

Procedure
• Engine oil temperature at least 30 ℃
• Battery voltage at least 12.5 V
– Remove fuse for fuel pump control unit - J538- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
– Remove ignition coils
⇒ “1.2 Removing and installing ignition coils with output
stages”, page 341 .
– Unscrew spark plugs using spark plug socket, 3/8" - VAS
6919- .

With adapter - V.A.G 1763/12- :

– Screw compression tester - V.A.G 1763- into corresponding
spark plug hole, as shown.
With adapter - V.A.G 1763/12A- :

– Screw compression tester - V.A.G 1763- into corresponding
spark plug hole, as shown.
Continued:
– Check compression pressure with compression tester -
V.A.G 1763- (see ⇒ operating instructions for details of how
to use tester).
– Have a 2nd mechanic press down the accelerator pedal com‐
pletely and at the same time operate the starter until the
pressure on the tester display no longer increases.
– Repeat procedure on each cylinder.
Compression pressure bar

2.9 ltr. engine 3.0 ltr. engine
When new 12.0 … 17.0 14.0 … 18.5
Wear limit 10.0 12.0
Maximum difference between cylinders 3.0 3.0
Assembly is performed in reverse sequence; note the following:

– Install spark plugs
⇒ “1.1 Exploded view - ignition system”, page 340 .
– Install ignition coils
– Insert fuse for fuel pump control unit - J538- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
– Erase any entries in event memory resulting from testing ⇒ Ve‐
hicle diagnostic tester.

4 Valve gear
⇒ “4.1 Exploded view - valve gear”, page 151
⇒ “4.2 Measuring axial clearance of camshaft”, page 153
⇒ “4.3 Measuring radial clearance of camshaft”, page 154
⇒ “4.4 Removing and installing camshaft”, page 154
⇒ “4.5 Removing and installing cam actuators”, page 156
⇒ “4.6 Removing and installing camshaft control valve 1 N205 ”,
page 157
⇒ “4.7 Removing and installing valve stem oil seals”, page 158
4.1 Exploded view - valve gear
1 - Exhaust valve
❑ Do not machine, only
grinding-in is permitted
❑ Mark installation posi‐
❑ Valve dimensions
⇒ “5.3 Valve dimen‐
sions”, page 170
❑ Checking valve guides
⇒ “5.1 Checking valve
guides”, page 169
2 - Valve stem oil seal
❑ Different versions; allo‐
cation ⇒ page 153
❑ Renewing
stalling valve stem oil
seals”, page 158
3 - Valve spring
❑ Installation position:
♦ Inlet valve
⇒ Fig. ““Installation position
of valve spring for inlet
valve”“ , page 152
♦ Exhaust valve
⇒ Fig. ““Installation position
of exhaust valve spring”“ ,
page 152
4 - Valve spring plate
5 - Valve cotters
6 - Roller rocker finger
❑ Mark installation posi‐
with a coloured pen
❑ Check roller bearings for ease of movement
❑ Oil running surfaces before fitting
❑ Clip onto hydraulic compensation element ⇒ Item 8 (page 152) using securing clip
7 - Securing clip
❑ Not supplied separately
4. Valve gear 151

❑ Check for firm attachment

8 - Hydraulic compensation element
❑ Clipped onto roller rocker finger ⇒ Item 6 (page 151)
❑ Mark installation position for re-installation with a coloured pen
❑ Oil running surfaces before fitting
9 - Cylinder head
❑ Checking valve guides ⇒ “5.1 Checking valve guides”, page 169
10 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Mark installation position for re-installation
❑ Valve dimensions ⇒ “5.3 Valve dimensions”, page 170
❑ Checking valve guides ⇒ “5.1 Checking valve guides”, page 169
Installation position of valve spring for inlet valve

• Closely spaced spring coils -arrow- face towards cylinder
head.
Installation position of exhaust valve spring

• Coloured markings -arrows- face upwards.

Allocation of valve stem oil seals

A - Exhaust side, painted red
B - Inlet side, painted green
4.2 Measuring axial clearance of camshaft

4. Valve gear 153

Procedure
• Camshaft housing removed
page 141 .
– Attach dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to camshaft housing.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance
• Inlet camshaft: 0.014 ... 0.064 mm
• Exhaust camshaft: 0.048 ... 0.155 mm
4.3 Measuring radial clearance of camshaft

♦ Plastigauge
Procedure
– Remove camshafts
⇒ “4.4 Removing and installing camshaft”, page 154 .
– Mark allocation of roller rocker fingers for re-installation.
– Carefully remove roller rocker fingers and place them on a
clean surface.
– Clean bearings and bearing journals.
bearing on the bearing journal or bearing shell to be measured.
• The Plastigauge must be positioned in the centre of the bear‐
ing.
– Re-insert camshafts, fit camshaft housing and tighten to speci‐
fied torque without rotating camshafts
⇒ Fig. ““Camshaft housing, cylinder bank 1 (right-side) - tight‐
ening torques and sequence”“ , page 124 .
– Remove camshaft housing and camshafts again.
Radial clearance:
• 0.024…0.066 mm
4.4 Removing and installing camshaft

The procedure is described for the cylinder bank 1 (right-side).

Removing
– Remove relevant camshaft housing
page 141 .
– Remove camshaft clamp -T40331/1- -arrows-.
– Unscrew bolts -arrows- and detach bearing caps -1 … 4-.

– Detach camshafts -5, 6-.
Installing
To prevent installation at the wrong locations, bearing caps are
marked in relation to camshaft housing as shown.
Note
The camshaft must be renewed if the slider for cam travel adjust‐
ment has been pushed out of the camshaft splines.
4. Valve gear 155

– Bring axial bearing -2- and camshafts into installation position

on camshaft housing.
• The ends of the rectangular section seals -5- must point up or
down, never to the side.
• Sleeve bearing -1- must be fitted on camshaft housing
-arrow- as far as stop.
– Bring all bearing caps -4- into installation position and secure
with bolts, noting allocation.
• Both dowel sleeves -3- must engage in holes in each bearing
cap.
• Spring pins must engage in holes in camshaft housing.
– Align camshafts and insert camshaft clamp -T40331/1- as far

as stop.
• Lettering on camshaft clamp faces forwards (“A” for cylinder
bank 1).
– Tighten bolts -arrows- hand-tight.
camshaft.
tioned groove (top) -2- on exhaust camshaft.
page 141 .
4.5 Removing and installing cam actuators

Removing cylinder bank 1 (right-side)
gr. 15 ; Valve gear; Removing and installing cam actuators .
1- For inlet cam actuator -F448- , -F452- , -F456-
2- For ignition coils -N70- , -N127- , -N291-
– Remove bolts -arrows- and move earth wiring clear.

Removing cylinder bank 2 (left-side)

gr. 15 ; Valve gear; Removing and installing cam actuators .
2- For ignition coils -N292- , -N323- , -N324- (lift wiring duct
slightly if necessary)

– Press top section of noise insulation upwards.
– Remove bolts -arrows- and detach cam actuator -1-.
Installing
• Check O-rings for damage ⇒ page 265 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Valve gear;
Removing and installing cam actuators .
Tightening torques
♦ ⇒ “4.1 Exploded view - valve gear”, page 151
♦ Earth wires ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
4.6 Removing and installing camshaft con‐

trol valve 1 - N205-
This procedure applies to camshaft control valves -N205- , -
N208- , -N318- and -N319- .
Removing
gr. 15 ; Valve gear; Removing and installing camshaft control
valve 1 - N205- .
– Remove engine cover panel ⇒ page 10 .
4. Valve gear 157


– Unscrew bolts -arrows- and remove camshaft control valve
-1-.
Installing
• Renew seals after removing.
– Install engine cover panel
⇒ “3.1 Removing and installing engine cover panel”,
page 10 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Valve gear;
Removing and installing camshaft control valve 1 - N205- .
Tightening torques
♦ ⇒ “1.1 Exploded view - timing chain cover”, page 79
4.7 Removing and installing valve stem oil

seals
⇒ “4.7.1 Removing and installing valve stem oil seals (cylinder
head installed)”, page 158
⇒ “4.7.2 Removing and installing valve stem oil seals (cylinder
head removed)”, page 163
4.7.1 Removing and installing valve stem oil

seals (cylinder head installed)
♦ Valve stem seal puller - 3364- for inlet side
♦ Valve stem oil seal fitting tool - 3365- for inlet side, or (de‐
pending on version/manufacturer of valve stem oil seal)
♦ Valve shaft seal fitting tool - T40376/1- (not illustrated)

♦ Removal and installation device for valve cotters - VAS 5161

A- with guide plate - VAS 5161A/38-
♦ Spark plug socket, 3/8" - VAS 6919- (not illustrated)

♦ Valve stem pliers - VAS 6770- for exhaust side
♦ Wrench, 21 mm - T40263-
4. Valve gear 159

♦ Valve shaft seal fitting tool -T40376/2- for exhaust side (not
illustrated)
♦ Assembly sleeve ⇒ Electronic parts catalogue
Preparing tool
– Secure M8 hexagon socket head bolts with large bolt head
diameter -arrows- (from tool kit) to underside of guide plate -
VAS 5161A/38- , as shown.
• Guide plate is centred to cylinder head using hexagon socket
head bolts.
Procedure
– Remove relevant camshaft housing
page 141 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Unscrew spark plugs using spark plug socket, 3/8" - VAS
6919- .
Caution
Avoid damage to timing chain.

♦ Camshaft timing chains must be guided when crankshaft
is turned.

crankshaft -arrow- until piston of corresponding cylinder is at
“bottom dead centre” position.

– Align guide plate - VAS 5161A/38- on cylinder head, noting

markings:
A - Exhaust side
E - Inlet side
– Tighten bolts -arrows- for guide plate to 9 Nm.
– Apply drift -VAS 5161/3A- to valve spring plate and use plastic-
headed hammer to release sticking valve cotters.
– Screw sealing pin -VAS 5161/10- hand-tight into guide plate -

VAS 5161A/38- .
– Screw adapter - T40012/1- with seal hand-tight into the cor‐
responding spark plug thread.
– Connect adapter to compressed air line using a commercially
available connection piece -arrow- and apply constant air
pressure.
• Minimum pressure: 6 bar
– Screw snap-in device -VAS 5161/6- with engaging fork into

guide plate using M8 stud -VAS 5161/5- .
– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw -arrow- of assembly car‐
tridge clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
• Knurled screw should slide into assembly cartridge as far as
stop.
– Release pressure fork.
– Take out assembly cartridge.
Caution
Risk of damage to valves if handled incorrectly.

♦ To prevent valve from falling into cylinder, do not unbolt
guide plate and sealing pin.
♦ The pressure in the cylinder must be held at at least 6 bar.
– Mark installation position of springs for exhaust valve with

paint for re-installation.
– Detach valve spring with valve spring plate.
4. Valve gear 161

– Detach valve stem oil seal.

Inlet side:
– Use valve stem seal puller - 3364- to do so.
Exhaust side:
– Use valve stem pliers - VAS 6770- to do so. If difficult to re‐
move, heat with hot air blower - V.A.G 1416- .
Continued:
If the valve stem seal puller - 3364- cannot be used on some of
the valve stem oil seals due to the confined space, proceed as
follows:
– Knock out pin -arrow- of puller using a drift and remove impact
extractor attachment.
– Secure bottom section of puller -3364- with punch or roll-pin

drift -1-.
– Apply puller at valve stem oil seal.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.
Inlet side:
• To avoid damaging the new valve stem oil seal -4- during in‐
stallation, fit the assembly sleeve -3- onto the valve stem -2-.
– Lightly oil sealing lip of valve stem oil seal.
• Use either pusher - 3365- or pusher - T40376/1- , depending
on version/manufacturer of valve stem oil seal.
– Insert valve stem oil seal into valve shaft seal fitting tool -5-
and use assembly sleeve to press it carefully onto valve guide
-1- as far as stop.
– Remove assembly sleeve .

Exhaust side:
– Insert valve stem oil seal into valve shaft seal fitting tool -
T40376/2- and use assembly sleeve to carefully press it onto
valve guide -1- as far as stop.
Continued:
If valve cotters have been removed from assembly cartridge, they
must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate:
• Installation position of inlet valve
⇒ Fig. ““Installation position of valve spring for inlet valve”“ ,
page 152
• Installation position of exhaust valve
⇒ Fig. ““Installation position of exhaust valve spring”“ ,
page 152
– Insert assembly cartridge -VAS 5161/8A- in guide plate - VAS

5161A/38- again.
– Press down pressure fork -VAS 5161/2- and pull knurled
screw -arrow- upwards while turning screw in both directions
- this will insert the valve cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Attaching
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install camshafts
⇒ “4.4 Removing and installing camshaft”, page 154 .
– Install spark plugs
⇒ “1.1 Exploded view - ignition system”, page 340 .
4.7.2 Removing and installing valve stem oil

seals (cylinder head removed)
4. Valve gear 163

♦ Valve stem seal puller - 3364- for inlet side
♦ Valve stem oil seal fitting tool - 3365- for inlet side, or (de‐
pending on version/manufacturer of valve stem oil seal)
♦ Valve shaft seal fitting tool - T40376/1- (not illustrated)

♦ Removal and installation device for valve cotters - VAS 5161
A- with guide plate - VAS 5161A/38-
♦ Engine and gearbox support - VAS 6095A-

♦ Cylinder head tensioning device - VAS 6419-
♦ Valve stem pliers - VAS 6770- for exhaust side
♦ Valve shaft seal fitting tool -T40376/2- for exhaust side (not
illustrated)
♦ Assembly sleeve ⇒ Electronic parts catalogue
Preparing tool
– Secure M8 hexagon socket head bolts with large bolt head
diameter -arrows- (from tool kit) to underside of guide plate -
VAS 5161A/38- , as shown.
• Guide plate is centred to cylinder head using hexagon socket
head bolts.
Procedure
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine

and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device.
– Connect cylinder head tensioning device to compressed air
supply.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seal is to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
4. Valve gear 165

– Align guide plate - VAS 5161A/38- on cylinder head, noting

markings:
A - Exhaust side
B - Inlet side
– Tighten bolts -arrows- for guide plate to 9 Nm.
– Apply drift -VAS 5161/3A- to valve spring plate and use plastic-
headed hammer to release sticking valve cotters.
– Screw snap-in device -VAS 5161/6- with engaging fork into

guide plate using M8 stud -VAS 5161/5- .
– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw -arrow- of assembly car‐
tridge clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
• Knurled screw should slide into assembly cartridge as far as
stop.
– Release pressure fork.
– Take out assembly cartridge.
– Mark installation position of springs for exhaust valve with
paint for re-installation.
– Detach valve spring with valve spring plate.
– Detach valve stem oil seal:

Inlet side:
– Use valve stem seal puller - 3364- to do so.
Exhaust side:
– Use valve stem pliers - VAS 6770- to do so. If difficult to re‐
move, heat with hot air blower - V.A.G 1416- .

Inlet side:
• Use either pusher - 3365- or pusher - T40376/1- , depending
on version/manufacturer of valve stem oil seal.
– Insert valve stem oil seal into valve shaft seal fitting tool -5-
and use assembly sleeve to press it carefully onto valve guide
-1- as far as stop.
Exhaust side:
• To avoid damaging new valve stem oil seal -4- during instal‐
lation, fit assembly sleeve -item 3- onto valve stem -2-.
– Insert valve stem oil seal into valve shaft seal fitting tool -
T40376/2- and use assembly sleeve to carefully press it onto
valve guide -1- as far as stop.
Continued:
If valve cotters have been removed from assembly cartridge, they
must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate:
• Installation position of inlet valve
⇒ Fig. ““Installation position of valve spring for inlet valve”“ ,
page 152
• Installation position of exhaust valve
⇒ Fig. ““Installation position of exhaust valve spring”“ ,
page 152
4. Valve gear 167

– Insert assembly cartridge -VAS 5161/8A- in guide plate - VAS

5161A/38- again.
– Press down pressure fork -VAS 5161/2- and pull knurled
screw -arrow- upwards while turning screw in both directions
- this will insert the valve cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Attaching
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
page 141 .

5 Inlet and exhaust valves

⇒ “5.1 Checking valve guides”, page 169
⇒ “5.2 Checking valves”, page 169
⇒ “5.3 Valve dimensions”, page 170
5.1 Checking valve guides

Procedure
• If the valve has to be renewed as part of a repair, use a new
valve for the measurement.
• Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide.
– Secure dial gauge - VAS 6079- to cylinder head with universal
dial gauge bracket - VW 387- as shown in illustration.
– Insert valve into guide.
• End of valve stem must be flush with valve guide.
– Measure the amount of sideways play.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded. Valve
guides cannot be renewed.
5.2 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.
5. Inlet and exhaust valves 169

– Renew valve if scoring is clearly visible.
5.3 Valve dimensions

• Inlet and exhaust valves must not be machined. Only grinding-
in is permitted.
Dimension Inlet valve Exhaust valve
2.9 ltr. 3.0l 2.9 ltr. 3.0l
∅a mm 32.0 ± 0.1 28.0 ± 0.1
∅b mm 5.92 ± 0.02 5.92 ± 0.02
c mm 102.43 103.184
α ∠ 44°50’ ± 10’ 45 44° 45
50’ ± 10’

17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 171
⇒ “1.2 Engine oil”, page 175
page 175
⇒ “1.4 Removing and installing sump (top section)”, page 177
⇒ “1.5 Removing and installing oil baffle plate”, page 185
⇒ “1.6 Removing and installing oil pump”, page 187
⇒ “1.7 Removing and installing oil level and oil temperature send‐
er G266 ”, page 189
1.1 Exploded view - sump/oil pump

♦ If large quantities of metal shavings or particles are found in
the engine oil when repairing the engine, the oil passages
must be cleaned thoroughly to ensure that this does not result
in damage. In addition, renew oil spray jets, engine oil cooler
and oil filter element.
♦ Oil spray jet for piston cooling
⇒ “5.1 Exploded view - pistons and conrods”, page 69 .
1. Sump/oil pump 171

1 - Bolt
sequence
⇒ Fig. ““Sump (bottom
section) - tightening tor‐
ques and sequence”“ ,
page 173
2 - Sump (bottom section)
stalling sump (bottom
section)”, page 175
3 - Intake connecting pipe
❑ For oil pump
❑ Supplied with
4 - Bolt
❑ Supplied with
⇒ Item 3 (page 172) ; not
available separately
❑ 8 Nm +90°
5 - Chain sprocket
❑ For oil pump
6 - Bolt
❑ 20 Nm +90°
7 - Bolt
sequence
⇒ Fig. ““Sump (top section) - tightening torques and sequence with bottom cover for camshaft timing
chains fitted”“ , page 174 or
⇒ Fig. ““Sump (top section) - tightening torques and sequence with camshaft timing chain cover (bottom)
removed”“ , page 174
8 - Sump (top section)
❑ Removing and installing ⇒ “1.4 Removing and installing sump (top section)”, page 177
9 - Dowel sleeve
10 - Bolt
⇒ Fig. ““Oil baffle plate - tightening torques and sequence”“ , page 174
11 - Oil baffle plate
❑ Removing and installing ⇒ “1.5 Removing and installing oil baffle plate”, page 185
12 - Dowel sleeve
13 - Dowel sleeve
14 - Bolt
172 Rep. gr.17 - Lubrication


⇒ Fig. ““Timing chain cover (bottom) - tightening torques and tightening sequence”“ , page 81 and
⇒ Fig. ““Oil baffle plate - tightening torques and sequence”“ , page 174
15 - Dowel sleeve
16 - Gasket
17 - Dowel sleeve
18 - Bolt
❑ 8 Nm +90°
19 - Oil pump
❑ Do not dismantle
❑ Removing and installing ⇒ “1.6 Removing and installing oil pump”, page 187
20 - O-ring
21 - Seal
22 - Oil drain plug
❑ Lubricate thread
❑ 30 Nm
23 - Oil level and oil temperature sender - G266-
⇒ “1.7 Removing and installing oil level and oil temperature sender G266 ”, page 189
24 - Bolt
❑ 3 Nm +90°
25 - Seal
Sump (bottom section) - tightening torques and sequence

angle.
2. -1 … 17- 3 Nm
3. -1 … 17- Turn 90° further

Oil baffle plate - tightening torques and sequence

angle.
1. -arrows- Screw in by hand until contact is made
2. -1, 2- 3 Nm
4. -1, 2- Turn 90° further
5. -arrows- Turn 90° further in diagonal sequence
Sump (top section) - tightening torques and sequence with bottom

cover for camshaft timing chains fitted
angle.
2. -20, 21- 3 Nm
3. -1 … 19- 3 Nm
4. -20, 21- Turn 90° further
5. -1 … 19- Turn 90° further
Sump (top section) - tightening torques and sequence with cam‐

shaft timing chain cover (bottom) removed
angle.
Stage Bolts Tightening torque
2. -1 … 19- 3 Nm
3. -1 … 19- Turn 90° further

1.2 Engine oil

♦ Draining and filling up engine oil, checking oil level, removing
and installing oil filter element ⇒ 6-cylinder direct injection en‐
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil
pump; Engine oil
♦ Oil capacities, oil specifications and viscosity grades ⇒ Main‐
tenance tables .
1.3 Removing and installing sump (bottom

section)

♦ Safety goggles
Removing
• Engine oil drained ⇒ “1.2 Engine oil”, page 175 .
– If fitted, remove bolt -1- and press bracket -2- with electrical
wiring harness to one side.

– Unplug electrical connector -arrow- at oil level and oil temper‐

ature sender - G266- .
– Move electrical wiring clear.
Caution
Take care to keep components clean.

♦ There will still be some oil in the sump (bottom section).

– Carefully release sump (bottom section) from bonded joint and
detach.
Installing
angle.
Caution
Protect lubrication system and bearings against contamina‐

tion.
WARNING
Risk of eye injury.

– Remove remaining sealant on bottom section -1- and top sec‐

tion of sump with a rotating plastic brush or similar.

mm).

Caution

– Apply sealant bead -arrow- onto clean sealing surface of sump

(bottom section) as shown in illustration.
• Install sump (bottom section) within 5 minutes of applying
sealant.
– Carefully fit bottom section of sump onto top section but do not
press sealant bead on yet.
note the following:
– Fill with engine oil and check oil level
⇒ “1.2 Engine oil”, page 175 .
Tightening torques
♦ ⇒ Fig. ““Sump (bottom section) - tightening torques and se‐
1.4 Removing and installing sump (top sec‐

tion)
⇒ “1.4.1 Removing and installing sump (top section) with timing
chain cover (bottom) installed”, page 177
⇒ “1.4.2 Removing and installing sump (top section) with timing
chain cover (bottom) removed”, page 181
1.4.1 Removing and installing sump (top sec‐

tion) with timing chain cover (bottom)
installed
Complete procedure if timing chain cover (bottom) has NOT been
removed during preparatory work
♦ Used oil collection and extraction unit - VAS 6622A-


♦ Safety goggles
♦ Bolt, M6x30 (4x)
Removing
gr. 17 ; Sump/oil pump; Removing and installing sump (top sec‐
tion) .
– If not yet removed, remove steering rack ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Steering rack; Removing and
installing steering rack .
page 175 .
– 2.9 ltr. engine: Remove bracket for air conditioner compressor
⇒ “1.6.3 Removing and installing bracket for air conditioner
compressor - vehicles with 2.9 ltr. engine without electric com‐
pressor”, page 39 .
– 3.0 ltr. engine: Detach poly V-belt for air conditioner compres‐
sor from pulley
– Vehicles with brace for subframe: Remove bolts -arrows- and
detach brace -1-.

– Move electrical wiring harness clear.

– To loosen sump (top section) -1-, screw in four M6x40 bolts

– Screw bolts 1/2 turn each in diagonal sequence until sump (top
section) is released.
– Remove bolts and detach sump (top section).
Installing
• Renew intake connecting pipe with bolt and O-ring after re‐
moval.
Caution

tion.
WARNING
Risk of eye injury.

– Remove sealant residue from sump (top section) and cylinder

block -1- using rotating plastic brush or similar.


mm).
– Detach dowel sleeves -1, 2-.

– Apply sealant at joints between cylinder block and timing chain
cover (bottom) -arrow-.

Caution

– Apply bead of sealant -arrow- onto clean sealing surface of

sump (top section).
• Install sump (top section) within 5 minutes of applying sealant.
– Carefully fit sump (top section) with the help of a second me‐
chanic. To do so, guide it towards sealing surface on cylinder
block and timing chain cover (bottom) at an angle from below,
but do not press sealant bead on yet.
note the following:
– 2.9 ltr. engine: Install bracket for air conditioner compressor
– 3.0 ltr. engine: Install poly V-belt for air conditioner compressor
page 175 .
– Install steering rack ⇒ Running gear, axles, steering; Rep. gr.
48 ; Steering rack; Removing and installing steering rack .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump (top section) .
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torques and sequence
with bottom cover for camshaft timing chains fitted”“ ,
page 174
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe
1.4.2 Removing and installing sump (top sec‐

tion) with timing chain cover (bottom)
removed
Simplified procedure if timing chain cover (bottom) has been re‐
moved during preparatory work

♦ Used oil collection and extraction unit - VAS 6622A-

♦ Safety goggles
♦ Bolt, M6x30 (4x)
Removing
gr. 17 ; Sump/oil pump; Removing and installing sump (top sec‐
tion) .
– Remove timing chain cover (bottom) ⇒ page 84 .
– If not yet removed, remove steering rack ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Steering rack; Removing and
installing steering rack .
page 175 .
– 2.9 ltr. engine: Remove bracket for air conditioner compressor
– Vehicles with brace for subframe: Remove bolts -arrows- and
detach brace -1-.


– To loosen sump (top section) -1-, screw in four M6x40 bolts

– Screw bolts 1/2 turn each in diagonal sequence until sump (top
section) is released.
– Remove bolts and detach sump (top section).
Installing
• Renew bolts after removing.
• Renew intake connecting pipe with bolt and O-ring after re‐
moval.
Caution

tion.

WARNING
Risk of eye injury.

– Remove sealant residue from sump (top section) and cylinder

block -1- using rotating plastic brush or similar.

mm).

Caution

– Apply bead of sealant -arrow- onto clean sealing surface of

sump (top section).
• Install sump (top section) within 5 minutes of applying sealant.
– Carefully fit sump (top section) with the help of a second me‐
chanic but do not press sealant bead on yet.
note the following:
– Install timing chain cover (bottom)
page 84 .
– 2.9 ltr. engine: Install bracket for air conditioner compressor
page 175 .
– Install steering rack ⇒ Running gear, axles, steering; Rep. gr.
48 ; Steering rack; Removing and installing steering rack .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump (top section) .
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torques and sequence
with camshaft timing chain cover (bottom) removed”“ ,
page 174
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe
1.5 Removing and installing oil baffle plate

♦ Safety goggles
Removing
– With timing chain cover (bottom) fitted, remove sump (top sec‐
tion)

⇒ “1.4.1 Removing and installing sump (top section) with tim‐

ing chain cover (bottom) installed”, page 177 .
– Remove bolts -arrows- and -1, 2-.
– Lever oil baffle plate downwards out of bonded joint on timing
chain cover (bottom) and detach oil baffle plate.
Installing
Caution

tion.
WARNING
Risk of eye injury.

– Remove sealant residue from oil baffle plate and cylinder block
-1- using rotating plastic brush or similar.

Caution

♦ The sealant must not be applied thicker than specified.
– Thinly coat sealing surfaces -arrows- on oil baffle plate and

timing chain cover (bottom) -2- with sealant.
• Install oil baffle plate within 5 minutes of applying sealant.
– Carefully fit oil baffle plate. To do so, guide it towards sealing
surface on cylinder block and timing chain cover (bottom) at
an angle and from below.
note the following:
– Install sump (upper section) ⇒ page 177 .
Tightening torques
♦ ⇒ Fig. ““Oil baffle plate - tightening torques and sequence”“ ,
page 174
1.6 Removing and installing oil pump

♦ Counterhold tool - T10172A-
Removing
– Remove sump (top section) ⇒ page 177 .

– Fit counterhold tool - T10172- with adapter -T10172/2- and

remove bolt -arrow-.
– Pull chain sprocket -1- off oil pump and leave it in position.
– Remove bolts -arrows- and detach oil pump -1-.

Installing
angle.
– Check that centring sleeves -arrows- are fitted in oil pump.

– Fit gasket -1-.
– Install sump (upper section)
⇒ “1.4.1 Removing and installing sump (top section) with tim‐
ing chain cover (bottom) installed”, page 177 .
Tightening torques

1.7 Removing and installing oil level and oil

temperature sender - G266-
Removing
• Engine oil drained ⇒ page 175 .
– Remove bolts -1- and detach oil level and oil temperature
sender - G266- -item 3-.
Installing
• Renew seal -4- after removing.
– Fill with engine oil and check oil level
⇒ “1.2 Engine oil”, page 175 .
Tightening torques

2 Engine oil cooler

⇒ “2.1 Exploded view - engine oil cooler”, page 190
⇒ “2.2 Removing and installing engine oil cooler”, page 190
⇒ “2.3 Removing and installing spray nozzle valve”, page 192
2.1 Exploded view - engine oil cooler
1 - O-ring
2 - O-ring
3 - Spray nozzle valve
stalling spray nozzle
valve”, page 192
4 - Seal
5 - Plug
❑ 10 Nm +45°
6 - Seals
7 - O-rings
8 - Hose
❑ For crankcase breather
❑ Cannot be removed
without being damaged
irreparably
9 - Engine oil cooler
stalling engine oil cool‐
er”, page 190
❑ If renewed, refill system
with fresh coolant
10 - Bolt
❑ 9 Nm
11 - Seals
2.2 Removing and installing engine oil cool‐

er

♦ Safety goggles
Removing
gr. 17 ; Engine oil cooler; Removing and installing engine oil
cooler .
– Remove bolts -arrows-.
– Release engine oil cooler -2- from bonded joint and detach
with crankcase breather hose -1-.
Installing
• Renew seals after removing.
Caution

tion.
♦ Cover exposed parts of engine and engine oil cooler.
WARNING
Risk of eye injury.

– Remove sealant residue on engine oil cooler -1- and cylinder

block using rotating plastic brush or similar.

mm).
2. Engine oil cooler 191

Caution

– Fit seals -2, 3-.

– Apply bead of sealant -1- onto clean sealing surface of cylinder
block.
• Install engine oil cooler within 5 minutes of applying the seal‐
ant.
• Do not reuse coolant.
– Fit engine oil cooler and tighten bolts.
note the following:
– Check oil level ⇒ “1.2 Engine oil”, page 175 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Engine oil
cooler; Removing and installing engine oil cooler
Tightening torques
♦ ⇒ “2.1 Exploded view - engine oil cooler”, page 190
2.3 Removing and installing spray nozzle

valve
♦ Hook - T40207-
Removing
– Remove engine oil cooler
⇒ “2.2 Removing and installing engine oil cooler”, page 190 .
– Remove screw plug -arrow-.

– Pull out spray nozzle valve -1- using hook - T40207- .

Installing
• Renew O-rings and oil seal after removing.
– Install engine oil cooler
⇒ “2.2 Removing and installing engine oil cooler”, page 190 .
Tightening torques
♦ ⇒ “2.1 Exploded view - engine oil cooler”, page 190
2. Engine oil cooler 193

3 Crankcase breather
⇒ “3.1 Exploded view - crankcase breather system”, page 194
⇒ “3.2 Removing and installing crankcase breather module”, page
195
3.1 Exploded view - crankcase breather system
1 - Camshaft housing
2 - Hose/sealing plug
❑ Depending on version
3 - O-ring
❑ For specific equipment
version
4 - Gasket
5 - Crankcase breather module
stalling crankcase
breather module”,
page 195
6 - Grommet
7 - Seal
❑ Renew if damaged
8 - Filler cap
9 - Bolt
sequence
⇒ Fig. ““Crankcase
breather module - tight‐
ening torques and se‐
10 - O-ring
11 - Hose
❑ For crankcase breather
❑ Crankcase breather hose cannot be detached from air pipe without being irreparably damaged
⇒ “2.1 Exploded view - charge air system”, page 259 .

Crankcase breather module - tightening torques and sequence

– Tighten bolts to 9 Nm in the sequence shown.
3.2 Removing and installing crankcase

breather module
Removing
installing.
– Remove engine cover panel and heat shield
page 10 .
– If fitted, open heat shield sleeve.
– Press release tabs on both sides and disconnect crankcase
breather connection -arrow-.
– Unscrew bolts -1 … 6- and remove crankcase breather mod‐
ule.
Installing
• Renew seal/gasket and O-ring after removal.
– Install heat shield and engine cover panel
page 10 .
Tightening torques
♦ ⇒ Fig. ““Crankcase breather module - tightening torques and
3. Crankcase breather 195

4 Oil filter/oil pressure switches

⇒ “4.1 Exploded view - oil filter”, page 196
⇒ “4.2 Exploded view - oil pressure switches/oil pressure control”,
page 198
⇒ “4.3 Removing and installing oil filter housing”, page 199
⇒ “4.4 Removing and installing oil pressure switch F22 ”,
page 201
⇒ “4.5 Removing and installing oil temperature sender G8 ”, page
203
page 205
⇒ “4.7 Checking oil pressure”, page 206
⇒ “4.8 Removing and installing valve for oil pressure control N428
”, page 207
4.1 Exploded view - oil filter
1 - Temperature regulator for

engine oil
stalling oil filter hous‐
ing”, page 199
2 - Gasket
3 - Bracket
❑ For air pipe (top)
❑ Not fitted on all models
4 - Bolt
sequence
⇒ Fig. ““Oil filter housing
- tightening torques and
5 - Oil filter housing
stalling oil filter hous‐
ing”, page 199
6 - O-ring
7 - Non-return valve
8 - O-ring
9 - Bolt
❑ 9 Nm
10 - Oil supply line
11 - Oil filter element
❑ Removing and installing ⇒ “1.2 Engine oil”, page 175

12 - O-ring
❑ Part of oil filter element
13 - Sealing cap
❑ 25 Nm
14 - Bolt
⇒ Fig. ““Oil filter housing - tightening torques and sequence”“ , page 197
15 - Bracket
16 - Cylinder block
Oil filter housing - tightening torques and sequence

angle.
2. -1 … 6- 5 Nm
3. -1 … 6- 8 Nm
4. Oil filter/oil pressure switches 197

4.2 Exploded view - oil pressure switches/oil pressure control

Shown on vehicle with 3.0 ltr. engine.
1 - Oil pressure sender - G10-

stalling oil pressure
sender G10 ”,
page 205
❑ 20 Nm
2 - Seal
3 - Oil pressure switch - F22-
❑ Opening/closing pres‐
sure 0.3 … 0.6 bar
(monitoring of switcha‐
ble piston oil spray jets)
❑ Green insulation
❑ Checking ⇒ Vehicle di‐
agnostic tester
stalling oil pressure
switch F22 ”, page 201
❑ 20 Nm
4 - Seal
5 - Bolt
❑ 9 Nm
6 - Oil temperature sender -
G8-
stalling oil temperature
sender G8 ”, page 203
7 - O-rings
8 - Bolt
❑ 9 Nm
9 - Valve for oil pressure control - N428-
❑ Checking ⇒ Vehicle diagnostic tester
⇒ “4.8 Removing and installing valve for oil pressure control N428 ”, page 207
10 - O-ring

4.3 Removing and installing oil filter housing

⇒ “4.3.1 Removing and installing oil filter housing - vehicles with
⇒ “4.3.2 Removing and installing oil filter housing - vehicles with
4.3.1 Removing and installing oil filter housing

- vehicles with 2.9 ltr. engine
Removing
– Remove turbocharger (left-side)
– Remove oil filter element ⇒ “1.2 Engine oil”, page 175 .
– Place a cloth underneath to catch escaping engine oil.
– Remove bolt -arrow- and disconnect oil supply line -1-.

– Unscrew bolts -1 … 6- using socket Torx T30 - T10405- , de‐

tach oil filter housing.
– Detach temperature regulator for engine oil.
Installing
• Renew O-ring and gasket after removal.
angle.
– Install oil filter element ⇒ “1.2 Engine oil”, page 175 .
– Install turbocharger (left-side)
Tightening torques
♦ ⇒ “4.1 Exploded view - oil filter”, page 196
4.3.2 Removing and installing oil filter housing

Removing
gr. 17 ; Oil filter/oil pressure switches; Removing and installing
oil filter housing .

– Unscrew bolts -1 … 6- using socket Torx T30 - T10405- , de‐

tach oil filter housing.
– Detach temperature regulator for engine oil.
Installing
• Renew O-ring and gasket after removal.
angle.
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Oil filter/oil
pressure switches; Removing and installing oil filter housing
Tightening torques
4.4 Removing and installing oil pressure

switch - F22-
⇒ “4.4.1 Removing and installing oil pressure switch F22 - vehi‐
⇒ “4.4.2 Removing and installing oil pressure switch F22 - vehi‐
4.4.1 Removing and installing oil pressure

switch - F22- - vehicles with 2.9 ltr. en‐
gine
♦ Articulated wrench, 24 mm - T40175-
Procedure
installing.
– Remove catalytic converter (left-side) ⇒ 6-cylinder direct in‐
jection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ;
Emission control system; Removing and installing catalytic
converter , move it to one side and secure it with Lambda
probe connected (to do so, move electrical wiring clear).

– Open heat insulation sleeve.

– Unplug electrical connector -arrow-.
– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐
sure switch - F22- .
• Renew seal after removing.
– Install catalytic converter (left-side) ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ;
converter .
Tightening torques
♦ ⇒ “4.2 Exploded view - oil pressure switches/oil pressure con‐
trol”, page 198

switch - F22- - vehicles with 3.0 ltr. en‐
gine
♦ Articulated wrench, 24 mm - T40175-
Procedure
installing.
Audi Q8
– Remove air cleaner housing ⇒ 6-cylinder direct injection en‐
gine (3.0 ltr. 4-valve TFSI EA 839); Rep. gr. 24 ; Air cleaner;
Removing and installing air cleaner housing .
All models except Audi Q8
page 10 .


– Open heat insulation sleeve.
– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐
sure switch - F22- .
page 10 .
Tightening torques
trol”, page 198
♦ ⇒ 6-cylinder direct injection engine (3.0 ltr. 4-valve TFSI EA
839); Rep. gr. 24 ; Air cleaner; Exploded view - air cleaner
housing
4.5 Removing and installing oil temperature

sender - G8-
⇒ “4.5.1 Removing and installing oil temperature sender G8 - ve‐
hicles with 2.9 ltr. engine”, page 203
⇒ “4.5.2 Removing and installing oil temperature sender G8 - ve‐
4.5.1 Removing and installing oil temperature

sender - G8- - vehicles with 2.9 ltr. en‐
gine
Removing
– Remove catalytic converter (left-side) ⇒ 6-cylinder direct in‐


– Unscrew bolt -2- and pull off oil temperature sender - G8- .
Note:
If O-rings remain lodged in cylinder block, lift them out with a piece
of wire.
– Fit new oil temperature sender immediately so that as little oil
as possible is lost.
– Install catalytic converter (left-side) ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ;
converter .
Tightening torques
trol”, page 198
4.5.2 Removing and installing oil temperature

gine
Removing
Audi Q8
gine (3.0 ltr. 4-valve TFSI EA 839); Rep. gr. 24 ; Air cleaner;
All models except Audi Q8
page 10 .


– Unscrew bolt -2- and pull off oil temperature sender - G8- .
Note:
If O-rings remain lodged in cylinder block, lift them out with a piece
of wire.
– Fit new oil temperature sender immediately so that as little oil
as possible is lost.
page 10 .
Tightening torques
trol”, page 198
♦ ⇒ 6-cylinder direct injection engine (3.0 ltr. 4-valve TFSI EA
839); Rep. gr. 24 ; Air cleaner; Exploded view - air cleaner
housing
4.6 Removing and installing oil pressure

sender - G10-
⇒ “4.6.1 Removing and installing oil pressure sender G10 - vehi‐
⇒ “4.6.2 Removing and installing oil pressure sender G10 - vehi‐

gine
♦ Socket, 24 mm - T40363- (not illustrated)
Procedure
gr. 17 ; Oil filter/oil pressure switches ; Removing and installing
oil pressure sender - G10- .
– If not removing oil pressure sender - G10- to measure oil pres‐
sure, remove coolant pipe (front left) ⇒ 6-cylinder direct in‐
– If removing oil pressure sender - G10- to measure oil pressure,
remove radiator with radiator cowl ⇒ 6-cylinder direct injection
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Radiators/
radiator fans; Removing and installing radiator .


– Unscrew oil pressure sender - G10- using socket, 24 mm -
T40363- .
– Fit new oil pressure sender immediately so that as little oil as
possible is lost.
– If removed previously, install radiator ⇒ 6-cylinder direct in‐
Radiators/radiator fans; Removing and installing radiator .
– If removed previously, install coolant pipe (front left) ⇒ 6-cyl‐
gr. 19 ; Coolant pipes; Removing and installing coolant pipes .
pressure switches ; Removing and installing oil pressure sender
- G10-
Tightening torques
trol”, page 198

gine
♦ Socket, 24 mm - T40363- (not illustrated)
Procedure
gr. 17 ; Oil filter/oil pressure switches ; Removing and installing
oil pressure sender - G10- .
– Unscrew oil pressure sender - G10- using socket, 24 mm -
T40363- .
– Fit new oil pressure switch immediately so that as little oil as
possible is lost.
pressure switches ; Removing and installing oil pressure sender
- G10-
Tightening torques
trol”, page 198
4.7 Checking oil pressure


♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure sender - G10-
page 205 .
– Connect oil pressure tester - V.A.G 1342- to opening for oil
pressure sender and tie up test hose so it is clear of vibration
damper.
– Screw oil pressure sender - G10- into oil pressure tester.
– Start engine and leave it running only as long as required for
the test.
– Start engine.
• Minimum oil pressure at idling speed: 0.9 bar.
• Minimum oil pressure at 2000 rpm: 1.3 bar.
Attaching
– Install oil pressure sender - G10-
page 205 .
– Erase any entries in event memory resulting from testing ⇒ Ve‐
hicle diagnostic tester.
4.8 Removing and installing valve for oil

pressure control - N428-
⇒ “4.8.1 Removing and installing valve for oil pressure control
N428 - vehicles with 2.9 ltr. engine”, page 207
⇒ “4.8.2 Removing and installing valve for oil pressure control
N428 - vehicles with 3.0 ltr. engine”, page 208
4.8.1 Removing and installing valve for oil

pressure control - N428- - vehicles with
2.9 ltr. engine
Removing
valve for oil pressure control - N428- .
– If not removed already, remove noise insulation (front) ⇒
General body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Removing and installing noise insulation .

– If not yet removed, remove front left wheel spoiler ⇒ General

body repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Re‐
moving and installing wheel housing liner (front) .
– Unplug electrical connector -2- and move electrical wiring har‐
ness clear.
– Detach valve for oil pressure control - N428- from cylinder
block.
Installing
pressure switches; Removing and installing valve for oil pressure
control - N428-
Tightening torques
trol”, page 198
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
4.8.2 Removing and installing valve for oil

pressure control - N428- - vehicles with
3.0 ltr. engine
Removing
valve for oil pressure control - N428- .
– Unplug electrical connector -2- and move electrical wiring har‐
ness clear.
– Detach valve for oil pressure control - N428- from cylinder
block.
Installing
pressure switches; Removing and installing valve for oil pressure
control - N428-
Tightening torques
trol”, page 198

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 209
⇒ “1.2 Checking cooling system for leaks”, page 209
⇒ “1.3 Draining and filling cooling system”, page 213
1.1 Connection diagram - coolant hoses

gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/
coolant; Connection diagram - coolant hoses .
1.2 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Cooling system tester adapter - V.A.G 1274B/15- for filler cap,

version 1
1. Cooling system/coolant 209

♦ Cooling system tester adapter - V.A.G 1274/9- for filler cap,

version 2
Procedure
• Engine must be warm.
• Ignition switched off.
gr. 19 ; Cooling system/coolant; Checking cooling system for
leaks .
WARNING
The cooling system is under pressure when the power unit is

hot. Risk of scalding due to hot steam and hot coolant.
Danger of scalding skin and other parts of the body.
• Put on protective gloves.
• Put on safety goggles.
• Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
– Release fastener -arrow- and open filler cap -1- on coolant

expansion tank.
210 Rep. gr.19 - Cooling

– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.0 bar.
• The pressure should not drop more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops more than 0.2 bar, locate leak and elim‐
inate fault.
Note:
The drop in pressure of 0.2 bar within 10 minutes is caused by
the decrease in coolant temperature. The colder the engine is,
the less the pressure will fall. If necessary, check again when the
engine is cold.
WARNING
Risk of scalding due to hot steam and hot coolant.

Danger of scalding skin and other parts of the body.
• To release pressure, press pressure relief valve on cool‐
ing system tester until reading on pressure gauge is 0.
Checking pressure relief valve in filler cap, version 1

V.A.G 1274 B/15- onto filler cap.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 2 bar.
Blue filler cap:
• The pressure must be reduced to 1.6 ... 1.4 bar and kept at
this level.
– Renew filler cap if pressure relief valve does not react as de‐
scribed.
Black filler cap:
• The pressure must be reduced to 1.8 ... 1.6 bar and kept at
this level.
scribed.

Checking pressure relief valve in filler cap, version 2

V.A.G 1274/9- onto filler cap.
– Build up pressure with hand pump on cooling system tester.
Blue filler cap:
• The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
scribed.
Black filler cap:
• The pressure relief valve should open at a pressure of
1.6 ... 1.8 bar.
scribed.
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling sys‐
tem/coolant; Checking cooling system for leaks

1.3 Draining and filling cooling system

Coolant specifications
Note
♦ The effectiveness of the coolant is greatly influenced by the

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . If you use other coolant additives, this can
significantly impair in particular the corrosion protection effect.
The resulting damage could lead to loss of coolant and con‐
sequently to serious damage to the power unit.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
♦ Because of its high boiling point, the coolant improves power
unit reliability under heavy loads, particularly in countries with
tropical climates.
♦ Refractometer - T10007A- or refractometer - T10007B- MUST
be used to determine the current level of frost protection.
♦ Scale -1- on the refractometer applies to coolant additives G12
++ and G12evo.
♦ Scale -2- on the refractometer applies to coolant additive G13.
♦ If more than one type of coolant additive has been used: Al‐
ways use the scale for G13 to determine the anti-freeze pro‐
tection.
♦ The mixture must guarantee frost protection down to at least
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ The temperature indicated on the refractometer corresponds
to the temperature at which the first ice crystals can form in
the coolant.
♦ Do not reuse coolant.
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
Draining and filling cooling system

gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/
coolant; Draining and filling cooling system .

2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump/thermostat”, page 214
⇒ “2.2 Exploded view - electric coolant pump”, page 216
⇒ “2.3 Exploded view - coolant temperature senders”,
page 216
⇒ “2.4 Removing and installing electric coolant pump”,
page 217
⇒ “2.5 Removing and installing coolant pump”, page 217
⇒ “2.6 Removing and installing map-controlled engine cooling
system thermostat F265 ”, page 217
⇒ “2.7 Removing and installing coolant temperature sender G62
”, page 220
⇒ “2.8 Removing and installing engine outlet coolant temperature
sender G82 ”, page 222
⇒ “2.9 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 224
⇒ “2.10 Removing and installing temperature sender for engine
temperature regulation G694 ”, page 225
⇒ “2.11 Removing and installing coolant valves”, page 227
2.1 Exploded view - coolant pump/thermostat


1 - Coolant shut-off valve

⇒ “2.11 Removing and
installing coolant
valves”, page 227
2 - Bolt
❑ 9 Nm
3 - Map-controlled engine cool‐
ing system thermostat - F265-
stalling map-controlled
engine cooling system
thermostat F265 ”, page
217
4 - Bolt
❑ 10 Nm +90°
5 - Pulley
6 - Coolant pump
stalling coolant pump”,
page 217
7 - Bolt
sequence
⇒ Fig. ““Coolant pump -
8 - Gasket
9 - Seal
❑ Renew after removing map-controlled engine cooling system thermostat -F265-
10 - O-ring
11 - O-ring
12 - Seal
13 - Bolt
❑ 9 Nm
2. Coolant pump/thermostat assembly 215

Coolant pump - tightening torques and sequence

Stage Bolts Tightening torque
1. -1, 2- 9 Nm
2. -1 … 7- 9 Nm
2.2 Exploded view - electric coolant pump

gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/
thermostat assembly; Exploded view - electric coolant pump .
2.3 Exploded view - coolant temperature senders

1 - O-rings
❑ Renew
2 - Engine outlet coolant tem‐
perature sender - G82-
stalling engine outlet
coolant temperature
sender G82 ”,
page 222
3 - Bolt
❑ 9 Nm
4 - O-rings
❑ Renew
5 - Temperature sender for en‐
gine temperature regulation -
G694-
❑ Black insulation
⇒ “2.10 Removing and
installing temperature
sender for engine tem‐
perature regulation
G694 ”, page 225
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 9 Nm
8 - Coolant temperature send‐
er - G62-
stalling coolant temper‐
ature sender G62 ”, page 220

9 - O-rings
❑ Renew
10 - O-rings
❑ Renew
11 - Radiator outlet coolant temperature sender - G83-
❑ Different installation position depending on model
❑ Removing and installing ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ;
Coolant pump/thermostat assembly; Removing and installing radiator outlet coolant temperature sender
- G83-
12 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by hand so that it is screwed into old thread. Then tighten bolt to torque
❑ 4.5 Nm
2.4 Removing and installing electric coolant

pump
thermostat assembly; Removing and installing electric coolant
pump .
2.5 Removing and installing coolant pump

Removing
– Disconnect vacuum hose -arrow-, taking care not to damage
it.
– Remove bolts -1 ... 7- and detach coolant pump.
Installing
angle.
necessary.
Tightening torques
♦ ⇒ Fig. ““Coolant pump - tightening torques and sequence”“ ,
page 216
2.6 Removing and installing map-controlled

engine cooling system thermostat -
F265-

♦ -VW 771/37- from multi-purpose tool - VW 771- with:
♦ Adapter -T10055/3-
♦ Striker -T10133/3- from tool set for FSI engines - T10133C-
♦ Press tool -T40357- (not illustrated)

♦ Threaded pin M10x20
Preparing tool
– Attach striker -T10133/3- to -VW 771/37- . Use adapter -
T10055/3- and threaded pin -1- to do so.

Removing
– Preparatory work may be necessary depending on model ⇒
6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI);
Rep. gr. 19 ; Coolant pump/thermostat assembly; Removing
and installing map-controlled engine cooling system thermo‐
stat - F265- .
– Remove coolant pipe (front left) ⇒ 6-cylinder direct injection
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
pipes; Removing and installing coolant pipes .
– Detach electrical connector -1- from bracket.
– Detach coolant valve for cylinder block - N545- -item 4- from
bracket and press it to side.
– Unplug electrical connector -2- and move electrical wiring
clear at map-controlled engine cooling system thermostat -
F265- .
– Remove bolts -arrows- and detach -F265- .
– Pull seal -arrow- off using tool prepared previously.
Installing
• Renew seal and O-ring after removing.
– Slide seal -arrow- on using press tool -T40357- and drive it in
as far as stop.
• Open side of oil seal faces engine.
– Install coolant pipe (front left) ⇒ 6-cylinder direct injection en‐
– Additional work depending on model ⇒ 6-cylinder direct in‐
Coolant pump/thermostat assembly; Removing and installing
map-controlled engine cooling system thermostat - F265-
Tightening torques
♦ ⇒ “2.1 Exploded view - coolant pump/thermostat”, page 214

2.7 Removing and installing coolant temper‐

ature sender - G62-
⇒ “2.7.1 Removing and installing coolant temperature sender G62
⇒ “2.7.2 Removing and installing coolant temperature sender G62
2.7.1 Removing and installing coolant temper‐

ature sender - G62- - vehicles with 2.9
ltr. engine
Procedure
gr. 19 ; Coolant pump/thermostat assembly; Removing and in‐
stalling coolant temperature sender - G62- .
• Engine cold.
– To relieve residual pressure in cooling system, release fas‐
tener -arrow- and briefly open filler cap -1- on coolant expan‐
sion tank.
– Close filler cap again (make sure it engages).
page 10 .


– Place a cloth underneath to catch escaping coolant.
– Unscrew bolt -1- and pull off coolant temperature sender -
G62- .
Note:
If an O-ring remains lodged in cylinder block, lift out O-ring with a
piece of wire.
– Fit new coolant temperature sender immediately so that as
little coolant as possible is lost.
page 10 .
– Fill up coolant ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/
thermostat assembly; Removing and installing coolant tempera‐
ture sender - G62-
Tightening torques
♦ ⇒ “2.3 Exploded view - coolant temperature senders”,
page 216
2.7.2 Removing and installing coolant temper‐

ature sender - G62- - vehicles with 3.0
ltr. engine
Procedure
stalling coolant temperature sender - G62- .
• Engine cold.
sion tank.
– Depending on model, remove engine cover panel
page 10 .


– Unscrew bolt -1- and pull off coolant temperature sender -
G62- .
Note:
piece of wire.
– Depending on model, install engine cover panel
page 10 .
thermostat assembly; Removing and installing coolant tempera‐
ture sender - G62-
Tightening torques
page 216
2.8 Removing and installing engine outlet

coolant temperature sender - G82-
⇒ “2.8.1 Removing and installing engine outlet coolant tempera‐
ture sender G82 - vehicles with 2.9 ltr. engine”, page 222
⇒ “2.8.2 Removing and installing engine outlet coolant tempera‐
ture sender G82 - vehicles with 3.0 ltr. engine”, page 223
2.8.1 Removing and installing engine outlet

coolant temperature sender - G82- - ve‐
♦ Flat-nose pliers, straight and long version (commercially avail‐

able)
♦ Flat-nose pliers, angled (45°) and long version (commercially
available)

Procedure
– Drain coolant ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
page 10 .
– Remove bolts -1, 2-, detach coolant pipes from turbochargers
and press to one side.

– Move crankcase breather hose -2- clear and press bracket
-1- to one side.

– Detach engine outlet coolant temperature sender - G82- and
unplug electrical connector -2- using flat-nose pliers.
– Fit coolant temperature sender using flat-nose pliers.
– Install large coolant pipe (rear right) ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
page 10 .
Tightening torques
page 216
2.8.2 Removing and installing engine outlet

coolant temperature sender - G82- - ve‐
Procedure

gr. 19 ; Coolant pump/thermostat assembly ; Removing and in‐

stalling engine outlet coolant temperature sender - G82- .
• Engine cold.
sion tank.
page 10 .

– Unscrew bolt -2- and pull off engine outlet coolant temperature
sender - G82- .
Note:
piece of wire.
page 10 .
thermostat assembly; Removing and installing engine outlet cool‐
ant temperature sender - G82-
Tightening torques
page 216
2.9 Removing and installing radiator outlet

coolant temperature sender - G83-
thermostat assembly; Removing and installing radiator outlet
coolant temperature sender - G83- .

2.10 Removing and installing temperature

sender for engine temperature regula‐
tion - G694-
⇒ “2.10.1 Removing and installing temperature sender for engine
temperature regulation G694 - vehicles with 2.9 ltr. engine”, page
225
⇒ “2.10.2 Removing and installing temperature sender for engine
temperature regulation G694 - vehicles with 3.0 ltr. engine”, page
226
2.10.1 Removing and installing temperature

tion - G694- - vehicles with 2.9 ltr. engine
♦ Flat-nose pliers, straight and long version (commercially avail‐

able)
♦ Flat-nose pliers, angled (45°) and long version (commercially
available)
Procedure
– Drain coolant ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
page 10 .
– Remove bolts -1, 2-, detach coolant pipes from turbochargers
and press to one side.


– Detach temperature sender for engine temperature regulation
- G694- and unplug electrical connector -1- using flat-nose pli‐
ers.
– Fit coolant temperature sender using flat-nose pliers.
– Install large coolant pipe (rear right) ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
page 10 .
Tightening torques
2.10.2 Removing and installing temperature

tion - G694- - vehicles with 3.0 ltr. engine
Procedure
stalling temperature sender for engine temperature regulation -
G694- .
• Engine cold.
sion tank.
– Remove oil filter housing ⇒ page 199 .


– Unscrew bolt -2- and detach temperature sender for engine
temperature regulation - G694- .
– Install oil filter housing
⇒ “4.3 Removing and installing oil filter housing”, page 199 .
thermostat assembly; Removing and installing temperature send‐
er for engine temperature regulation - G694-
Tightening torques
2.11 Removing and installing coolant valves

⇒ “2.11.1 Removing and installing coolant shut-off valve - vehicles
⇒ “2.11.2 Removing and installing coolant shut-off valve - vehicles
2.11.1 Removing and installing coolant shut-off

valve - vehicles with 2.9 ltr. engine
Removing
– Remove air pipe (bottom) ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;
– If necessary, remove coolant pipe (front) ⇒ 6-cylinder direct

– Unscrew bolts -arrows- and detach coolant shut-off valve -2-.

– Being careful not to damage it, detach vacuum hose -1-.
Installing
• Renew O-ring and seal after removal.
necessary.
– Install coolant pipe (front) ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pipes;
– Install air pipe (bottom) ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;
Tightening torques
2.11.2 Removing and installing coolant shut-off

valve - vehicles with 3.0 ltr. engine
Removing
stalling coolant valves .
– Unscrew bolts -arrows- and detach coolant shut-off valve -2-.
Installing
• Renew O-ring and seal after removal.
necessary.
– Install coolant pipe (front) ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pipes;
thermostat assembly; Removing and installing coolant valves
Tightening torques

3 Coolant pipes
Coolant pipes .
3. Coolant pipes 229

4 Radiators/radiator fans
Radiators/radiator fans .

21 – Turbocharging/supercharging
1 Turbochargers
⇒ “1.1 Exploded view - turbocharger”, page 231
⇒ “1.2 Removing and installing turbocharger”, page 238
⇒ “1.3 Renewing vacuum unit for turbocharger”, page 246
1.1 Exploded view - turbocharger

⇒ “1.1.1 Exploded view - turbocharger, vehicles with 2.9 ltr. en‐
gine”, page 231
⇒ “1.1.2 Exploded view - turbocharger, vehicles with 3.0 ltr. en‐
gine”, page 234
1.1.1 Exploded view - turbocharger, vehicles with 2.9 ltr. engine

Part I
Part II ⇒ page 232
1 - Bolt
❑ 9 Nm
2 - Overrun air recirculation
valve
♦ Overrun air recirculation
valve for bank 1 - N625-
♦ Overrun air recirculation
installing overrun air re‐
circulation valve - vehi‐
page 277
3 - O-ring
4 - O-ring
5 - Connection
❑ For activated charcoal
filter system
6 - Bolt
❑ 9 Nm
7 - Coolant pipe (rear right)
❑ Exploded view ⇒ 6-cyl‐
inder direct injection en‐
gine (2.9 ltr., 3.0 ltr. 4-
valve TFSI); Rep. gr.
19 ; Coolant pipes; Ex‐
ploded view - coolant
pipes
8 - Bolt
❑ Tightening torque ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
pipes; Exploded view - coolant pipes
1. Turbochargers 231
9 - O-ring
❑ Fitting instructions ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
pipes; Exploded view - coolant pipes
11 - Bolt
❑ 9 Nm
12 - O-ring
13 - Turbocharger
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 238
14 - Bolt
❑ 9 Nm
15 - Coolant return line
16 - Bolt
❑ 9 Nm
17 - O-ring
18 - O-ring
19 - O-ring
❑ Green
20 - Venturi nozzle
❑ Press in until it engages
21 - O-ring
❑ Red
22 - Seal
23 - Plug
❑ 25 Nm
Part II
Part I ⇒ page 231
232 Rep. gr.21 - Turbocharging/supercharging

1 - Oil return line

2 - Clip
3 - Bottom air pipe
❑ Exploded view
⇒ “2.1.1 Exploded view
- charge air system (en‐
gine end), vehicles with
2.9 ltr. engine”,
page 259
4 - Bolt
5 - Gaskets
6 - Air pipe
7 - Bolt
❑ 9 Nm
8 - Vacuum unit
❑ For turbocharger
❑ Different versions. Re‐
pair kit ⇒ Electronic
parts catalogue
⇒ “1.3 Renewing vac‐
uum unit for turbocharg‐
er”, page 246
9 - Nut
❑ 8 Nm
10 - Threaded piece
11 - Retaining clip
12 - Ball socket
13 - Nut
❑ 8 Nm
14 - Nut
❑ 9 Nm
15 - Turbocharger
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 238
16 - Nut
❑ Tightening torques:
♦ 1st stage: 15 Nm
♦ 2nd stage: 30 Nm
♦ 3rd stage: After finishing work, tighten nuts to 30 Nm
17 - Nut
❑ 30 Nm
18 - Tensioner
19 - Gasket
20 - Stud
❑ Renew
❑ 15 Nm
1.1.2 Exploded view - turbocharger, vehicles with 3.0 ltr. engine

Part I
Part III ⇒ page 237
1 - Connecting pipe
❑ For activated charcoal
filter system
2 - O-ring
3 - Turbocharger
stalling turbocharger”,
page 238
4 - O-ring
❑ Lubricate with coolant
5 - Coolant supply line
6 - Bolt
❑ 9 Nm
7 - O-ring
8 - Overrun air recirculation
installing overrun air re‐
circulation valve - vehi‐
page 278
9 - Bolt
❑ 9 Nm
10 - Bolt
11 - Bolt
❑ 9 Nm
13 - O-ring


14 - O-ring
15 - Bolt
❑ 9 Nm
16 - Coolant return line
17 - Bolt
❑ 9 Nm
18 - O-ring
19 - O-ring
20 - Bolt
❑ 9 Nm
21 - Venturi nozzle
❑ Press in until it engages
22 - Plug
❑ 25 Nm
23 - Seal
24 - O-ring
❑ Red
25 - O-ring
❑ Green
Part II
Part I ⇒ page 234
Part III ⇒ page 237
1 - Nut
❑ If loosened, renew stud
❑ 30 Nm
2 - Tensioner
3 - Gasket
4 - Stud
❑ Renew if nut
has been loosened
❑ 15 Nm
5 - Tensioner
6 - Nut
❑ If loosened, renew stud
❑ 30 Nm
7 - Oil return line
8 - Clip
9 - Air pipe
10 - Bolt
11 - Seal
12 - Air pipe
13 - Bolt
14 - Seal
15 - Nut
16 - Turbocharger
⇒ “1.2.4 Removing and installing turbocharger - vehicles with 3.0 ltr. engine”, page 242
17 - Screw-type clip
❑ 20 Nm
18 - Gasket

19 - Flexible joint (decoupling element)

❑ If a new turbocharger is fitted, also renew flexible joint
20 - Nut
21 - Gasket
22 - Stud
❑ Renew if nut ⇒ Item 20 (page 237) has been loosened
❑ 15 Nm
Part III
Part I ⇒ page 234
1 - Bolt
❑ 9 Nm
2 - Bracket
❑ For vacuum unit
3 - Turbocharger
installing turbocharger -
vehicles with 3.0 ltr. en‐
gine”, page 242
4 - Nut
❑ 9 Nm
5 - Retaining clip
6 - Ball socket
7 - Nut
❑ 8 Nm
8 - Threaded piece
9 - Nut
❑ 8 Nm
10 - Vacuum unit
❑ Repair kit ⇒ Electronic
parts catalogue
⇒ “1.3 Renewing vac‐
uum unit for turbocharg‐
er”, page 246
Temperature sender for engine cover panel - G765- - tightening

torque
– Tighten bolt -1- to 9 Nm.
1.2 Removing and installing turbocharger

⇒ “1.2.1 Removing turbocharger, cylinder bank 1 (right-side) -
vehicles with 2.9 ltr. engine”, page 238
⇒ “1.2.2 Removing turbocharger, cylinder bank 2 (left-side) - ve‐
⇒ “1.2.3 Installing turbocharger - vehicles with 2.9 ltr. engine”,
page 241
⇒ “1.2.4 Removing and installing turbocharger - vehicles with 3.0
1.2.1 Removing turbocharger, cylinder bank 1

(right-side) - vehicles with 2.9 ltr. engine
If the turbocharger has suffered mechanical damage
⇒ page 242
Removing
– Observe rules for cleanliness
⇒ “3.1 Rules for cleanliness”, page 6 .
gr. 21 ; Turbochargers; Removing and installing turbochargers .

– Unscrew bolts -arrows-, disconnect hose -1- for activated

charcoal filter system from turbochargers and move it to one
side.
– Loosen screw-type clip -1- and press catalytic converter slight‐

ly towards rear.
– Unplug electrical connector -2- for Lambda probe - G39- and

move wiring clear.
– Unscrew bolts -left arrows- and detach air pipe slightly.
– Unscrew bolts -arrows- and disconnect oil line and coolant

line.
– Unplug electrical connector -4- for overrun air recirculation
valve for bank 1 - N625- .
– Remove nuts -2- and detach turbocharger -3-.
Installing
page 241
1.2.2 Removing turbocharger, cylinder bank 2

(left-side) - vehicles with 2.9 ltr. engine
If the turbocharger has suffered mechanical damage
⇒ page 242
Removing
– Unscrew bolts -arrows-, disconnect hose -1- for activated
charcoal filter system from turbochargers and move it to one
side.


ly towards rear.
– Unplug electrical connector -2- for Lambda probe 2 - G108-

and move wiring clear.
– Unscrew bolts -arrows- and detach air pipe slightly.
– Unscrew bolts -arrows- and disconnect oil line and coolant

line.
– Remove nuts -2- and detach turbocharger -1-.
Installing
page 241
1.2.3 Installing turbocharger - vehicles with

2.9 ltr. engine
Installing
• Renew screw-type clip and oil return line after removing.
• Renew gaskets, seals, O-rings and self-locking nuts after re‐

moval.
• Renew studs.
• Fill turbocharger with engine oil at connection for oil supply
line.
necessary.
– Install catalytic converter ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Emission control
system; Removing and installing catalytic converter .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Turbochargers;
Removing and installing turbochargers
– Tighten nuts ⇒ Item 16 (page 233) and
⇒ Item 17 (page 233) . This step is necessary to compensate
for the settling of the turbocharger connection.
• After installing turbocharger, allow engine to idle for approx. 1
minute and do not rev up immediately to ensure turbocharger
is supplied with oil.
Tightening torques
♦ ⇒ “1.1.1 Exploded view - turbocharger, vehicles with 2.9 ltr.
engine”, page 231
1.2.4 Removing and installing turbocharger -

If the turbocharger has suffered mechanical damage (e.g. dam‐
aged compressor wheel), it is not sufficient merely to fit a new
turbocharger. The following work must be performed in order to
avoid further damage:
• Check air cleaner housing, air filter element and air hoses for
dirt and foreign particles.
• Check the entire charge air system (including the charge air
cooler) for foreign matter.
• If foreign matter is found in the charge air system, clean all
relevant ducts and hoses and renew charge air cooler if nec‐
essary.
Removing

– Unplug electrical connector -2- for Lambda probe - G39- , re‐

move from bracket and move electrical wire clear.
– Unscrew bolts -arrows- and detach coolant lines -2, 4- and oil
supply line -3-.
– If fitted, disconnect hose -5- for activated charcoal filter system
by pressing release tabs on both sides.
– Remove nuts -3-.

– Remove studs -arrows-.

ly towards rear.
– Unscrew nuts -arrows- and studs and lift out turbocharger
-1-.
– Detach retaining clip -arrow- and remove oil return line -1-.
Installing
• Renew screw-type clip and oil return line after removing.
• If fitting a new turbocharger, renew flexible joint and screw-
type clip.
• Renew gaskets, seals, O-rings and self-locking nuts after re‐
moval.
• Renew studs.
• Fill turbocharger with engine oil at connection for oil supply
line.
necessary.
If turbocharger was renewed:

– Fit new flexible joint -1- on turbocharger -3- using a new screw-
type clip -2-, as shown in illustration.
– Tighten screw-type clip -2- far enough for flexible joint to still
be able to move at turbocharger flange.

– Move oil return line -1- into installation position and secure it
with retaining clip -arrow-.
– Move turbocharger into installation position while guiding oil
return line to cylinder block.
– Tighten studs and nuts -arrows-.

– Fit and tighten studs -arrows-.

– Tighten nuts -3-.
If turbocharger was renewed:

– Press flexible joint in direction of -arrow- by hand while tight‐
ening screw-type clip.
• Pressure must be applied at right angle -arrow- to flexible joint.
– When tightening, ensure that flange contour of flexible joint

-1- is positioned flush with contour on turbine housing of tur‐
bocharger.
Note
It is possible to check the correct installation -arrow- of the flexible

joint -1- by examining the screw-type clip from above.
The remaining installation steps are carried out in the reverse se‐
quence.
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Turbochargers;
Removing and installing turbochargers
– Tighten nuts ⇒ Item 15 (page 236) and
⇒ Item 20 (page 237) . This step is necessary to compensate
for the settling of the turbocharger connection.
page 10 .
• After installing turbocharger, allow engine to idle for approx. 1
minute and do not rev up immediately to ensure turbocharger
is supplied with oil.
Tightening torques
engine”, page 234
♦ ⇒ “2.2 Exploded view - hose connections for charge air sys‐
tem”, page 269
1.3 Renewing vacuum unit for turbocharger

⇒ “1.3.1 Renewing vacuum unit for turbocharger, cylinder bank 1
(right-side) - vehicles with 2.9 ltr. engine”, page 246
⇒ “1.3.2 Renewing vacuum unit for turbocharger, cylinder bank 2
(left-side) - vehicles with 2.9 ltr. engine”, page 250
⇒ “1.3.3 Renewing vacuum unit for turbocharger - vehicles with
1.3.1 Renewing vacuum unit for turbocharger,

cylinder bank 1 (right-side) - vehicles
A repair kit is available to renew the vacuum unit ⇒ Electronic
parts catalogue (ETKA) .

♦ Pressure sensor - V.A.G 1397B- (not illustrated)

♦ Hand vacuum pump - VAS 6213-
♦ Dial gauge set, 4-part - VAS 6341-
♦ Pressure control valve - VAS 6342-
♦ Small mole grips, long version (commercially available)
Removing
page 10 .
– Detach vacuum hose -4- from vacuum unit, making sure not
to damage it.
– Unplug electrical connector -3- for turbocharger air recircula‐
tion valve - N249- , move electrical wiring harness clear and
press it to one side.
– Remove retaining clip -1- and detach control rod from actuat‐
ing lever of turbocharger.
– Remove nuts -arrows- and detach vacuum unit -2-.
– If vacuum unit cannot be removed as described, remove over‐
run air recirculation valve for bank 1 - N625-
⇒ “2.8.1 Removing and installing overrun air recirculation
valve - vehicles with 2.9 ltr. engine”, page 277 .
Installing
– Install vacuum unit -2- with adjustable control rod on turbo‐
charger.
– To do so, tighten nuts -arrows- and press ball socket -1- onto
ball stud of operating lever.
– Adjust control rod on threaded collar so that operating lever

-1- makes contact at stop -2-.
– From this position, turn threaded collar -2- 1.5 turns anti-clock‐
wise.
• This will increase the length of the control rod.
– Tighten lock nuts -1, 3-.

– Clamp small vice-grip pliers -1- on ball socket shaft -2-. The
vice-grip pliers serve as a stop for the dial gauge.
– Secure universal dial gauge bracket - VW 387- to engine lifting

eye -2-.
– Align dial gauge, 0-30 mm - VAS 6341/1- in universal dial
gauge bracket - VW 387- so that measurement button is as
parallel as possible with control rod of vacuum unit. To do so,
have measurement button make contact with vice-grip pliers
-1-.
– With 20 mm preload, set dial gauge to “0”.
– Set up measuring equipment and testers as shown and con‐

nect to pressure sensor - V.A.G 1397B- and to vacuum unit
for turbocharger.
– Close lever -1- on pressure control valve - VAS 6342- .
– Move adjuster ring -1- on hand vacuum pump - VAS 6213- to

position -A- to select “vacuum”.
– Switch on pressure sensor - V.A.G 1397B- .
– Generate a vacuum of -300 mbar using hand vacuum pump -
VAS 6213- .
– Open testing valve and slowly reduce vacuum pressure:
• The operating rod should start to move at a pressure of -200
mbar at the latest.
• At 230 … 170 mbar, travel of 7 … 9 mm should be shown on
dial gauge.
dial gauge.
– If necessary, loosen lock nuts -1, 3- and adjust threaded collar

-2-.
– Repeat test.
– Tighten lock nuts.
• The ball socket must be parallel to the operating lever.

necessary.
– Remove measuring equipment and connect vacuum hose to
vacuum unit.
page 10 .
1.3.2 Renewing vacuum unit for turbocharger,

cylinder bank 2 (left-side) - vehicles with
2.9 ltr. engine

♦ Small mole grips, long version (commercially available)

Removing
page 10 .
– Press release tabs on both sides and detach hose -arrow- for
activated charcoal filter system.
to damage it.
ing lever of turbocharger.
– Remove nuts -arrows- and detach vacuum unit -2-.
Installing
– Install vacuum unit -2- with adjustable control rod on turbo‐
charger.
– To do so, tighten nuts -arrows- and press ball socket -1- onto
ball stud of operating lever.

wise.


eye -2-.
-1-.

for turbocharger.

VAS 6213- .
mbar at the latest.
dial gauge.
dial gauge.

-2-.
– Repeat test.

necessary.
vacuum unit.
page 10 .
1.3.3 Renewing vacuum unit for turbocharger


♦ Small vice-grip pliers (commercially available)

Removing
page 10 .
to damage it.
ing lever -4- of turbocharger.
– Remove nuts -2, 5- and detach vacuum unit.
Installing
– Install vacuum unit with adjustable control rod on turbocharg‐
er.
– To do so, tighten nuts -1, 2- and press ball socket -3- onto ball
stud of operating lever.

wise.


eye -2-.
-1-.

for turbocharger.

VAS 6213- .
mbar at the latest.
dial gauge.
dial gauge.

-2-.
– Repeat test.

necessary.
vacuum unit.
page 10 .
1.4 Removing and installing temperature

sender for engine cover panel - G765-
cylinder direct injection engine (3.0 ltr. 4-valve TFSI EA 839); Rep.
gr. 21 ; Turbochargers; Exploded view - turbochargers , Remov‐
ing and installing temperature sender for engine cover panel -
G765- .
Removing
page 10 .
– Unscrew bolt -1- and detach temperature sender for engine
cover panel - G765- .
Installing
engine (3.0 ltr. 4-valve TFSI EA 839); Rep. gr. 21 ; Turbocharg‐
ers; Exploded view - turbochargers , Temperature sender for
engine cover panel - G765- .
page 10 .
Tightening torques
♦ ⇒ Fig. ““ Temperature sender for engine cover panel -G765- -
tightening torque”“ , page 238

2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 259
⇒ “2.2 Exploded view - hose connections for charge air system”,
page 269
⇒ “2.3 Removing and installing air pipe”, page 270
⇒ “2.5 Removing and installing charge air cooler”, page 276
⇒ “2.6 Removing and installing charge pressure sender G31 ”,
page 276
⇒ “2.7 Removing and installing charge air temperature sender”,
page 276
⇒ “2.8 Removing and installing overrun air recirculation valve”,
page 277
⇒ “2.9 Checking charge air system for leaks”, page 279
2.1 Exploded view - charge air system

⇒ “2.1.1 Exploded view - charge air system (engine end), vehicles
with 3.0 ltr. engine (version 1)”, page 263
with 3.0 ltr. engine (version 2)”, page 266
⇒ “2.1.4 Exploded view - charge air system (body end)”,
page 269
2.1.1 Exploded view - charge air system (engine end), vehicles with 2.9 ltr. engine
2. Charge air system 259

1 - O-ring
2 - Intake air temperature
sender - G42- / intake manifold
pressure sender - G71-
stalling intake air tem‐
perature sender G42 /
intake manifold pres‐
sure sender G71 ”, page
304
3 - Bolt
❑ 5 Nm
4 - Air pipe (top)
⇒ 6-cylinder direct in‐
jection engine (2.9 ltr.,
3.0 ltr. 4-valve TFSI);
Rep. gr. 21 ; Charge air
system; Removing and
installing air pipe
5 - Bolt/nut
❑ Tightening torque:
♦ Bolt, 9 Nm
♦ Nut, 20 Nm
6 - Bracket
❑ For air pipe (bottom)
❑ Different versions
7 - Bolt
❑ 9 Nm
8 - Washer
9 - Grommet
10 - Air hose
11 - Air hose
12 - Bottom air pipe
Charge air system; Removing and installing air pipe
13 - Bolt
❑ 9 Nm
14 - O-ring
❑ 2.9 ltr. engine with electric compressor only
15 - Charge pressure sender 2 - G447-
Charge air system ; Removing and installing charge pressure sender 2 - G447-
16 - Bolt
❑ 9 Nm

17 - Seal
18 - Temperature sender 1 for charge air cooler - G763-
❑ Removing and installing ⇒ “2.7 Removing and installing charge air temperature sender”, page 276
❑ 22 Nm
19 - Gasket
20 - Intake manifold
⇒ “2.4.1 Removing and installing intake manifold - vehicles with 2.9 ltr. engine”, page 271
21 - Bolt
❑ 9 Nm
22 - Gasket
23 - Turbocharger
❑ Cylinder bank 1 (right-side)
❑ Exploded view ⇒ “1.1.1 Exploded view - turbocharger, vehicles with 2.9 ltr. engine”, page 231
24 - Turbocharger
❑ Cylinder bank 2 (left-side)
25 - Intake manifold with crankcase breather hose
❑ Depending on the version of the replacement intake manifold supplied, the retaining tab for the retaining
clip on the electrical wiring harness may be located in a different position on the new intake manifold. In
this case, the retaining clip on the electrical wiring harness must be repositioned
❑ Removing and installing ⇒ “2.4 Removing and installing intake manifold”, page 271
❑ Crankcase breather hose is connected to intake manifold and cannot be separated; observe notes:
♦ Crankcase breather hose on intake manifold - rest-of-world vehicles ⇒ page 262
♦ Crankcase breather hose on intake manifold - USA vehicles ⇒ page 263
26 - Gasket
27 - Bolt
❑ 9 Nm
28 - Gasket
29 - Temperature sender 2 for charge air cooler - G764-
❑ Removing and installing ⇒ “2.7 Removing and installing charge air temperature sender”, page 276
❑ 22 Nm
30 - Seal
31 - Bolt
❑ 9 Nm
❑ Different versions

33 - Spacer sleeve
34 - Throttle valve module - J338-
Intake manifold; Removing and installing throttle valve module - J338-
❑ Cleaning ⇒ “4.4 Cleaning throttle valve module”, page 290
35 - Seal
36 - Connection
37 - Bolt
❑ Thread-forming
⇒ Fig. ““ Throttle valve module -J338- - tightening torques and sequence”“ , page 266
❑ Exploded view ⇒ “4.1 Exploded view - intake manifold”, page 287
39 - Seal
40 - Bolt
❑ Thread-forming
❑ Tightening torques and sequence ⇒ Fig. ““Top air pipe - tightening torques and sequence”“ , page 266
41 - Seal
42 - Bolt
Crankcase breather hose on intake manifold - rest-of-world vehi‐

cles
Crankcase breather hose -2- cannot be detached from intake
manifold -1- without being irreparably damaged.
• Renew crankcase breather hose.
• When installing, ensure plug-in connector engages audibly
and that it is not seated at an angle on connection for intake
manifold -1-.

Crankcase breather hose on intake manifold - USA vehicles
Caution
Risk of violating emission legislation applying to USA vehicles.

♦ Do not disconnect crankcase breather hose -2-.
On USA vehicles, the crankcase breather hose -2- must not be

separated from the intake manifold -1-.
• The crankcase breather hose -2- supplied via the ⇒ Electronic
parts catalogue (ETKA) is only available together with the in‐
take manifold -1-.
(version 1)
1 - Bolt
sequence
⇒ Fig. ““Top air pipe -
2 - Air pipe (top)
⇒ 6-cylinder direct in‐
jection engine (2.9 ltr.,
3.0 ltr. 4-valve TFSI);
Rep. gr. 21 ; Charge air
system; Removing and
installing air pipe
3 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by
hand so that it is
screwed into old thread.
Then tighten bolt to tor‐
que
sequence
4 - Bolt
❑ 5 Nm
5 - Bolt
❑ For model variant
❑ 8 Nm
6 - Connection
❑ Model variant
7 - Seal
❑ For model variant
8 - Air pipe
❑ Different versions available; for allocation refer to ⇒ Electronic parts catalogue

9 - Bolt
❑ 9 Nm
10 - Seal
❑ Removing and installing ⇒ “2.4 Removing and installing intake manifold”, page 271
12 - Bolt
❑ 9 Nm
13 - Seal
14 - Turbocharger
15 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
⇒ “6.5 Removing and installing intake air temperature sender G42 / intake manifold pressure sender G71
”, page 304
16 - O-ring
18 - Seal
19 - Connection
20 - Bolt
❑ Thread-forming
♦ 1st stage: 5 Nm
♦ 2nd stage: 6 Nm
21 - Seal
23 - Seal
24 - Bolt
❑ Thread-forming


cles
manifold -1-.
Caution


take manifold -1-.
Checking O-rings for damage

– Check O-rings for damage and renew if necessary.
1- O-ring (black)
2- O-ring (blue)
3- Crankcase breather hose
5- Hose for activated charcoal filter system
6- O-ring (black)
7- O-ring (orange)
9- Vacuum hose

Top air pipe - tightening torques and sequence

Stage Bolts Procedure/tightening torques
1. Bring air pipe into installation position
2a. -1 … 7- • Air pipe to used intake manifolds:
Fit and screw in by hand so that bolts
make contact and are screwed into old
thread
2b. -1 … 3- • Air pipe to new intake manifolds:
Fit and screw in by hand until contact is
made
3. -2 … 7- 6 Nm
4. -1- 9 Nm
Throttle valve module - J338- - tightening torques and sequence

– Tighten bolts in stages:
1. Move throttle valve module - J338- with
connection into installation position
2. -arrows- Fit and screw in by hand in diagonal se‐
quence so that bolts make contact and are
screwed into old thread
(version 2)

1 - Air pipe
2 - Bolt
❑ Thread-forming
hand so that it is
que
sequence
3 - Bolt
❑ Thread-forming
hand so that it is
que
sequence
4 - O-ring
5 - Charge pressure sender -
G31-
stalling charge pressure
sender G31 ”,
page 276
6 - Bolt
❑ 5 Nm
7 - Bolt
❑ Thread-forming
8 - Air pipe (top)
9 - Bolt
11 - Bolt
❑ 9 Nm
12 - Seal


⇒ “2.4.3 Removing and installing intake manifold - Audi A8 with 3.0 ltr. engine”, page 275
14 - Bolt
❑ 9 Nm
15 - Seal
16 - Turbocharger
17 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
⇒ “6.5 Removing and installing intake air temperature sender G42 / intake manifold pressure sender G71
”, page 304
18 - Bolt
❑ 5 Nm
19 - O-ring
21 - Seal
22 - Bolt
❑ Thread-forming
23 - Seal
25 - Seal

cles
manifold -1-.

Caution


take manifold -1-.
Top air pipe - tightening torques and sequence

1. Bring air pipe into installation position
2 -1- Fit and screw in by hand until contact is
made
3 -2 … 7- Fit and screw in by hand so that bolts
thread
4. -1- 9 Nm
5. -2 … 7- 5 Nm
Throttle valve module - J338- - tightening torques and sequence

– Tighten bolts in stages:
1. Move throttle valve module - J338- with air
pipe into installation position
2. -1 … 5- Fit and screw in by hand so that bolts
thread
3. -2 … 5- 5 Nm
4. -1- 5 Nm
2.1.4 Exploded view - charge air system (body

end)
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air
system; Exploded view - charge air system .
2.2 Exploded view - hose connections for

charge air system
• Hose connections and air pipes/hoses must be free of oil and
grease prior to fitting.
• If using used hose clips to secure the air hoses at their con‐
nections, spray rust remover onto the worm threads before
installing.

Hose clips on pressure side are fitted with retaining hooks

-arrows-.
• To disconnect air hose, hose clip must be loosened far
enough.
• Hose clips which have been loosened can be re-used.
• Hose clip -1- with retaining hooks -arrows- must not be pulled
off air hose.
• If a hose clip with retaining hooks is pulled off air hose, air hose
must be renewed.
• New air hoses are supplied with hose clip fitted.
Tightening torques for:

1- Hose clip with width -a- = 12 mm: 5 Nm
2- Hose clip with width -b- = 9 mm: 3.4 Nm
Air hoses to air pipes/charge air cooler - installation position and

tightening torque
• Markings on air hose must be aligned opposite edge of hous‐
ing and notch on air pipe/charge air cooler -arrows-.
– Tighten hose clips to 5 Nm.
2.3 Removing and installing air pipe

system; Removing and installing air pipe .

2.4 Removing and installing intake manifold

⇒ “2.4.1 Removing and installing intake manifold - vehicles with
⇒ “2.4.2 Removing and installing intake manifold - Audi A4/A5/
A6/A7/Q5 with 3.0 ltr. engine”, page 273
⇒ “2.4.3 Removing and installing intake manifold - Audi A8 with
2.4.1 Removing and installing intake manifold

Note
Crankcase breather hose is connected to intake manifold and

cannot be separated; observe notes ⇒ Item 25 (page 261) .

Removing
– Observe repair instructions ⇒ “3 Repair instructions”, page 6 .
– Remove engine cover panel
page 10 .
Audi A4/A5, Q5:
– Release hose clip -right arrow- and detach air hose -1-.

Audi A6/A7:
– Remove bolts -arrows-. Detach air duct -1-.
– Release hose clip -right arrow- and detach air hose -1-.
All vehicles:
– Unplug electrical connectors and move electrical wiring har‐
ness clear:
1- For temperature sender 2 for charge air cooler - G764-

breather hose -2-.
– Move intake manifold -1- clear.


breather hose -arrows-.
– Detach intake manifold.
Installing
• Check O-rings for damage
⇒ Fig. ““Checking O-rings for damage”“ , page 265 .
page 10 .
Tightening torques
♦ ⇒ “2.1.1 Exploded view - charge air system (engine end), ve‐
tem”, page 269

- Audi A4/A5/A6/A7/Q5 with 3.0 ltr. en‐
gine
Note


Removing
page 10 .
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front) .

Audi A4/A5:
– Remove bolts -arrows- and detach air duct -2-.
Audi A6/A7:
– Unscrew bolts -arrows- and remove air duct.
Audi Q5:
– Remove bolts -arrows- and detach air duct -1-.
All vehicles:
– Release hose clip -2- and detach air pipe.
– Move electrical wiring harness -3- clear.
– Detach intake manifold and remove crankcase breather hose
-1-. To do so, press release tabs on both sides.


breather hose -arrow-.
Installing
Tightening torques
hicles with 3.0 ltr. engine (version 1)”, page 263
tem”, page 269

- Audi A8 with 3.0 ltr. engine
Note


Removing
page 10 .

– Release hose clip -1- and detach air pipe.

– Move electrical wiring harness -3- clear.
breather hose -4-.
– Remove bolts -arrows- and move intake manifold -2- clear.

breather hose -arrow-.
Installing
Tightening torques
hicles with 3.0 ltr. engine (version 2)”, page 266
tem”, page 269
2.5 Removing and installing charge air cool‐

er
system; Removing and installing charge air cooler .
2.6 Removing and installing charge pres‐

sure sender - G31-
system; Removing and installing charge pressure sender - G31- .
2.7 Removing and installing charge air tem‐

perature sender
Procedure applies for vehicles with 2.9 ltr. engine only.
Removing
page 10 .

– Unplug corresponding electrical connector:

– Unscrew charge air temperature sender.
Installing
Installation is carried out in reverse sequence.
page 10 .
Tightening torques
2.8 Removing and installing overrun air re‐

circulation valve
⇒ “2.8.1 Removing and installing overrun air recirculation valve -
⇒ “2.8.2 Removing and installing overrun air recirculation valve -
2.8.1 Removing and installing overrun air re‐

circulation valve - vehicles with 2.9 ltr.
engine
Removing
gr. 21 ; Charge air system; Removing and installing overrun air
circulation valve .
– Remove oil filter element ⇒ page 175 and cover opening with
a clean cloth.
– Unplug electrical connectors and move electrical wiring har‐
ness clear:


breather hose -2-.
– Move air pipe -1- to one side.

– Remove bolts -arrows- and detach overrun air recirculation
valve for bank 1 - N625- -item 2-.

Installing
– Install oil filter element ⇒ page 175 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air
system; Removing and installing overrun air circulation valve
Tightening torques
engine”, page 231
2.8.2 Removing and installing overrun air re‐

circulation valve - vehicles with 3.0 ltr.
engine
Removing
page 10 .


Installing
page 10 .
Tightening torques
engine”, page 234
2.9 Checking charge air system for leaks

♦ Ultrasonic tester - V.A.G 1842- (not illustrated)
♦ Leak detection spray (commercially available)
Procedure
gr. 21 ; Charge air system; Checking charge air system for leaks .

Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely and close
valves -3, 4-.
• Make sure knob is pulled out before turning pressure control
valve.
– Using a commercially available connection piece, connect
charge air system tester - V.A.G 1687- to compressed air -1-.
– If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high.

♦ The pressure must not exceed 0.2 bar.
– Adjust pressure to 0.2 bar via pressure control valve -2-.

– Open valve -4- and wait until test system is pressurised. If
necessary, adjust pressure to 0.2 bar again.
– Check charge air system for audible leaks or leaks that can be
felt with the hand; apply commercially available leak detecting
spray or use ultrasonic tester - V.A.G 1842- (refer to ⇒ oper‐
ating manual ).
Note:
A small amount of air escapes through the valves and enters the
engine. Therefore it is not possible to perform a pressure retention
test.
– Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
Attaching
• Renew seal and O-rings after removal.
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air
system; Checking charge air system for leaks

24 – Mixture preparation - injection

1 Injection system
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injection system .
1. Injection system 281

2 Vacuum system
⇒ “2.1 Connection diagram - vacuum system”, page 282
⇒ “2.2 Checking vacuum system”, page 284
2.1 Connection diagram - vacuum system

⇒ “2.1.1 Connection diagram - vacuum system, vehicles with
2.9 ltr. engine without electric compressor”, page 282
⇒ “2.1.2 Connection diagram - vacuum system, vehicles with
2.9 ltr. engine with electric compressor”, page 283
⇒ “2.1.3 Connection diagram - vacuum system, vehicles with 3.0
2.1.1 Connection diagram - vacuum system,

vehicles with 2.9 ltr. engine without elec‐
tric compressor
Caution
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.
282 Rep. gr.24 - Mixture preparation - injection

1 - Coolant valve for cylinder

block - N545-
2 - Coolant pump
3 - Switch valve for mechanical
coolant pump - N649-
4 - Vacuum unit
❑ For turbocharger, cylin‐
der bank 1 (right-side)
5 - Vacuum unit
❑ For turbocharger, cylin‐
der bank 2 (left-side)
6 - Charge pressure control
solenoid valve - N75-
7 - Vacuum pump
8 - To brake servo
9 - Vacuum connecting piece
❑ With non-return valve
10 - Vacuum reservoir
11 - To air pipe

vehicles with 2.9 ltr. engine with electric
compressor
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Vacuum system;
Connection diagram - vacuum system .

Caution
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.
2. Vacuum system 283

1 - Coolant valve for cylinder

block - N545-
2 - Coolant pump
3 - Switch valve for mechanical
coolant pump - N649-
4 - Charge pressure control
solenoid valve - N75-
5 - Vacuum unit
6 - Vacuum reservoir
7 - To brake servo
8 - Vacuum connecting piece
❑ With non-return valve
9 - To air pipe
10 - Vacuum pump
2.2 Checking vacuum system

Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites

♦ Kinked or crushed lines

♦ Porous or leaking lines
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check the vacuum lines
leading to the corresponding component and also check the
remaining vacuum lines in the system.
– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.
2. Vacuum system 285

3 Air cleaner
Air cleaner .

4 Intake manifold
⇒ “4.1 Exploded view - intake manifold”, page 287
⇒ “4.2 Removing and installing intake manifold”, page 288
⇒ “4.3 Removing and installing throttle valve module J338 ”, page
290
⇒ “4.4 Cleaning throttle valve module”, page 290
4.1 Exploded view - intake manifold
1 - Air pipe (top)

❑ Exploded view
⇒ “2.1 Exploded view -
charge air system”,
page 259
2 - Seal
❑ Renew if damaged
❑ When renewing lever
out with screwdriver
❑ Press in by hand
3 - Gasket
4 - Bolt
sequence:
⇒ Fig. ““Intake manifold,
cylinder bank 1 (right-side)
- tightening torques and se‐
⇒ Fig. ““Intake manifold,
cylinder bank 2 (left-side) -
tightening torques and se‐
5 - Intake manifold
2 (left-side)
stalling intake manifold”,
page 288
6 - Bolt
4. Intake manifold 287

Intake manifold, cylinder bank 1 (right-side) - tightening torques

and sequence
angle.
tion
1. -1 … 10- 2 Nm
2. -1 … 10- 8 Nm
3. -1 … 10- Turn 45° further
Intake manifold, cylinder bank 2 (left-side) - tightening torques

and sequence
angle.
tion
1. -1 … 10- 2 Nm
2. -1 … 10- 8 Nm
3. -1 … 10- Turn 45° further
4.2 Removing and installing intake manifold

Removing
gr. 24 ; Intake manifold; Removing and installing intake manifold .

Intake manifold (cylinder bank 1, right-side):

– Release hose clips -1- and disconnect coolant hoses.
– Unscrew bolts -arrows- and remove connection -2-.
– Remove bolts -arrows- for air pipe.
– Take electrical connectors -arrows- out of bracket and move

clear to side.
– Loosen and remove bolts in the sequence: -10 ... 1- and de‐
tach intake manifold.
Intake manifold (cylinder bank 2, left-side):

– Remove bolts -arrows- for air pipe.

– Vehicles with 2.9 ltr. engine: Detach electrical connectors

-1, 2- from bracket and place to one side.
– Loosen and remove bolts in the sequence: -10 ... 1- and de‐
tach intake manifold.
Caution
Risk of irreparable damage to engine.

♦ Close off the intake ports with clean cloths to prevent small
objects from dropping into the engine through the intake
ports in the cylinder heads.
Installing
angle.
• Renew seals/gaskets after removing.
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Intake mani‐
fold; Removing and installing intake manifold
Tightening torques
♦ ⇒ Fig. ““Intake manifold, cylinder bank 1 (right-side) - tighten‐
ing torques and sequence”“ , page 288
♦ ⇒ Fig. ““Intake manifold, cylinder bank 2 (left-side) - tightening
torques and sequence”“ , page 288
♦ ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve
TFSI); Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes
4.3 Removing and installing throttle valve

module - J338-
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Intake manifold;
Removing and installing throttle valve module - J338- .
4.4 Cleaning throttle valve module

Carbon deposits and dirt in the limit stop can lead to incorrect
adaption values.
♦ Acetone (commercially available)
♦ Brush

Procedure
– Remove throttle valve module - J338- ⇒ 6-cylinder direct in‐
Intake manifold; Removing and installing throttle valve module
- J338- .
• Take care not to scratch the throttle valve housing when clean‐
ing it.
– Open throttle valve by hand and lock it in open position with a
wedge (plastic or wood) -arrow-.
WARNING
Acetone is highly flammable.

♦ Please observe all accident prevention regulations and
safety precautions when handling flammable liquids.
♦ Do not use compressed air when cleaning the throttle
valve.
♦ Wear safety goggles and protective clothing to avoid any
contact with skin and risk of injury.
– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush.
– Wipe out throttle valve housing with a lint-free cloth.
– Allow acetone to flash off completely.
– Install throttle valve module - J338- ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Intake
manifold; Removing and installing throttle valve module -
J338- .
– Erase learnt values and perform adaption ⇒ Vehicle diagnostic
tester.

5 Injectors
⇒ “5.1 Exploded view - fuel rail with injectors”, page 292
⇒ “5.2 Removing and installing fuel rail”, page 293
⇒ “5.3 Removing and installing injectors”, page 295
⇒ “5.4 Cleaning injectors”, page 301
5.1 Exploded view - fuel rail with injectors
1 - Sealing washer
2 - Combustion chamber ring
seal
stalling injectors”,
page 295
❑ Do not apply grease or
use any other lubricants
3 - Injector
❑ For 2.9 ltr. engines with
noise insulation; instal‐
lation position
⇒ Fig. ““Noise insulation
for injector on 2.9 ltr. en‐
gine - installation posi‐
tion”“ , page 293
stalling injectors”,
page 295
❑ Cleaning
⇒ “5.4 Cleaning injec‐
tors”, page 301
4 - Fuel rail
1 (right-side)
stalling fuel rail”,
page 293
5 - Fuel pressure sender -
G247-
stalling fuel pressure sender G247 ”, page 304
❑ Lubricate threads lightly with clean engine oil
❑ 25 Nm
6 - High-pressure pipe
❑ Removing and installing ⇒ “7.3 Removing and installing high-pressure pipe”, page 315
❑ Do not alter shape
❑ Check for damage before re-installing
❑ To loosen and tighten high-pressure pipe, counterhold at connecting piece
❑ Lubricate threads of union nuts with clean engine oil

7 - Connection
❑ Counterhold at connecting piece when loosening high-pressure pipe
❑ Check secure fit before fitting high-pressure pipe
❑ Renew connecting piece if it is damaged or loose
❑ 40 Nm
8 - Bolt
♦ 1st stage: 5 Nm
♦ 2nd stage: 9 Nm
♦ 3rd stage: 9 Nm
9 - Support ring
❑ Must be properly seated
10 - O-ring
❑ Lubricate lightly with clean engine oil
11 - Spacer ring
Noise insulation for injector on 2.9 ltr. engine - installation position

– Attach and secure noise insulation -1- on injector -2-, as shown
in illustration -arrows-.
5.2 Removing and installing fuel rail

Observe rules for cleanliness
Removing fuel rail for cylinder bank 1 (right-side)
– Remove high-pressure pipe (right-side)
⇒ “7.3.1 Removing high-pressure pipe (right-side)”,
page 315 .
5. Injectors 293

2- For Hall sender - G40-
3- For fuel pressure sender - G247-
4- For injectors -N30- , -N31- , -N32-
– Detach electrical wiring harnesses and move clear to the side.
– Detach noise insulation (top section).
Caution
Risk of engine damage due to dirt.

♦ Injectors must not be pulled out.
– Detach fuel rail -1- from injectors and remove.

Removing fuel rail for cylinder bank 2 (left-side)
gr. 24 ; Injectors; Removing and installing fuel rail .

1 - For Hall sender 4 - G301-
2 - For injectors -N33- , -N83- , -N84-
4 - For Hall sender 2 - G163-
5 - For inlet cam actuator -F460- , -F464- , -F468-
– Remove bolt -arrow-, detach bracket -3- for wiring channel and
noise insulation (top section).

– Unscrew union nut -2- (counterhold at connecting piece).
Caution
Risk of engine damage due to dirt.

♦ Injectors must not be pulled out.
– Detach fuel rail -1- from injectors and remove.

Installing
– Fit noise insulation (top section).
– Install high-pressure pipe
page 315 .
– Install ignition coils
– Install throttle valve module - J338-
⇒ “4.3 Removing and installing throttle valve module J338 ”,
page 290 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injectors; Re‐
moving and installing fuel rail
Tightening torques
♦ ⇒ “5.1 Exploded view - fuel rail with injectors”, page 292
5.3 Removing and installing injectors

♦ Spark plug socket, 3/8" - VAS 6919- (not illustrated)
5. Injectors 295
♦ Tool set for FSI engines - T10133 C-
♦ Adapters - T40012-
♦ Wrench, 21 mm - T40263-
♦ Special tool -T90006- (not illustrated)

Removing
– Remove relevant fuel rail
⇒ “5.2 Removing and installing fuel rail”, page 293 .

– Unscrew relevant spark plug using spark plug socket, 3/8" -

VAS 6919- .
– Screw adapter - T40012/1- with seal hand-tight into the cor‐
responding spark plug thread.
– Connect adapter to compressed air line using a commercially
available connection piece -arrow- and apply constant air
pressure.
• Pressure: 1 bar
Caution
Irreparable engine damage can be caused if the camshaft tim‐

ing chains slip.

crankshaft -arrow- until valves in corresponding cylinder close.
• Air will not escape audibly.
• Pressure of 1 bar is maintained.
– Detach support ring.

– Slide sleeve -T10133/18A- over injector.
– Carefully knock against stop sleeve several times with a soft-
faced hammer -1- to loosen injector.
– Pull off injector as described below.
WARNING
Risk of eye injury due to dirt particles. The pressure in the cyl‐
inder causes dirt to be blown out when the injector is pulled off.
5. Injectors 297
• Use a torque wrench to pull out injector.

– Set torque wrench to 5 Nm.
– Fit puller -T10133/2A- to groove on injector.
Note
If injectors manufactured by Delphi are installed, puller -

T10133/10- must be used instead of puller -T10133/2A- .
– Attach puller -T10133/16A- .

– Pull out injector by turning bolt - T10133/21- with torque
wrench.
• The torque must not exceed 5 Nm to avoid irreparable damage
to the injector.
– If necessary, knock again several times, as described above.
– Unscrew adapter - T40012/1- and close spark plug hole.
– Insert adapter -T90006/2- with handle -T90006/1- into hole for

injector as far as stop and unscrew handle.
– Blow dirt out of injector shaft using compressed air.
– If necessary, use brush -T90006/3- to loosen dirt.
– Screw in handle and remove adapter -T90006/2- .
– Close injector shaft.
Continued:
– Remove old combustion chamber ring seal -arrow-. To do so,
cut open combustion chamber ring seal using side-cutting pli‐
ers or prise open with small screwdriver and then pull off.
• Take care not to damage the groove on the injector.
– Repeat procedure for each injector.
Installing
• Use complete repair set when installing.
• Renew support ring and sealing washer.
• Renew combustion chamber ring seal before re-installing in‐
jector.
• Lightly lubricate O-rings for injectors with clean engine oil.

– Clean bore -arrow- in cylinder head with nylon cylinder brush

-T10133/4- .
– Before new combustion chamber ring seal is fitted, remove

any combustion residue from ring groove and injector stem
using a clean cloth.
– Fit assembly cone -T10133/5- with new combustion chamber

ring seal -1- from repair kit onto injector -2-.
– Using assembly sleeve -T10133/6- , push combustion cham‐

ber ring seal -1- onto assembly cone -T10133/5- as far as it
will go. (Knurled side of assembly sleeve faces towards com‐
bustion chamber ring seal.)
– Turn round assembly sleeve -T10133/6- and slide combustion

chamber ring seal into groove. (Smooth side of assembly
sleeve faces towards combustion chamber ring seal.)
5. Injectors 299
Note:
The combustion chamber ring seal is widened when it is pushed
onto the injector. After pushing it on, it therefore has to be com‐
pressed again. This is done in two stages, as described below.
– Push calibration sleeve -T10133/7- onto injector as far as it will
go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again by turning it in the
opposite direction.
– Push calibration sleeve -T10133/8- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again by turning it in the
opposite direction.
– Fit parts from repair kit onto injector -1-:

2 - Support ring
3 - O-ring
4 - Spacer ring
5 - Sealing washer (if included in repair kit)
– To make it easier to install injector in fuel rail, lubricate new O-
ring lightly with clean engine oil before installing it.
• The combustion chamber ring seal -6- must not be lubricated.
– Use assembly tool -T10133/9- to insert injector as far as it will

go into hole in cylinder head; note correct installation position.
• Electrical connector of injector must engage in recess in cyl‐
inder head.
• It should be possible to insert the injector easily. If necessary
wait until the combustion chamber ring seal has contracted
sufficiently.
note the following:
– Install fuel rail
⇒ “5.2 Removing and installing fuel rail”, page 293 .

5.4 Cleaning injectors

♦ Ultrasonic cleaning unit - VAS 6418-
♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid - VAS 6418/2-
Cleaning
– Close drain tap -arrow- on ultrasonic cleaning unit - VAS 6418-
(located on right side of housing).
– Fill up ultrasonic unit.
• Ratio of cleaning fluid: 2,100 ml of tap water which has been
allowed to settle for a few minutes and 20 ml of cleaning fluid
- VAS 6418/2-
• The ideal fluid level is approx. 1 ... 4 mm above the base of
the mounting plate. The ultrasonic cleaning unit - VAS 6418-
can be damaged if the fluid level is too low.
– Place mounting plate for injection modules - VAS 6418/1- on

top of cleaning unit.
– Remove combustion chamber ring seal ⇒ page 299 .
• It is important to read the safety notes in the operating instruc‐
tions before switching on the ultrasonic cleaning unit - VAS
6418- .
– Insert injectors all the way into guides of mounting plate for
injection modules - VAS 6418/1- .
– Switch on cleaning unit by pressing on/off button -C-.

– Select a cleaning time of 30 minutes with rotary control -A-.
– Set rotary control -B- to a temperature of 50°C.
– Press ► button -D- to start cleaning procedure.
• The actual cleaning process commences when the tempera‐
ture reaches at least 50 ℃ and must last for at least 30
minutes.
– Install injectors with new combustion chamber seal
5. Injectors 301
6 Senders and sensors

⇒ “6.1 Exploded view - actuator for structure-borne sound and
control unit for structure-borne sound”, page 302
⇒ “6.2 Exploded view - pressure differential sender”, page 302
⇒ “6.3 Removing and installing actuator for structure-borne sound
R214 ”, page 304
⇒ “6.4 Removing and installing control unit for structure-borne
sound J869 ”, page 304
⇒ “6.5 Removing and installing intake air temperature sender
G42 / intake manifold pressure sender G71 ”, page 304
⇒ “6.6 Removing and installing fuel pressure sender G247 ”, page
304
⇒ “6.7 Removing and installing fuel pressure sender for low pres‐
sure G410 ”, page 305
⇒ “6.8 Removing and installing pressure differential sender”, page
306
6.1 Exploded view - actuator for structure-

borne sound and control unit for struc‐
ture-borne sound
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Senders and
sensors; Exploded view - actuator for structure-borne sound and
control unit for structure-borne sound .
6.2 Exploded view - pressure differential sender

1 - Pressure differential sender

for particulate filter
❑ 2.9 ltr. engine:
♦ Cylinder bank 1 (right-side):
pressure differential sender
for particulate filter -
G1037-
♦ Cylinder bank 2 (left-side):
pressure differential sender
2 for particulate filter -
G1038-
❑ 3.0 ltr. engine:
♦ Pressure differential send‐
er for particulate filter -
G1037-
stalling pressure differ‐
ential sender”,
page 306
2 - Bolts
❑ 8 Nm
3 - Bracket
installing bracket for
pressure differential
sender for particulate fil‐
ter”, page 309
4 - Clamps
5 - Hoses
6 - Clamps
7 - Line
❑ Installation position
⇒ Fig. ““Fitting location of lines for pressure differential sender for particulate filter -G1037- - vehicles with
3.0 ltr. engine”“ , page 304
❑ Installation position on Audi Q7/Q8
⇒ Fig. ““Fitting location of lines for pressure differential sender for particulate filter -G1037- - Q7/Q8 with
⇒ “6.8.2 Removing and installing lines for pressure differential sender for particulate filter”, page 306
❑ 45 Nm
8 - Line
❑ Installation position
⇒ Fig. ““Fitting location of lines for pressure differential sender for particulate filter -G1037- - vehicles with
❑ Installation position on Audi Q7/Q8
⇒ Fig. ““Fitting location of lines for pressure differential sender for particulate filter -G1037- - Q7/Q8 with
⇒ “6.8.2 Removing and installing lines for pressure differential sender for particulate filter”, page 306
❑ 45 Nm
9 - Bolt
❑ 8 Nm
6. Senders and sensors 303

Fitting location of lines for pressure differential sender for partic‐

ulate filter - G1037- - vehicles with 3.0 ltr. engine
• Pressure differential lines must be in area -a- shown in illus‐
tration.
Fitting location of lines for pressure differential sender for partic‐

ulate filter - G1037- - Q7/Q8 with 3.0 ltr. engine
• Pressure differential lines must be in area -a- shown in illus‐
tration.
6.3 Removing and installing actuator for

structure-borne sound - R214-
sensors ; Removing and installing actuator for structure-borne
sound - R214- .
6.4 Removing and installing control unit for

structure-borne sound - J869-
sensors ; Removing and installing control unit for structure-borne
sound - J869- .
6.5 Removing and installing intake air tem‐

perature sender - G42- / intake manifold
pressure sender - G71-
sensors; Removing and installing intake air temperature sender -
G42- / intake manifold pressure sender - G71- .
6.6 Removing and installing fuel pressure

sender - G247-
♦ Socket, 24 mm -T40363- (not illustrated)
Removing

WARNING
The fuel system is pressurised.

Risk of injury as fuel may spray out.
• Put on safety goggles.
• Put on protective gloves.
• Release pressure (wrap a clean cloth around connection
and open connection carefully).
– Wrap a clean cloth around connection and unscrew fuel pres‐

sure sender - G247- using socket, 24 mm -T40363- .
Installing
Tightening torques
♦ ⇒ “5.1 Exploded view - fuel rail with injectors”, page 292
6.7 Removing and installing fuel pressure

sender for low pressure - G410-
♦ Socket, 24 mm -T40363- (not illustrated)
Removing
page 10 .
– Unscrew fuel pressure sender for low pressure - G410- using
socket, 24 mm -T40363- (counterhold at connection).
Installing
page 10 .
Tightening torques
♦ ⇒ “7.1 Exploded view - high-pressure pump”, page 310

6.8 Removing and installing pressure differ‐

ential sender
⇒ “6.8.1 Removing and installing pressure differential sender for
particulate filter”, page 306
⇒ “6.8.2 Removing and installing lines for pressure differential
sender for particulate filter”, page 306
⇒ “6.8.3 Removing and installing lines for pressure differential
sender for particulate filter - Q7/Q8”, page 308
⇒ “6.8.4 Removing and installing bracket for pressure differential
sender for particulate filter”, page 309
6.8.1 Removing and installing pressure differ‐

ential sender for particulate filter
Removing
installing.
page 10 .
– If fitted, open heat shield sleeve.
– Loosen clamps -3-.
– Disconnect hoses -4-.
– Remove pressure differential sender for particulate filter -5-.
Installing
– Blow through hoses (towards particulate filter) with com‐
pressed air.
Tightening torques
♦ ⇒ “6.2 Exploded view - pressure differential sender”,
page 302
6.8.2 Removing and installing lines for pres‐

sure differential sender for particulate
filter

♦ Tool set - T10395A-
Removing
page 10 .
2.9 ltr. engine:
– Lines (right-side): Remove plenum chamber partition panel ⇒
General body repairs, exterior; Rep. gr. 50 ; Bulkhead; Re‐
moving and installing plenum chamber partition panel .
– Lines (left-side): Remove noise insulation (rear): ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded
view - noise insulation .
All versions (continued):
– If necessary, remove bracket for pressure differential sender
for particulate filter - G1037-
⇒ “6.8.4 Removing and installing bracket for pressure differ‐
ential sender for particulate filter”, page 309 .
Caution
The exhaust system can become extremely hot. This can

cause injuries. Danger of burns to hands and other parts of the
body.
♦ Allow exhaust system to cool down.

– Loosen clamps -1- and -4-.

– Disconnect hoses -2- and -5-.
– Detach lines -3- and -6- using suitable tool(s) from tool set -
T10395A- . (Shown on vehicle with 3.0 ltr. engine.)
Installing
– Vehicles with 3.0 ltr. engine: Observe installation position
⇒ Fig. ““Fitting location of lines for pressure differential sender
for particulate filter -G1037- - vehicles with 3.0 ltr. engine”“ ,
page 304 .
– Blow through hoses and lines with compressed air.
– Coat threads of lines with high-temperature paste ⇒ Electronic
• High-temperature paste must not get into lines.
Tightening torques
page 302
6.8.3 Removing and installing lines for pres‐

sure differential sender for particulate
filter - Q7/Q8
Removing
– Remove bracket for pressure differential sender for particulate
filter - G1037-
⇒ “6.8.4 Removing and installing bracket for pressure differ‐
ential sender for particulate filter”, page 309 .
Caution

body.

– Loosen clamps -2- and -4-.

– Disconnect hoses -3- and -6-.
– Detach lines -1- and -5- using suitable tool(s) from tool set -
T10395A- .
Installing
– Vehicles with 3.0 ltr. engine: Observe installation position
⇒ Fig. ““Fitting location of lines for pressure differential sender
for particulate filter -G1037- - Q7/Q8 with 3.0 ltr. engine”“ ,
page 304 .
– Blow through hoses and lines with compressed air.
– Coat threads of lines with high-temperature paste ⇒ Electronic
• High-temperature paste must not get into lines.
Tightening torques
page 302
6.8.4 Removing and installing bracket for

pressure differential sender for particu‐
late filter
Removing
– Remove pressure differential sender for particulate filter -
G1037-
⇒ “6.8.1 Removing and installing pressure differential sender
for particulate filter”, page 306 .
– Detach hoses -1- from retainer -2-. (Shown on vehicle with 3.0
ltr. engine.)
– Remove bolts -3-.
– Detach bracket -4-.
Installing
Tightening torques
page 302

7 High-pressure pump
⇒ “7.1 Exploded view - high-pressure pump”, page 310
⇒ “7.2 Removing and installing high-pressure pump”, page 313
⇒ “7.3 Removing and installing high-pressure pipe”, page 315
7.1 Exploded view - high-pressure pump
1 - Bolt
❑ Tightening torque and
sequence
⇒ Fig. ““High-pressure
pipe (rear) - tightening
torques and se‐
2 - Retaining clamp
3 - High-pressure pipe (rear)
stalling high-pressure
pipe”, page 315
❑ Counterhold at connect‐
ing piece when loosen‐
ing high-pressure pipe
❑ Check for damage be‐
fore re-installing
❑ Lubricate threads of un‐
ion nuts with clean en‐
gine oil
sequence
⇒ Fig. ““High-pressure
pipe (rear) - tightening
torques and se‐
4 - Connection
❑ Counterhold at connect‐
ing piece when loosen‐
ing high-pressure pipe
❑ Check secure fit before
fitting high-pressure
pipe (40 Nm)
❑ Tightening torque for new connecting piece: 65 Nm
5 - Bolt
❑ 9 Nm
6 - High-pressure pipe (right-side)
❑ Removing and installing ⇒ “7.3.1 Removing high-pressure pipe (right-side)”, page 315
❑ To loosen and tighten high-pressure pipe, counterhold at pipe connection


⇒ Fig. ““High-pressure pipe (right-side) - tightening torques and sequence”“ , page 312
7 - Fuel hose (low-pressure section)
❑ Renew if disconnected from fuel pipe (low-pressure section) ⇒ Item 14 (page 311)
8 - Spring-type clip
9 - Connection
❑ Counterhold at connecting piece when loosening high-pressure pipe
❑ Check secure fit before fitting high-pressure pipe (40 Nm)
❑ Tightening torque for new connecting piece: 65 Nm
10 - High-pressure pump
❑ With fuel metering valve - N290-
❑ Do not dismantle
❑ Removing and installing ⇒ “7.2 Removing and installing high-pressure pump”, page 313
11 - Bolt
⇒ Fig. ““High-pressure pump - tightening torques and sequence”“ , page 312
12 - O-ring
❑ Lubricate lightly with clean engine oil before installing
13 - Roller tappet
❑ Can only be installed in one position
❑ Lubricate lightly with clean engine oil before installing
14 - Fuel pipe (low-pressure section)
❑ To loosen and tighten high-pressure pipe, counterhold at pipe connection
⇒ Fig. ““Fuel pipe (low-pressure section) - tightening torques and sequence”“ , page 313
15 - Nut
❑ Tightening torque and sequence
⇒ Fig. ““Fuel pipe (low-pressure section) - tightening torques and sequence”“ , page 313
16 - Fuel pressure sender for low pressure - G410-
⇒ “6.7 Removing and installing fuel pressure sender for low pressure G410 ”, page 305
❑ 15 Nm
7. High-pressure pump 311

High-pressure pump - tightening torques and sequence

angle.
– To prevent flange of high-pressure pump from being deformed
during installation, fit bolts -arrows- in stages as follows:
Stage Procedure/tightening torques/angle specification
1. Screw in by hand until contact is made
2. Tighten one turn alternately until flange of high-pressure
pump makes contact with camshaft housing
3. 5 Nm
4. 20 Nm
5. Turn 45° further
High-pressure pipe (right-side) - tightening torques and sequence

• Lubricate threads of union nuts with clean engine oil
• Counterhold at connecting piece when tightening union nuts
-arrows-.
– Tighten bolts and union nuts in stages as follows:
Stage Bolts/union nuts Tightening torques
1. -arrows- 5 Nm
2. -2- Screw in by hand until contact is made
3. -arrows- 27 Nm
4. -2- 9 Nm
5. -arrows- 27 Nm
High-pressure pipe (rear) - tightening torques and sequence

angle.
• Counterhold at connecting piece when tightening union nuts.
– Tighten bolts and union nuts in stages as follows:
Stage Bolts/union nuts Tightening torques/angle specifica‐
tion
1. -2, 5- 5 Nm
2. -1, arrows- Screw in by hand until contact is made
3. -2, 5- 25 Nm
4. -1, arrows- 8 Nm
5. -1, arrows- Turn 45° further

Fuel pipe (low-pressure section) - tightening torques and se‐

quence
– Tighten nuts and union nuts in stages as follows:
Stage Nuts/union nuts Tightening torques/angle specifica‐
tion
1. -4- 5 Nm
2. -1, arrows- Screw in by hand until contact is made
3. -4- 22 Nm
4. -1- 8 Nm
6. -arrows- 9 Nm
7.2 Removing and installing high-pressure

pump
♦ Wrench, 21 mm - T40263-
Removing
page 315 .

– Unplug electrical connector -3- for fuel pressure sender for low
pressure - G410- .
– Remove bolt -1- and nuts -arrows-.
– Unscrew union nut -4- (counterhold at connecting piece).
Place fuel line -2- to one side.

– Carefully pull out high-pressure pump -2-. Roller tappet re‐
mains lodged inside camshaft housing.
Installing
angle.
• The connections of the high-pressure pipe must not be dam‐
aged.

– Have a second mechanic turn crankshaft with wrench, 21 mm
- T40263- and adapter - T40314- in direction of normal engine
rotation -arrow- until roller tappet reaches its lowest point.

– Check roller tappet -1- for damage and renew if necessary.

– Lightly lubricate roller tappet with oil and insert it so that lug
-arrow A- slides into guide notch -arrow B-.
– Tighten bolts alternately, taking care not to tilt high-pressure
pump
⇒ Fig. ““High-pressure pump - tightening torques and se‐
quence”“ , page 312 .
note the following:
– Install high-pressure pipe (right-side)
page 315 .
Tightening torques
♦ ⇒ “7.1 Exploded view - high-pressure pump”, page 310
♦ ⇒ Fig. ““High-pressure pump - tightening torques and se‐
♦ ⇒ Fig. ““Fuel pipe (low-pressure section) - tightening torques
7.3 Removing and installing high-pressure

pipe
⇒ “7.3.1 Removing high-pressure pipe (right-side)”, page 315
⇒ “7.3.2 Removing high-pressure pipe (rear) - vehicles with 2.9
⇒ “7.3.3 Removing high-pressure pipe (rear) - vehicles with 3.0
⇒ “7.3.4 Installing high-pressure pipe”, page 319
7.3.1 Removing high-pressure pipe (right-

side)
♦ Socket - T40055-
Procedure
installing.
gr. 24 ; High-pressure pump; Removing and installing high-pres‐
sure pipe .

– Detach heat insulation sleeve, remove activated charcoal filter

solenoid valve 1 - N80- -item 1- from bracket and press it up‐
wards.
– Pull switch valve for mechanical coolant pump - N649-
-item 2- off bracket and press it to the side.
– Detach wiring duct -3- from ball studs and press it upwards
slightly.
– Remove bolt -arrow- and press ignition coil for cylinder 1

slightly to one side.
– Press noise insulation to one side and unscrew union nuts

-arrows- (counterhold at corresponding connecting piece).
– Unscrew bolt -2- and detach high-pressure pipe (right-side)
-1-.
Installing ⇒ “7.3.4 Installing high-pressure pipe”, page 319
7.3.2 Removing high-pressure pipe (rear) -


♦ Socket - T40055-
Procedure
– Remove catalytic converter (both sides) ⇒ 6-cylinder direct
♦ Small coolant pipe (rear right)
♦ Coolant pipe (rear left)
– Release hose clip -3-.
– Detach large coolant pipe (rear right) and press to one side.

– If fitted, remove bolts -arrows- and nut -2-, and press bracket
-1- to one side.
– Unplug electrical connectors -3, 6- and move electrical wires

clear.
– Remove centre hex stud -1- and bolts -arrows-.
– Unscrew union nuts -2, 5- (counterhold at corresponding con‐
necting piece). Detach high-pressure pipe (rear).
7.3.3 Removing high-pressure pipe (rear) -

♦ Socket - T40055-
Procedure
♦ Large coolant pipe (rear right)
♦ Small coolant pipe (rear right)
♦ Coolant pipe (rear left)

– Unplug electrical connectors -3, 6- and move electrical wires

clear.
– Remove centre hex stud -1- and bolts -arrows-.
– Unscrew union nuts -2, 5- (counterhold at corresponding con‐
necting piece). Detach high-pressure pipe (rear).
7.3.4 Installing high-pressure pipe

Procedure
angle.
• The connections of the high-pressure pipe must not be dam‐
aged.
• Do not attempt to bend high-pressure pipe to a different shape.
– Lubricate threads of union nuts with clean engine oil.
– First tighten union nut by hand until it makes contact, making
sure that high-pressure pipe is not under tension.
– Pre-tighten union nut to 5 Nm.
– Tighten bolts for retaining clips.
– Tighten union nut to final tightening torque (counterhold at
corresponding connecting piece).
note the following:
– If removed previously, install heat shield and engine cover
panel
page 10 .
– If removed previously, install catalytic converter (left-side) ⇒
Rep. gr. 26 ; Emission control system; Removing and instal‐
ling catalytic converter .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; High-pressure
pump; Removing and installing high-pressure pipe
Tightening torques
♦ ⇒ “4.1 Exploded view - intake manifold”, page 287
♦ ⇒ Fig. ““High-pressure pipe (right-side) - tightening torques
♦ ⇒ Fig. ““High-pressure pipe (rear) - tightening torques and se‐

8 Lambda probe
⇒ “8.1 Exploded view - Lambda probe”, page 320
⇒ “8.2 Removing and installing Lambda probe”, page 323
8.1 Exploded view - Lambda probe

⇒ “8.1.1 Exploded view - Lambda probe, vehicles with 2.9 ltr. en‐
gine without particulate filter”, page 320
gine without particulate filter”, page 321
gine and particulate filter”, page 322
gine and particulate filter, Q7/Q8”, page 323
8.1.1 Exploded view - Lambda probe, vehicles with 2.9 ltr. engine without partic‐
ulate filter
1 - Lambda probe 2 after cata‐

lytic converter - G131-
❑ With Lambda probe 2
heater after catalytic
converter - Z30-
installing Lambda probe
- vehicles with 2.9 ltr. en‐
gine”, page 323
2 - Lambda probe 2 - G108-
❑ With Lambda probe
heater 2 - Z28-
gine”, page 323
❑ 55 Nm
3 - Lambda probe - G39-
heater - Z19-
gine”, page 323
❑ 55 Nm
4 - Lambda probe after catalyt‐
ic converter - G130-
converter - Z29-
installing Lambda probe - vehicles with 2.9 ltr. engine”, page 323
❑ 55 Nm

8.1.2 Exploded view - Lambda probe, vehicles with 3.0 ltr. engine without partic‐
ulate filter
1 - Lambda probe after catalyt‐

converter - Z29-
gine”, page 325
❑ 55 Nm
2 - Lambda probe - G39-
heater - Z19-
gine”, page 325
❑ 55 Nm
8. Lambda probe 321

8.1.3 Exploded view - Lambda probe, vehicles with 3.0 ltr. engine and particulate
filter
1 - Lambda probe 1 before cat‐

alytic converter - GX10-
❑ Consists of:
♦ Lambda probe - G39-
♦ Lambda probe heater -
Z19-
gine”, page 325
❑ 45 Nm
lytic converter - GX7-
❑ Consists of:
♦ Lambda probe after catalyt‐
♦ Lambda probe 1 heater af‐
ter catalytic converter -
Z29-
1 after catalytic convert‐
er GX7 - vehicles with
3.0 ltr. engine and par‐
ticulate filter”,
page 326
❑ 45 Nm

8.1.4 Exploded view - Lambda probe, vehicles with 3.0 ltr. engine and particulate
filter, Q7/Q8

lytic converter - GX7-
❑ Consists of:
♦ Lambda probe after catalyt‐
♦ Lambda probe 1 heater af‐
ter catalytic converter -
Z29-
1 after catalytic convert‐
er GX7 - vehicles with
3.0 ltr. engine and par‐
ticulate filter”,
page 326
❑ 45 Nm
2 - Lambda probe 1 before cat‐
alytic converter - GX10-
❑ Consists of:
♦ Lambda probe - G39-
♦ Lambda probe heater -
Z19-
gine”, page 325
❑ 45 Nm
8.2 Removing and installing Lambda probe

⇒ “8.2.1 Removing and installing Lambda probe - vehicles with
⇒ “8.2.2 Removing and installing Lambda probe - vehicles with
⇒ “8.2.3 Removing and installing Lambda probe 1 after catalytic
converter GX7 - vehicles with 3.0 ltr. engine and particulate filter”,
page 326
⇒ “8.2.4 Removing and installing Lambda probe 1 after catalytic
converter GX7 - vehicles with 3.0 ltr. engine and particulate filter,
Q7/Q8”, page 328
8.2.1 Removing and installing Lambda probe

8. Lambda probe 323

♦ Lambda probe open ring spanner set - 3337-
Removing
gr. 24 ; Lambda probe; Removing and installing Lambda probe .
• Re-install all cable ties in original positions.
– Remove engine cover panel ⇒ page 10 ; also remove heat
shield to remove Lambda probes -G39- / -G108- .
Lambda probe - G39- / Lambda probe after catalytic converter -
G130- :
– Detach electrical connectors from bracket one after another,
unplug and move electrical wires clear:
1- For Lambda probe after catalytic converter - G130-
2- For Lambda probe - G39-
– Remove Lambda probes using spanner -3337/7- (illustration

shows vehicle without particulate filter):
1- Lambda probe after catalytic converter - G130-
2- Lambda probe - G39-
Lambda probe 2 - G108- / Lambda probe 2 after catalytic con‐

verter - G131- :
1- For Lambda probe 2 after catalytic converter - G131-
2- For Lambda probe 2 - G108-

– Remove Lambda probes using spanner -3337/7- (illustration

shows vehicle without particulate filter):
1- Lambda probe 2 after catalytic converter - G131-
2- Lambda probe 2 - G108-
Installing
• Threads of new Lambda probes are already coated with as‐
sembly paste; the paste must not get into the slots on the probe
body.
• In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Electronic parts catalogue
• When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into
contact with the exhaust pipe.
page 10 .
Lambda probe; Removing and installing Lambda probe
Tightening torques
♦ ⇒ “8.1.1 Exploded view - Lambda probe, vehicles with 2.9 ltr.
engine without particulate filter”, page 320

Removing
gr. 24 ; Lambda probe; Removing and installing Lambda probe .
• Re-install all cable ties in original positions.
– Remove engine cover panel ⇒ page 10 ; also remove heat
shield to remove Lambda probe - G39- .
8. Lambda probe 325


1- For Lambda probe after catalytic converter - G130-
2- For Lambda probe - G39-
– Unscrew Lambda probes using ring spanner -3337/7- :

1- Lambda probe after catalytic converter - G130-
2- Lambda probe - G39-
Installing
• Threads of new Lambda probes are already coated with as‐
sembly paste; the paste must not get into the slots on the probe
body.
• In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Electronic parts catalogue
• When installing, the Lambda probe wire must always be reat‐
tached at the same locations to prevent it from coming into
contact with the exhaust pipe.
page 10 .
Lambda probe; Removing and installing Lambda probe
Tightening torques
engine without particulate filter”, page 321

1 after catalytic converter - GX7- - vehi‐
cles with 3.0 ltr. engine and particulate
filter

Removing
page 10 .
– Remove heat shield
page 10 .
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Air cleaner;
8. Lambda probe 327

– Detach electrical connector -1- from retainer.

Caution

body.
– Move electrical wiring harness for Lambda probe 1 after cat‐

alytic converter - GX7- -2- clear.
– Detach Lambda probe 1 after catalytic converter - GX7- -2-
using a suitable ring spanner from Lambda probe open ring
spanner set - 3337- .
Installing
Note
New Lambda probe 1 after catalytic converter - GX7- must be

coated with assembly paste. This paste must not get into the slots
on Lambda probe 1 after catalytic converter - GX7- .
– Coat thread of Lambda probe 1 after catalytic converter - GX7-

with high-temperature paste ⇒ Electronic parts catalogue
(ETKA) .
• High-temperature paste must not get into the slots on Lambda
probe 1 after catalytic converter - GX7- .
Tightening torques
engine and particulate filter”, page 322

1 after catalytic converter - GX7- - vehi‐
filter, Q7/Q8

Removing
page 10 .
page 10 .
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Air cleaner;
Caution

body.

– Detach Lambda probe 1 after catalytic converter - GX7- -2-
using a suitable ring spanner from Lambda probe open ring
spanner set - 3337- .
Installing
Note
New Lambda probe 1 after catalytic converter - GX7- must be

coated with assembly paste. This paste must not get into the slots
on Lambda probe 1 after catalytic converter - GX7- .
– Coat thread of Lambda probe 1 after catalytic converter - GX7-

with high-temperature paste ⇒ Electronic parts catalogue
(ETKA) .
• High-temperature paste must not get into the slots on Lambda
probe 1 after catalytic converter - GX7- .
Tightening torques
engine and particulate filter, Q7/Q8”, page 323
8. Lambda probe 329

9 Engine control unit

Engine control unit .

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 331
⇒ “1.2 Separating exhaust pipes/silencers”, page 331
⇒ “1.3 Removing and installing front silencers”, page 331
⇒ “1.4 Stress-free alignment of exhaust system”, page 331
⇒ “1.5 Checking exhaust system for leaks”, page 331
1.1 Exploded view - silencers

gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust pipes/
silencers; Exploded view - silencers .
1.2 Separating exhaust pipes/silencers

silencers; Separating exhaust pipes/silencers .
1.3 Removing and installing front silencers

silencers; Removing and installing front silencers .
1.4 Stress-free alignment of exhaust system

silencers; Stress-free alignment of exhaust system .
1.5 Checking exhaust system for leaks

– Start engine and run at idling speed.
– Plug tailpipes (e. g. with rags or stopper) and leave plugged
until the check is complete.
– Listen for noise at connection points (cylinder head/turbo‐
charger, turbocharger/front exhaust pipe etc.) to locate any
leaks.
– Rectify any leaks that are found.
1. Exhaust pipes/silencers 331

2 Emission control system

Emission control system .
332 Rep. gr.26 - Exhaust system

3 Exhaust gas temperature control

⇒ “3.1 Exploded view - exhaust gas temperature control”,
page 333
3.1 Exploded view - exhaust gas tempera‐

ture control
⇒ “3.1.1 Exploded view - exhaust gas temperature control, vehi‐
⇒ “3.1.2 Exploded view - exhaust gas temperature control, vehi‐
3.1.1 Exploded view - exhaust gas temperature control, vehicles with 2.9 ltr. en‐
gine
1 - Catalytic converter with par‐

ticulate filter
❑ Cylinder bank 1 (right-
side) shown
2 - Exhaust gas temperature
sender 3
♦ Exhaust gas temperature
sender 3 - G495- for cylin‐
der bank 1 (right-side)
♦ Exhaust gas temperature
sender 3 for bank 2 - G497-
for cylinder bank 2 (left-
side)
installing exhaust gas
temperature sender 3
G495 / G497 - vehicles
with 2.9 ltr. engine”,
page 334
3 - Bracket
❑ For electrical connector
3. Exhaust gas temperature control 333

3.1.2 Exploded view - exhaust gas temperature control, vehicles with 3.0 ltr. en‐
gine
1 - Catalytic converter with par‐

ticulate filter
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue
2 - Exhaust gas temperature
sender 3 - G495-
❑ Different installation po‐
sition depending on
model
❑ Removing and instal‐
ling:
♦ ⇒ “3.2.2 Removing and in‐
stalling exhaust gas tem‐
perature sender 3 G495 -
all vehicles with 3.0 ltr.
engine and particulate filter
except Q7/Q8”, page 336
♦ ⇒ “3.2.3 Removing and in‐
stalling exhaust gas tem‐
perature sender 3 G495 -
and particulate filter, Q7/
Q8”, page 338
3 - Bracket
❑ For electrical connector
3.2 Removing and installing parts of ex‐

haust gas temperature control
⇒ “3.2.1 Removing and installing exhaust gas temperature sender
3 G495 / G497 - vehicles with 2.9 ltr. engine”, page 334
⇒ “3.2.2 Removing and installing exhaust gas temperature send‐
er 3 G495 - all vehicles with 3.0 ltr. engine and particulate filter
except Q7/Q8”, page 336
⇒ “3.2.3 Removing and installing exhaust gas temperature send‐
er 3 G495 - vehicles with 3.0 ltr. engine and particulate filter, Q7/
Q8”, page 338
3.2.1 Removing and installing exhaust gas

temperature sender 3 -G495- / -G497- -

Removing
page 10 .
Exhaust gas temperature sender 3 - G495- , cylinder bank 1
(right-side):
– Detach electrical connector -2- from bracket, unplug and move
electrical wire clear.
Caution

body.
– Detach exhaust gas temperature sender 3 - G495- -item 1-

using suitable tool from tool set - T10395A- .

Exhaust gas temperature sender 3 for bank 2 - G497- , cylinder

bank 2 (left-side):
– Detach electrical connector -1- from bracket, unplug and move
electrical wire clear.
Caution

body.
– Detach exhaust gas temperature sender 3 - G495- -item 2-

using suitable tool from tool set - T10395A- .
Installing
Note
Protect exhaust gas temperature senders against knocks and im‐

pact. If dropped, exhaust gas temperature senders must no lon‐
ger be used.
– Coat thread of exhaust gas temperature sender with high-

temperature paste ⇒ Electronic parts catalogue .
• High-temperature paste must not get into slots on exhaust gas
temperature sender.
Installation position of exhaust gas temperature sender 3 -

G495- , cylinder bank 1 (right-side):
– Align exhaust gas temperature sender 3 - G495- :
• Angle -α- = 5°
Installation position of exhaust gas temperature sender 3 for bank

2 - G497- , cylinder bank 2 (left-side):
– Align exhaust gas temperature sender 3 - G495- :
• Angle -α- = 5°
Tightening torques
♦ ⇒ “3.1.1 Exploded view - exhaust gas temperature control,

temperature sender 3 - G495- - all vehi‐


filter except Q7/Q8
Removing
page 10 .
page 10 .
– Detach electrical connector -1- from retainer.
Caution

body.
– Move electrical wiring harness for exhaust gas temperature

sender 3 - G495- -2- clear.
– Detach exhaust gas temperature sender 3 - G495- -2- using
suitable tool from tool set - T10395A- .
Installing
– Observe correct installation position ⇒ page 338 .
Note

ger be used.

temperature sender.

Installation position of exhaust gas temperature sender 3 - G495-

• Exhaust gas temperature sender 3 - G495- must be within
area -a- shown.
Tightening torques

temperature sender 3 - G495- - vehicles
with 3.0 ltr. engine and particulate filter,
Q7/Q8
Removing
page 10 .
page 10 .

Caution

body.

– Detach exhaust gas temperature sender 3 - G495- -2- using
suitable tool from tool set - T10395A- .
Installing
– Observe correct installation position
⇒ Fig. ““Installation position of exhaust gas temperature send‐
er 3 -G495- ”“ , page 339 .
Note

ger be used.

temperature sender.
Installation position of exhaust gas temperature sender 3 - G495-

• Exhaust gas temperature sender 3 - G495- must be within
area -a- shown.
Tightening torques

28 – Ignition system
1 Ignition system
⇒ “1.1 Exploded view - ignition system”, page 340
⇒ “1.2 Removing and installing ignition coils with output stages”,
page 341
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 344
⇒ “1.4 Removing and installing Hall senders”, page 344
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
345
1.1 Exploded view - ignition system

1 - Bolt
❑ 25 Nm
❑ The tightening torque in‐
fluences the function of
the knock sensor
2 - Knock sensor 2 - G66-
stalling knock sensor 1
G61 ”, page 344
3 - O-ring
4 - Hall sender 2 - G163-
❑ Inlet side
stalling Hall senders”,
page 344
5 - Bolt
❑ 9 Nm
6 - O-ring
❑ Exhaust side
stalling Hall senders”,
page 344
8 - Bolt
❑ 9 Nm
9 - Spark plug connectors
❑ Installation position ⇒ “1.2 Removing and installing ignition coils with output stages”, page 341
10 - Bolt
❑ 9 Nm
340 Rep. gr.28 - Ignition system

11 - Ignition coil
♦ Ignition coil 1 with output stage - N70-
❑ Removing and installing ⇒ “1.2 Removing and installing ignition coils with output stages”, page 341
12 - Spark plug
❑ Change interval ⇒ Maintenance tables
❑ 23 Nm
13 - O-ring
❑ Exhaust side
❑ Removing and installing ⇒ “1.4 Removing and installing Hall senders”, page 344
15 - Bolt
❑ 9 Nm
16 - O-ring
17 - Hall sender - G40-
❑ Inlet side
❑ Removing and installing ⇒ “1.4 Removing and installing Hall senders”, page 344
18 - Bolt
❑ 9 Nm
19 - Knock sensor 1 - G61-
❑ Removing and installing ⇒ “1.3 Removing and installing knock sensor 1 G61 ”, page 344
20 - Bolt
❑ 25 Nm
❑ The tightening torque influences the function of the knock sensor
21 - Bolt
❑ 9 Nm
22 - Engine speed sender - G28-
❑ Removing and installing ⇒ “1.5 Removing and installing engine speed sender G28 ”, page 345
23 - O-rings
1.2 Removing and installing ignition coils

with output stages
The ignition coils are easier to remove when the engine is warm.
The silicone paste used at the factory facilitates removal of the
ignition coils and spark plug connectors when the engine is warm.
1. Ignition system 341

♦ Puller - T10530-
♦ Silicone paste ⇒ Electronic parts catalogue (ETKA) .

Removing
gr. 28 ; Ignition system; Removing and installing ignition coils with
output stages .
– Remove bolt -arrow- for relevant ignition coil.
– Insert puller - T10530- into hole -1- in ignition coil.

– Turn knurled nut -2- clockwise -arrow- until puller is secured
in place.

– Carefully pull ignition coil out vertically -arrow- with puller -

T10530- .
Installing
– Push spark plug connector -2- onto ignition coil -1- by hand as
far as stop.
• The arrow markings on the spark plug connector and the ig‐
nition coil must be aligned, as shown.
Caution
Ignition coils can be damaged irreparably if the wrong lubricant

is used.
♦ Use only the approved silicone paste ⇒ Electronic parts
catalogue .
– Apply a thin bead of silicone paste all around end of sealing

hose of ignition coil with output stage -arrow-.
– Press ignition coils onto spark plugs by hand evenly (do not
use tools).
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 28 ; Ignition system;
Removing and installing ignition coils with output stages
Tightening torques
♦ ⇒ “1.1 Exploded view - ignition system”, page 340

1.3 Removing and installing knock sensor 1

- G61-
This procedure applies to knock sensor 1 - G61- and knock sen‐
sor 2 - G66- .
Removing
– Preparatory work may be necessary depending on model ⇒
Rep. gr. 28 ; Ignition system; Removing and installing knock
sensor 1 - G61- .
– Unscrew bolt -arrow- and remove knock sensor -1- (shown on
knock sensor 2 - G66- ).
Installing
Note:
The tightening torque influences the function of the knock sensor.
Tightening torques
1.4 Removing and installing Hall senders

♦ Torx T30 bit - T10573- (not illustrated)
Removing Hall sender - G40- / Hall sender 2 - G163- (inlet cam‐
shaft)
Hall sender - G40- : Preparatory work may be necessary depend‐
ing on model ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr.
4-valve TFSI); Rep. gr. 28 ; Ignition system; Removing and in‐
stalling Hall senders .
– Hall sender 2 - G163- : Remove engine cover panel
page 10 .
– Press top section of noise insulation upwards slightly.
– Unscrew bolt -arrow- and remove Hall sender -1- (shown on -
G40- ).
Removing Hall sender 3 - G300- (exhaust camshaft, cylinder bank

1)
page 315 .
– Unscrew bolt -arrow- and remove Hall sender -1-.

Removing Hall sender 4 - G301- (version 1)

– Remove throttle valve module - J338-
page 290 .
– Press top section of noise insulation upwards slightly.
– Unscrew bolt -arrow- and remove Hall sender -1-.
Removing Hall sender 4 - G301- (version 2)

page 10 .
– Unscrew bolt -2- and detach Hall sender.
Installing
– Install throttle valve module - J338-
page 290 .
– Install high-pressure pipe
page 315 .
page 10 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 28 ; Ignition system;
Removing and installing Hall senders
Tightening torques
1.5 Removing and installing engine speed

sender - G28-
– Remove noise insulation (rear) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .


– Unscrew bolt -1- and pull out engine speed sender - G28- .
Installing
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation

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Service

Service Department. Technical Information

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Copyright © 2019 Audi AG, Ingolstadt D4B80641D39

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Exploded view - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

1.1 Engine number/engine data

2.1 Safety precautions when working on the high-voltage system

Risk of injury - engine may start unexpectedly

Risk of damage to high-voltage wiring

2 Rep. gr.00 - Technical data

– Pay attention to coding when connecting high-voltage con‐

Risk of injury if auxiliary air conditioner is activated

2.2 Safety precautions when working in the vicinity of high-voltage components

2.3 Safety precautions when working on the fuel supply system

Risk of fire due to escaping fuel

2.4 Safety precautions when working on vehicles with start/stop system

2.6 Safety precautions when working on the subframe

2.7 Safety precautions when working on the ignition system

Risk of damage to components

4 Rep. gr.00 - Technical data

– Switch off ignition before connecting/disconnecting electrical

2.8 Safety precautions when working on the cooling system

2.9 Safety precautions when working on the exhaust system

Risk of injury caused by components of the exhaust system

3.1 Rules for cleanliness

3.2 Foreign particles in engine

3.3 Contact corrosion

6 Rep. gr.00 - Technical data

3.4 Routing and attachment of pipes, hoses

3.5 Installing radiators and condensers

3.6 Checking fuel system for leaks

– Road-test vehicle and accelerate with full throttle at least once.

10 – Removing and installing engine

8 Rep. gr.10 - Removing and installing engine

3 Engine cover panel

3.1 Removing and installing engine cover

Removing engine cover panel (version 2)

10 Rep. gr.10 - Removing and installing engine

Removing heat shield

Danger of fire and damage if the heat shield/engine cover pan‐

– To avoid damage, do not strike the engine cover panel with

3. Engine cover panel 11

1.1 Exploded view - cylinder block (pulley

12 Rep. gr.13 - Crankshaft group

1. Cylinder block (pulley end) 13

Belt routing for alternator

Bracket for alternator - tightening torques and sequence

14 Rep. gr.13 - Crankshaft group

1. Cylinder block (pulley end) 15

Belt routing for starter-alternator

Bracket -1- for starter-alternator - tightening torque and tightening

16 Rep. gr.13 - Crankshaft group