Service: Audi A6 2005

Service
Workshop Manual
Audi A6 2005 ➤
6-cylinder direct petrol injection engine (3.2 ltr. 4-
valve), mechanics
Engine ID BKH AUK BYU
Edition 12.2008
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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
26 - Exhaust 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 © 2015 Audi AG, Ingolstadt A005A601120

Audi A6 2005 ➤
6-cylinder direct petrol injection engine (3.2 ltr. 4-valve), mechanics - Edition 12.2008
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 4
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Rules for cleanliness when working on fuel supply system and injection system . . . . . . . . 5
4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.6 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.7 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Removing and installing engine - vehicles with manual gearbox . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Separating engine from manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Removing and installing engine - vehicles with multitronic gearbox . . . . . . . . . . . . . . . . . . 35
2.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Detaching multitronic gearbox from engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3 Removing and installing engine - vehicles with automatic gearbox 09L . . . . . . . . . . . . . . 62
3.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2 Separating engine from automatic gearbox 09L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1 Assembly mountings - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2 Removing and installing engine mounting (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.3 Removing and installing engine mounting with (right-side) . . . . of. .information
respect to the correctness . . . . . in. .this
. .document.
. . . . . Copyright
. . . . . by
. .AUDI
. AG.
99
5.4 Removing and installing torque reaction support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.1 Poly V-belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.2 Removing and installing coolant pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.3 Removing and installing power steering pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.4 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.6 Renewing sealing flange (pulley end) with crankshaft oil seal . . . . . . . . . . . . . . . . . . . . . . 109
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.1 Dual-mass flywheel on vehicles with manual gearbox - exploded view . . . . . . . . . . . . . . . . 113
2.2 Removing and installing dual-mass flywheel - vehicles with manual gearbox . . . . . . . . . . 113
2.3 Extracting and driving in needle bearing for dual-mass flywheel - vehicles with manual
gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.4 Flywheel for vehicles with multitronic gearbox - exploded view . . . . . . . . . . . . . . . . . . . . . . 117
2.5 Removing and installing damper unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.6 Removing and installing flywheel - vehicles with multitronic gearbox . . . . . . . . . . . . . . . . 119
2.7 Drive plate on vehicles with automatic gearbox 09L - exploded view . . . . . . . . . . . . . . . . 120
2.8 Removing and installing drive plate - vehicles with automatic gearbox 09L . . . . . . . . . . . . 121
Contents i
Audi A6 2005 ➤
2.9 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.3 Measuring axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.4 Measuring radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.2 Piston and cylinder
permitted dimensions
unless authorised by AUDI AG.. .AUDI
. . .AG. .does
. . .not. guarantee
. . . . . . or. accept
. . . . any
. . liability
...................... 134
4.3 Checkingwith
radial
respectclearance of of
to the correctness conrod bearings
information . . .Copyright
in this document. . . . . .by. AUDI
. . . AG.
...................... 134
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Timing chain covers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Removing and installing timing chain covers (left and right) . . . . . . . . . . . . . . . . . . . . . . . . 135
1.3 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.4 Camshaft timing chains - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.5 Detaching timing chains from camshafts, removing and installing chain tensioners . . . . . . 150
1.6 Drive chain for valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.7 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.8 Drive chain for auxiliary drives on vehicles up to 04.2006 - exploded view . . . . . . . . . . . . 163
1.9 Removing and installing drive chain for auxiliary drives on vehicles up to 04.2006 . . . . . . 164
1.10 Drive chain for auxiliary drives on vehicles from 04.2006 - exploded view . . . . . . . . . . . . 168
1.11 Removing and installing drive chain for auxiliary drives on vehicles from 04.2006 . . . . . . 169
1.12 Balance shaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.13 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.2 Removing and installing cylinder head cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.3 Removing and installing cylinder head cover (left-side) - USA vehicles . . . . . . . . . . . . . . 180
2.4 Removing and installing cylinder head cover (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.5 Removing and installing cylinder head cover (right-side) - USA vehicles . . . . . . . . . . . . . . 185
2.6 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3.2 Measuring axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.5 Renewing valve stem oil seals (cylinder head installed) . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.6 Renewing valve stem oil seals (cylinder head removed) . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.7 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.10 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.1 Sump (bottom section), sump (top section), oil pump, engine oil cooler - exploded view . . 218
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 220
1.3 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.4 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.6 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.7 Oil filter housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
ii Contents
Audi A6 2005 ➤
1.8 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

1.9 Oil retention valves, oil separator - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.10 Removing and installing crankcase breather hoses - not applicable for USA vehicles . . . . 237
1.11 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.12 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.13 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.14 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.3 Thermostat, coolant pump and connection - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 248
1.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
1.5 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.6 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.7 Coolant pipes - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 252
1.9 Removing and installing coolant pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.10 Removing and installing coolant pipes (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
1.11 Removing and installing Protected
coolant pipe (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by copyright. Copying for private or commercial purposes, in part or in whole, is not
258
1.12 Removing and installing radiator
with respect. to. the
. . correctness
. . . . . . of. .information
. . . . . .in.this
. .document.
. . . . . Copyright
. . . . . .by. AUDI
. . . AG.
........ 261
1.13 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.14 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.15 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.1 Exhaust system on vehicles with front-wheel drive - exploded view . . . . . . . . . . . . . . . . . . 269
1.2 Exhaust system on vehicles with four-wheel drive - exploded view . . . . . . . . . . . . . . . . . . 273
1.3 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1.4 Renewing tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
1.5 Removing and installing front exhaust pipe (left-side) with catalytic converter . . . . . . . . . . 279
1.6 Removing and installing front exhaust pipe (right-side) with catalytic converter . . . . . . . . 284
1.7 Exhaust manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
1.8 Removing and installing exhaust manifold (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
1.9 Removing and installing exhaust manifold (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
1.10 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
1.11 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Contents iii
Audi A6 2005 ➤
iv Contents
Audi A6 2005 ➤
00 – Technical data
1 Engine number
– Pull off engine cover panel (front) -arrows-.
♦ The engine number (“engine code” and “serial number”) can

be found on the front of the cylinder block beneath the cylinder
head (right-side) -arrow 1-.
♦ Additionally there is a sticker on the coolant pipe (front)
-arrow 2- showing the “engine code” and “serial number”.
♦ The engine code is also included on the vehicle data sticker.
1. Engine number 1
Audi A6 2005 ➤
2 Engine data
Code letters AUK BKH BYU
Capacity ltr. 3.123 3.123 3.123
Power output kW at rpm 188/6500 188/6500 183/6500
Torque Nm at rpm 330/3250 330/3250 330/3250
Bore ∅ in mm 84.5 84.5 84.5
Stroke mm 92.8 92.8 92.8
Compression ratio 12.5 12.5 12.5
RON at least 95 1) 95 1) 95 1)
Injection system/ignition system Simos Simos Simos
Firing order 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5
Exhaust gas recirculation no no no
Turbocharging/supercharging no no no
Knock control 2 sensors 2 sensors 2 sensors
Lambda control 2 probes before cat‐ 2 probes before cat‐ 2 probes before cat‐
alytic converter alytic converter alytic converter
2 probes
with respect to the correctnessafter cata‐ in this
of information 2 document.
probes Copyright
after cata‐by AUDI 2AG.probes after cata‐
lytic converter lytic converter lytic converter
Variable valve timing Inlet Inlet Inlet
Exhaust Exhaust Exhaust
Intake manifold change-over yes yes yes
Secondary air system no no no
Valves per cylinder 4 4 4
• 1) Unleaded regular grade petrol (RON 91) can also be used, but this will result in a loss of power
2 Rep. Gr.00 - Technical data

Audi A6 2005 ➤
3 Safety precautions
When working on the fuel system note the following warnings:
WARNING
The fuel system operates at extremely high pressure. This can

cause injury.
♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system.
– Procedure before opening high-pressure section of injection

system ⇒ Rep. Gr. 24 .
Observe the following to prevent injuries to persons and damage
to the injection and ignition system:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Always switch off ignition before washing engine.
♦ Faults are stored in engine control unit if electrical connectors
were unplugged and engine was started: “Generate readiness
code” in “Guided Functions” ⇒ Vehicle diagnosis, testing and
information system VAS 5051.
Caution
To prevent damage to the electronic components when dis‐

connecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Rep. Gr. 27 .

When working on the cooling system note the following warnings:
WARNING
Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on expan‐
sion tank with cloth and open carefully.
3. Safety precautions 3
Audi A6 2005 ➤
Note the following if testers and measuring instruments have to

be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test

equipment while road-testing, or if test equipment is not prop‐
erly secured.
Persons sitting in the front passenger's seat could be injured if
the airbag is triggered in an accident.
• The use of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.
3.1 Procedure before opening high-pres‐

sure section of injection system
WARNING
♦ The injection system consists of a high-pressure section

(maximum approx. 120 bar) and a low-pressure section
(approx. 6 bar).
♦ The fuel pressure in the high-pressure section must be
reduced to a residual pressure of approx. 5 bar prior to
opening the system. Procedure ⇒ Rep. Gr. 24 .

Audi A6 2005 ➤
4 General repair instructions
4.1 Rules for cleanliness when working on

fuel supply system and injection system
Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system and injection system:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections immediately with
clean plugs, e.g. from engine bung set -VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. 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.
Do not move the vehicle unless absolutely necessary.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
4.2 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 inspect high-pressure section of fuel system again for
leaks.
4.3 Foreign particles in engine

♦ When performing assembly work on engine, all open passag‐
es in the intake and exhaust systemsProtected
must by becopyright.
sealed withfor private or commercial purposes, in part or in whole, is not
Copying
suitable plugs (e.g. from engine bungpermitted
set -VAS unless6122- ) toby pre‐
authorised AUDI AG. AUDI AG does not guarantee or accept any liability
vent foreign particles from entering thewith
engine.
respect to the correctness of information in this document. Copyright by AUDI AG.
♦ 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
to prevent further damage occurring later.
4.4 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
used.
4. General repair instructions 5

Audi A6 2005 ➤
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 .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.
4.5 Routing and attachment of pipes, hoses

and wiring
Mark hydraulic lines, vacuum lines and electrical wiring before
removal so they can be re-installed in the original positions and
correctly connected. Make sketches or take photographs if nec‐
essary.
4.6 Installing radiators and condensers

Even when the radiator and condenser are correctly 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 or the condenser.
4.7 Checking vacuum system

Special tools and workshop equipment required
♦ Hand vacuum pump -VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the fault 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 pressure with the hand vacuum
pump -VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.

Audi A6 2005 ➤
10 – Removing and installing engine

1 Removing and installing engine - ve‐
hicles with manual gearbox
1.1 Removing engine
Special tools and workshop

equipment required
♦ Removal lever -80 - 200-permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Hose clamps for hoses up

to 25 mm -3094-
♦ Stepladder -VAS 5085-
♦ Engine bung set -VAS
6122-
♦ Scissor-type assembly
platform -VAS 6131 A- with
support set for Audi -VAS
6131/10-
♦ Drip tray for workshop hoist
-VAS 6208-
1. Removing and installing engine - vehicles with manual gearbox 7

Audi A6 2005 ➤
♦ Hose clip pliers -VAS 6362-
♦ Tensioning strap -T10038-
♦ Puller -T10369-
Procedure
Note
♦ The engine is removed from underneath together with the permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
gearbox and subframe (with lock carrier installed).

♦ Renew all cable ties which are released or cut open when re‐
moving the engine. Refit in the same position when installing
the engine.
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.
WARNING
Before removing the engine secure the vehicle against tipping

over. To do so, the luggage compartment must be empty.
8 Rep. Gr.10 - Removing and installing engine

Audi A6 2005 ➤
Caution
Observe notes on procedure for disconnecting the battery ⇒

Rep. Gr. 27 .
Note
♦ To make sure you can still move the front wheels when the
battery has been disconnected, only disconnect the battery
with the ignition key inserted.
♦ On four-wheel drive vehicles, the electronic parking brake
must be released before disconnecting the battery, so that the
propshaft can be turned during removal.
– With ignition switched off, disconnect battery earth cable

-arrow- ⇒ Rep. Gr. 27 .
– Pull off engine cover panel (rear) -arrows-.
WARNING
Hot steam or hot coolant can escape when expansion tank is

opened; cover filler cap with cloth and open carefully.
– Open filler cap on coolant expansion tank.

Audi A6 2005 ➤
Note
Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.
– To slacken poly V-belt turn tensioner in direction of -arrow-.

– Remove poly V-belt and release pressure from the tensioner.
– Remove both front wheels.
Note
Secure brake discs with wheel bolts.
– Remove noise insulation panels ⇒ Rep. Gr. 50 .
– Place drip tray for workshop hoist -VAS 6208- under engine.
– Open drain plug -1- and let coolant drain.
– Then disconnect coolant hose -2- from radiator.
– Disconnect coolant hose -arrow- at engine oil cooler and drain

off remaining coolant.
– Then remove coolant hose.

Audi A6 2005 ➤
– Unplug electrical connector -1- for magnetic clutch on air con‐

ditioner compressor.
WARNING
The air conditioner refrigerant circuit must not be opened.
– Unscrew air conditioner compressor from bracket -arrows-.
Note
To prevent damage to the refrigerant lines, ensure that the pipes

and hoses are not stretched, kinked or bent.
– Tie up air conditioner compressor with lines attached to left-

side of vehicle.
Note
Lay a cloth under the hydraulic lines to catch any escaping hy‐
draulic fluid.
– Clamp off hydraulic hose -1- for power steering pump using a
hose clamp -3094- .
– Disconnect hydraulic hose from power steering pump.
– Unbolt hydraulic pressure line -2- at power steering pump and
lay pressure line on top of longitudinal member.
– Seal off open pipes/lines and connections with clean plugs
from engine bung set -VAS 6122- .
Vehicles with auxiliary heater:

– Detach wheel housing liner (front left) at the front ⇒ Rep. Gr.
66 .
– Remove bolt -arrow- for corrugated exhaust pipe.
– Loosen nut -A- at clamp for corrugated exhaust pipe.

– Unscrew bolt -B- and remove silencer together with corruga‐
ted exhaust pipes.

Audi A6 2005 ➤
All vehicles:
– Unscrew bolts -arrows- and remove torque reaction support
from engine.
– Unbolt earth cable -arrow- at longitudinal member (right-side).
– Detach brake servo vacuum hose from grommet -arrow- at

plenum chamber partition panel.
– Disconnect coolant hose -arrow- leading to heat exchanger for

heater at rear of engine.

Audi A6 2005 ➤
– Disconnect coolant hoses -1- and -2- at coolant expansion

tank.
– Unbolt coolant expansion tank -arrow-.
– Detach electrical connector at coolant shortage indicator
switch -F66- on coolant expansion tank (bottom).
– Detach coolant hose -arrow- from coolant pipe (front).
– Remove coolant hose (front left) in engine compartment

-arrows-.

Audi A6 2005 ➤
USA models:
– Disconnect vacuum hose -arrow- leading to leak diagnostic
pump.
All vehicles:
Caution
Rules for cleanliness when working on the injection system

⇒ page 5 .
WARNING
The fuel system is pressurised. Before opening the low-pres‐

sure part of the injection system a clean cloth must be wrapped
around the connection and the residual pressure dissipated by
carefully loosening the connection.
– Disconnect fuel line -arrow- and move clear.

– Remove bolts -arrows-.

– Remove air ducts -1- and -2-.
– Pull non-return valve -1- off connection at air intake hose.

– Remove air intake hose. To do so, release hose clip -2- and
clamps -arrows-.

Audi A6 2005 ➤
– Release clamps -arrows- and detach air cleaner (top section).
– Disconnect vacuum pipe -1-.

– Pull out pin of fastener -3-.
– Remove air cleaner (bottom section) and unplug electrical
connector -2- on reverse side at variable intake manifold
changeover valve -N335- .
– Disconnect vacuum hose -arrow- leading to activated charcoal

filter.
– Unscrew nuts -2- and -3- and remove bracket for connectors
(right-side) from plenum chamber partition panel.
– Unbolt earth cable -1- at suspension turret (right-side).

Audi A6 2005 ➤
– Unbolt earth cable -arrow- at suspension turret (left-side).
– Remove
Protectedbracket (left-side)
by copyright. Copying for for connectors
private or commercial -1- andin-2-
purposes, partfrom ple‐is not
or in whole,
numpermitted
chamber unlesspartition
authorised bypanel.
AUDI AG. AUDI AG does not guarantee or accept any liability
– Pull off rubber seal -1- and remove plenum chamber cover
-2-.
– Use screwdriver to pry off caps on wiper arms and slacken off
nuts -arrows- several turns.

Audi A6 2005 ➤
– Apply puller -T10369/1- to wiper arm -1-, as shown in illustra‐

tion.
– Apply thrust piece -2- onto wiper shaft.
– Turn bolt -3- in clockwise direction until wiper arm is pulled off
wiper shaft.
– Remove nuts completely and take off wiper arms.
– Unscrew bolts -arrows- for cowl panel trim -1-.
Caution
To avoid cracking the cowl panel trim -1- during removal, apply
a small amount of soap solution to the joint between theunless
permitted wind‐ authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
screen and the cowl panel trim and pull the trim vertically upthe correctness of information in this document. Copyright by AUDI AG.
with respect to
out of the windscreen surround, starting from the edge of the
windscreen.
– Pull cowl panel trim off windscreen.
– If fitted, remove bolts -1- and -3- and detach body brace -2-.
– Unscrew bolts -arrows- and take off cover for electronics box
in engine compartment (left-side).

Audi A6 2005 ➤
– Release retainers and lift off fuse holder -1-; then lift off 3-po‐
sition relay carrier -4-.
– Unscrew electrical wiring -3-.
– Unplug all connectors -2- at rear of connector console.
– Disengage engine wiring harness at electronics box and move
it clear.
in engine compartment (right-side).
– If fitted, open cover -1- with screwdriver -arrow- and detach.
WARNING
The pump valve unit for heating system (left in front of elec‐
tronics box) gets very hot – risk of burns!
– Carefullywith
lever outto the
respect retaining
the correctness strap -3-
of information using
in this a screwdriver
document. Copyright by AUDI AG.
-arrows 1 and 2- and remove the engine control unit from the
electronics box.
Note
The engine control unit remains connected to the wiring harness.
– Unclip suppressor capacitor -5- and take out of retainer in

electronics box.
– Unplug electrical connector -4- at rear of connector console.
– Unscrew electrical wiring connections -1- and -2-.

Audi A6 2005 ➤
– Release electrical wiring up to the alternator using removal

lever -80 - 200- .
– Place both wiring harnesses on top of engine and secure the
engine control unit to prevent it falling.
– Have a 2nd mechanic press the brake pedal.
Caution
When slackening the flange bolt securing the drive shaft, the
wheel bearing must not be under load (vehicle must not be
standing on its wheels).
– Unscrew flange bolt -2- from drive shaft -1- (left and right).
– Unscrew nuts -1- evenly on
withboth
respectsides.
to the correctness of information in this document. Copyright by AUDI AG.
– Remove bolts -2- (left and right) and detach anti-roll bar.
– Unplug electrical connector -2- at vehicle level sender.

– Detach coupling rod -1- at track control link.

Audi A6 2005 ➤
Caution
Danger of damage to the swivel joints of the upper links.

♦ Support wheel bearing housing.
– Tie up wheel bearing housing using tensioning strap -T10038-

as illustrated.
– Unbolt suspension strut from track control link -arrow-.
– Unbolt guide link -1- and track control link -2- at subframe.
– Pivot guide link -1- and track control link -2- outwards.
Caution
The guide link and track control link must not be allowed to
hang down without support. Tie up both the guide link and track
control link to the wheel bearing housing as illustrated
-arrows-.
– Repeat procedure on other side of vehicle.

Audi A6 2005 ➤
– Unbolt heat shield for drive shaft -arrows-.

– Unbolt drive shaft from flange shaft on gearbox.
Caution
Take care not to damage brake hose.
– Pivot wheel bearing housing outwards and remove drive shaft.

– Unscrew connecting rod -2- of selector rod.

– Unbolt push rod -1- using hexagon key (8 mm) to remove bolt.
– Unscrew nut -arrow- and pull gearbox selector lever off selec‐
tor shaft.
– Remove clutch slave cylinder -arrow- and tie up with wire. Do

not open pipes.

Audi A6 2005 ➤
– Loosen clamps -1- and -2-.
– Unbolt cross piece (front) -arrows-.
Vehicles with four-wheel drive:

– Unscrew heat shield -A- for propshaft -arrows-.
– Unscrew bolts at gearbox/propshaft flange.
– Push propshaft back towards rear final drive. The constant
velocity joints can be moved axially.
– Tie propshaft up to side of heat shield -arrow-.

Audi A6 2005 ➤
All vehicles:
– Unbolt cross piece from subframe -arrows-.
Set up the scissor-type assembly platform as follows:

– Set up scissor-type assembly platform -VAS 6131 A- with sup‐
port set for Audi -VAS 6131/10- as follows:
Platform Parts of support set for Audi -VAS 6131/10-
coordinates
B4 /10-1 /10-4 /10-5 /10-11
F4 /10-1 /10-4 /10-5 /10-12
B10 /10-1 /10-2 /10-5 /10-8
G10 /10-1 /10-2 /10-5 /10-8
C12 /10-1
permitted unless /10-4
authorised by AUDI AG. /10-5
AUDI AG does not /10-6 or accept any liability
guarantee
F13 /10-1 /10-4 /10-5 /10-9
D16 /10-1 /10-3 /10-5 /10-6
– Initially tighten the support elements on the assembly platform
only hand-tight.
– Adjust the scissor-type assembly platform -VAS 6131 A- so
that it is horizontal.
• Take note of spirit level (bubble gauge).
– Place scissor-type assembly platform -VAS 6131 A- under en‐
gine/gearbox assembly.
– Position support elements from -VAS 6131/10- at front of en‐

gine, as shown in illustration.

Audi A6 2005 ➤
– Position support elements from -VAS 6131/10- at left and right

of subframe, as shown in the illustration.
– Position support elements from -VAS 6131/10- at rear of gear‐

box, as shown in illustration.
– Position support elements from -VAS 6131/10- at rear of tun‐

nel cross member, as shown in the illustration.
– Turn all spindles for the support elements upwards until all lo‐
cating lugs make contact with the mounting points.
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform -VAS 6131 A- .
– Remove bolts -arrows- at tunnel cross member.

Audi A6 2005 ➤
– Remove bolts -1-.

– Mark the installation position of the subframe and the two con‐
soles for engine mountings on the longitudinal members with
a felt-tip pen.
– Unscrew bolts -2-, -3- and -4- in a diagonal sequence and in
stages.
Note
♦ Check that all hoses and wiring connections between engine,

gearbox, subframe and body have been detached.
♦ Carefully guide out engine/gearbox assembly with subframe
from engine compartment when lowering to avoid damage.
– Lower engine/gearbox assembly gradually.

– Pull out scissor-type assembly platform -VAS 6131 A- from
under the vehicle.
1.2 Separating engine from manual gear‐with respect to the correctness of information in this document. Copyright by AUDI AG.
box
♦ Plate -VAS 6131/10-1- , support set for Audi -VAS 6131/11-
and -VAS 6131/12- .
Procedure
• Engine/gearbox assembly removed and secured to scissor-
– Screw down spindles of the support elements (left and right)
at subframe as far as possible.
– Remove locating lugs from spindles.
– Remove subframe to the side.
Note
A second mechanic is required for removing the subframe.
– Unscrew the two base plates for support elements (for sub‐
frame) on scissor-type assembly platform -VAS 6131 A- .
Note
The mounting points for engine (front), gearbox (rear) and tunnel
cross members remain unchanged.

Audi A6 2005 ➤

port set for Audi -VAS 6131/10- , -VAS 6131/11- and -
VAS 6131/12- as follows:
Platform Parts of support set for Audi -VAS 6131/10- , -
coordinates VAS 6131/11- and -VAS 6131/12-
B4 1) /10-1 /10-4 /10-5 /10-11
F4 1) /10-1 /10-4 /10-5 /10-12
B7 /10-1 /10-4 /10-5 /10-11
F7 /10-1 /10-4 /10-5 /10-10
B10 /10-1 /10-4 /10-5 /12-1
F10 /10-1 /10-3 /10-5 /11-3
C12 1) /10-1 /10-4 /10-5 /10-6
F13 1) /10-1 /10-4 /10-5 /10-9
D16 1) /10-1 /10-3 /10-5 /10-6
• 1) Support elements remain unchanged.
– permitted
Position support elements from -VAS 6131/10- and -
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
VAS 6131/12- on left side of engine/gearbox assembly, as

shown in illustration.
– Position support elements from -VAS 6131/10- and -

VAS 6131/11- on right side of engine/gearbox assembly, as
– Turn spindles for the support elements upwards until all locat‐
ing lugs make contact with the mounting points.
– Unplug electrical connector -arrow- at engine speed sender -

G28- .

Audi A6 2005 ➤
– Unplug electrical connector -2- for Lambda probe 2 after cat‐

alytic converter -G131- and move wiring clear.
Note
♦ Illustration shows electrical connector when installed.

♦ Disregard -item 1-.
Note
To avoid any damage, the flexible joint in the front exhaust pipe
must not be bent more than 10°.
– Remove bolts -1- on bracket (rear) for exhaust system.
Note
Disregard items marked -2- and -3-.
– Remove bolt -1- on bracket (left-side) for front exhaust pipe.

Note with respect to the correctness of information in this document. Copyright by AUDI AG.
Disregard -item 2-.
– Remove nuts -1 ... 3-.

– Detach front exhaust pipe (left-side) with catalytic converter.

Audi A6 2005 ➤
– Unplug electrical connector -arrow- for reversing light switch -

F4- and move wiring clear.
– Unplug electrical connector -2- for Lambda probe after cata‐

lytic converter -G130- and move wiring clear.
Note

Note
Note
– Remove bolt -1- on bracket (right-side) for front exhaust pipe.
Note
Disregard -item 2-.

Audi A6 2005 ➤

– Detach front exhaust pipe (right-side) with catalytic converter.
– Remove engine/gearbox securing bolts -1 ... 10-.
– Loosen the clamping bolts -1- on sides of scissor-type assem‐

bly platform -VAS 6131 A- and pull rear section of platform
together with the gearbox towards rear -arrow-.
1.3 Installing engine
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew bolts which are tightened to a specified angle as well
as seals, gaskets and O-rings.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ Fit all cable ties in the original positions when installing.
– Install engine supports with engine mountings ⇒ page 95 .

– When fitting a new clutch plate together with a used pressure
plate (self-adjusting clutch), the adjuster ring in the pressure
plate has to be reset by turning it back as far as it will go. If this
is not done, the pressure plate will operate with reduced
clamping force, causing clutch slip ⇒ Rep. Gr. 30 .

Audi A6 2005 ➤
Note
♦ If the clutch plate is not being replaced, it is not necessary to

reset the adjuster ring.
♦ New SAC pressure plates are already pre-set accordingly, and
do not have to be reset.
– Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease -G 000 100- to the splines. Do not lubricate
guide sleeve. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Check that the clutch plate is properly centralised (only nec‐
essary if you have carried out other work on the clutch).
– Check clutch release bearing for wear and make sure that
plastic ring is securely seated ⇒ Rep. Gr. 30 .
– A needle bearing must be fitted in the crankshaft on vehicles
with manual gearbox; install needle bearing if not already fitted
⇒ page 115 .
– Check whether dowel sleeves -A- for centring engine and
gearbox are fitted in cylinder block; install missing dowel
sleeves.
– Press intermediate plate between engine and gearbox onto
dowel sleeves.
– Bolt gearbox to engine.
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gearbox oil may be
used, but do not use lubricants containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques ± 15 %.

Audi A6 2005 ➤
Securing engine to gearbox

Item Bolt Nm
1 M12x130 65
2 M12x140 65
3, 4, 5 M12x105 65
6 M12x120 65
7 M10x150 65 1)
8, 9, 10 M10x70 45
A Dowel sleeves for centralising
• 1) Bolt strength rating 10.9
Perform further installation in reverse order, paying attention to

the following:
– Install front exhaust pipes: left-side ⇒ page 279 , right-side
⇒ page 284 .
– Vehicles with four-wheel drive: The threaded holes in the
flange shaft for the propshaft on the gearbox must be cleaned
with a thread tap to remove remaining locking fluid before as‐
sembling.
– Screw down spindles of support elements on left side of en‐

– Unscrew both base plates for support elements (left-side) at
scissor-type assembly platform -VAS 6131 A- .
– Screw down spindles of support elements on right side of en‐

– Unscrew both base plates for support elements (right-side) at
The mounting points for engine (front), gearbox (rear) and tunnel
cross members remain unchanged.

Audi A6 2005 ➤

coordinates
B4 1) /10-1 /10-4 /10-5 /10-11
F4 1) /10-1 /10-4 /10-5 /10-12
B10 /10-1 /10-2 /10-5 /10-8 2)
G10 /10-1 /10-2 /10-5 /10-8 2)
C12 1) /10-1 /10-4 /10-5 Protected/10-6
F13 1) /10-1 /10-4 /10-5 /10-9

D16 1) /10-1 /10-3 /10-5 /10-6

• 2) Secure support elements only after installing the subframe.
Note
A second mechanic is required for positioning the subframe on

the support elements.
– Fit subframe onto the two support elements -VAS 6131/10-8- .

– Screw up the spindles for support elements on both sides.
– Carefully guide engine/gearbox assembly together with sub‐
frame into the body from below using scissor-type assembly
platform -VAS 6131 A- .
– Adjust the subframe and consoles for engine mountings ac‐

cording to the markings made on the longitudinal members
during removal.
– Only tighten bolts for subframe and consoles for engine
mountings to the specified torque (do not turn further); tighten
bolts to final setting only after performing wheel alignment
check ⇒ Rep. Gr. 40 .
WARNING
The vehicle must not be driven at this stage.

Audi A6 2005 ➤
– Tighten bolts -arrows- for tunnel cross member ⇒ Rep. Gr.

34 .
the following:
– Install clutch slave cylinder ⇒ Rep. Gr. 30 .
– Fit selector linkage to gearbox ⇒ Rep. Gr. 34 .
– Install drive shafts ⇒ Rep. Gr. 40 .
– Install guide links, track control links, anti-roll bar and suspen‐
sion struts ⇒ Rep. Gr. 40 .
– Install cross piece for subframe ⇒ Rep. Gr. 40 .
– Install cross piece (front) ⇒ Rep. Gr. 50 .
– Vehicles with four-wheel drive: Install propshaft ⇒ Rear final
drive 01R; Rep. Gr. 39 .
– Align exhaust system so it is free of stress ⇒ page 293 .
– Secure hydraulic pressure line at power steering pump ⇒ Rep.
Gr. 48 .
– Install air conditioner compressor ⇒ Rep. Gr. 87 .
– Install poly V-belt ⇒ page 108 .
– Install torque reaction support ⇒ page 102 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Observe notes on procedures required after connecting bat‐
tery ⇒ Rep. Gr. 27 .
Caution
Do not use a battery charger to boost starting. There is danger

of damaging the vehicle's control units.
– Check oil level ⇒ Maintenance ; Booklet 405 .

– Bleed fuel system ⇒ Rep. Gr. 24 .
– Fill cooling system ⇒ page 245 .
Note
♦ Drained-off coolant
Protected may Copying
by copyright. only be usedoragain
for private if the
commercial original
purposes, in partcyl‐
or in whole, is not
inder head andrespect

cylinder block are re-installed.
with to the correctness of information in this document. Copyright by AUDI AG.
♦ Contaminated or dirty coolant must not be used again.
– Top up power steering fluid and bleed steering system ⇒ Rep.

Gr. 48 .
– Install and adjust wiper arms ⇒ Rep. Gr. 92 .
– Adjust subframe and the two consoles for engine mountings
⇒ Rep. Gr. 40 .
– Perform wheel alignment check ⇒ Rep. Gr. 44 .

Audi A6 2005 ➤
WARNING
Tighten bolts for subframe to final setting after performing

wheel alignment check.
Tightening torques
Note

Component Nm
Bolts/nuts M6 9
M8 20
M10 40
M12 65
Except for the following:
Fuel hose to fuel line permitted unless authorised by AUDI AG. AUDI AG 22does not guarantee or accept any liability
Hose clips (9 mm wide) 3
Hose clips (13 mm wide) 5.5

Audi A6 2005 ➤

hicles with multitronic gearbox
2.1 Removing engine

equipment required
♦ Removal lever -80 - 200-
to 25 mm -3094-
6122-
6131/10-
-VAS 6208-
♦ Used oil collection and extraction unit -V.A.G 1782-
2. Removing and installing engine - vehicles with multitronic gearbox 35

Audi A6 2005 ➤
♦ Tensioning strap -T10038-
♦ Puller -T10369-
Procedure
Note
♦ The engine is removed from underneath together with the

the engine.
posal.
WARNING


Audi A6 2005 ➤
Caution

Rep. Gr. 27 .
Note
To make sure you can still move the front wheels when the battery
has been disconnected, only disconnect the battery with the ig‐
nition key inserted.
With ignition switched off, disconnect battery earth cable -arrow-

⇒ Rep. Gr. 27 .

WARNING


Audi A6 2005 ➤
Note


Note


Audi A6 2005 ➤

WARNING
Note


side of vehicle.
Note
draulic fluid.
hose clamp -3094- .
lay onto longitudinal member above.

66 .

ted exhaust pipes.

Audi A6 2005 ➤
All vehicles:
from engine.
Note
Observe rules for cleanliness when working on automatic gear‐

box ⇒ Rep. Gr. 00 .
– Position used oil collection and extraction unit -V.A.G 1782-

below connection point.
– Unscrew union nuts -2- and -3- and disconnect ATF pipes.
from engine bung set
Protected -VAS 6122-
by copyright. Copying .for private or commercial purposes, in part or in whole, is not
Note
Disregard -item 1-.
– Detach vacuum hose -arrow- going to brake servo at plenum

chamber partition panel.

Audi A6 2005 ➤


tank.
– Detach electrical connector
permitted unless authorised byat coolant
AUDI AG. AUDI shortage
AG does notindicator
guarantee or accept any liability

-arrows-.

Audi A6 2005 ➤
USA models:
pump. with respect to the correctness of information in this document. Copyright by AUDI AG.
All vehicles:
Caution

⇒ page 5 .
WARNING
The fuel system is pressurised. Wrap a cloth around the con‐

nection before opening the system. Then release pressure by



Audi A6 2005 ➤
– Pull non-return valve -1- off air intake hose.

clamps -arrows-.


filter.

Audi A6 2005 ➤
– Remove bracket (left-side) for connectors -1- and -2- from ple‐
num chamber partition panel.
-2-.

Audi A6 2005 ➤

tion.
wiper shaft.
Caution
a small amount of soap solution to the joint between the wind‐
screen and the cowl panel trim and pull the trim vertically up
windscreen.

Audi A6 2005 ➤
– Unscrew electrical wiring -3-.
it clear.

Audi A6 2005 ➤
WARNING
– Carefully lever out the retaining strap -3- using a screwdriver

electronics box.
Note

electronics box.

lever -80 - 200- .
Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Unscrew nuts -1- evenly on both sides.


Audi A6 2005 ➤

Caution

– Tie up wheel bearing housing using tensioning strap -T10038-

as illustrated.

Audi A6 2005 ➤
Caution
-arrows-.
– Unbolt heat shield for drive shaft -arrows-.

Caution


Audi A6 2005 ➤

coordinates
B4 /10-1 /10-4 /10-5 /10-11
G4 /10-1 /10-4 /10-5 /10-12
B10 /10-1 /10-2 /10-5 /10-8
G10 /10-1 /10-2 /10-5 /10-8
E13 /10-1 /10-3 /10-5 /10-6
D16 /10-1 /10-3 /10-5 /10-6
only hand-tight.
• Take note of spirit level (bubble gauge).
– Place scissor-type assembly platform -VAS 6131 A- under en‐

– Make sure that threaded spindles are screwed in completely.

Audi A6 2005 ➤

– Position support elements from -VAS 6131/10- at rear of tun‐

nel cross member, as shown in the illustration.
– Remove bolts -arrows- at tunnel cross member.

a felt-tip pen.
stages.
Note

– Lower engine/gearbox assembly gradually (approx. 10 cm).

Audi A6 2005 ➤
– Mark installation position of support bracket for selector lever

cable.
– Unscrew bolt -1- for support bracket for selector lever cable.
– Push ball socket -2- of selector lever cable off gearbox selector
lever.
Note
Take care not to bend or kink selector lever cable.
– Lower the scissor-type assembly platform -VAS 6131 A- com‐

pletely and pull it out together with engine/gearbox assembly
from beneath the vehicle.
2.2 Detaching multitronic gearbox from en‐

gine
♦ Support set for Audi -VAS 6131/10- and supplementary set -
VAS 6131/12-
Procedure
– Remove bracket -arrow- for ATF lines.
Note

– Unscrew bolt -arrow- and detach ATF pipes from gearbox.


Audi A6 2005 ➤
Note
The mounting points for engine (front) and tunnel cross member
remain unchanged.

port set for Audi -VAS 6131/10- and -VAS 6131/12- as follows:
Platform Parts of support set -VAS 6131/10- and -
coordinates VAS 6131/12-
B4 1) /10-1 /10-4 /10-5 /10-11
G4 1) /10-1 /10-4 /10-5 /10-12
B7 /10-1 /10-4 /10-5 /10-11
G7 /10-1 /10-4 /10-5 /10-10
C10 /10-1 /10-4 /10-5 /12-1
G10 /10-1 /12-2 /10-5 /12-1
E13 1) /10-1 /10-3 /10-5 /10-6
D16 1) /10-1 /10-3 /10-5 /10-6

VAS 6131/12- on left side of engine/gearbox assembly, as

VAS 6131/12- on right side of engine/gearbox assembly, as

Audi A6 2005 ➤
– Release electrical connector -1- and detach from gearbox.

– Move wiring harness going to engine clear -arrows-.
– Unplug electrical connector -arrow- leading to engine speed

sender -G28- .

alytic converter -G131- and move wiring clear.
Note

Note
Note

Audi A6 2005 ➤
Note
Disregard -item 2-.


Note

Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note

Audi A6 2005 ➤
Note
Disregard -item 2-.

– Loosen the clamping bolts -1- on sides of scissor-type assem‐

bly platform -VAS 6131 A- and pullpermitted
rear section of platform
together with the gearbox towards rear -arrow-.

Audi A6 2005 ➤
Note

work.
♦ Clean input shaft splines and splines of damper unit on fly‐
wheel; remove corrosion and apply only a very thin coating of
grease -G 000 100- to the splines. Remove any excess
grease.

sleeves.
– Bolt gearbox to engine (use new bolts).
Note

♦ Tolerance for tightening torques ± 15%.

Item Bolt 1 Nm
1, 7 M10x100 65 2)
2 M12x120 65
3, 5 M12x100 65
4, 6 M12x95 65
8, 9, 10 M10x70 45
• 1) Renew bolts for securing engine/gearbox.
• 2)
Protected byBolt strength
copyright. Copying rating
for private10.9
or commercial purposes, in part or in whole, is not
the following:
– Install front exhaust pipes together with catalytic converter:
left-side ⇒ page 279 , right-side ⇒ page 284 .
– Secure ATF lines ⇒ Rep. Gr. 37 .

Audi A6 2005 ➤
– Screw down spindles of support elements on left side of en‐

– Unscrew both base plates for support elements (left-side) at
– Screw down spindles of support elements on right side of en‐

– Unscrew both base plates for support elements (right-side) at
Note
The mounting points for engine (front) and tunnel cross member
remain unchanged.

coordinates
B4 1) /10-1 /10-4 /10-5 /10-11
G4 1) /10-1 /10-4 /10-5 /10-12
B10 /10-1 /10-2 /10-5
with respect to the correctness of information in this document. Copyright by2)
/10-8
AUDI AG.
G10 /10-1 /10-2 /10-5 /10-8 2)

E13 1) /10-1 /10-3 /10-5 /10-6
D16 1) /10-1 /10-3 /10-5 /10-6


Audi A6 2005 ➤

during removal.
bolts only after performing wheel alignment check ⇒ Rep. Gr.
40 .
WARNING

Audi A6 2005 ➤
– Tighten bolts -arrows- at tunnel cross member ⇒ Rep. Gr.

37 .
the following:
– Install selector lever cable and check adjustment if necessary
⇒ Rep. Gr. 37 .
– Install cross piece (front) for subframe ⇒ Rep. Gr. 40 .
Gr. 48 .
Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability


Note
♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.

Gr. 48 .
– Check ATF level ⇒ Rep. Gr. 37 .
⇒ Rep. Gr. 40 .
WARNING


Audi A6 2005 ➤
Tightening torques
Note

Component Nm
Bolts/nuts M6 9
M8 20
M10 40
M12 65
Fuel hose to fuel line 22

Audi A6 2005 ➤

hicles with automatic gearbox 09L
3.1 Removing engine

equipment required
♦ Removal lever -80 - 200-
to 25 mm -3094-

6122-
6131/10-
-VAS 6208-

Audi A6 2005 ➤
♦ Tensioning strap -T10038- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Puller -T10369-
Procedure
Note
♦ The engine is removed from underneath together with the

the engine.
posal.
WARNING

3. Removing and installing engine - vehicles with automatic gearbox 09L 63

Audi A6 2005 ➤
Caution

Rep. Gr. 27 .
Note
♦ To make sure you can still move the front wheels when the
battery has been disconnected, only disconnect the battery
with the ignition key inserted.
♦ On four-wheel drive vehicles, the electronic parking brake
must be released before disconnecting the battery, so that the
propshaft can be turned during removal.
– With ignition switched off, disconnect battery earth cable

-arrow- ⇒ Rep. Gr. 27 .
WARNING


Audi A6 2005 ➤
Note


Note


Audi A6 2005 ➤

WARNING
Note


side of vehicle.
Note
draulic fluid.
hose clamp -3094- .
lay onto longitudinal member above.

66 .

ted exhaust pipes.

Audi A6 2005 ➤
All vehicles:
from engine.
Note


– Unscrew union nuts -2- and -3- and disconnect ATF pipes.
Note
Disregard -item 1-.
– Detach brake servo vacuum hose from grommet -arrow- at

plenum chamber partition panel.

Audi A6 2005 ➤


tank.
– Detach electrical connector at coolant shortage indicator

-arrows-.

Audi A6 2005 ➤
USA models:
pump.
All vehicles:
Caution

⇒ page 5 .
WARNING
The fuel system is pressurised. Before opening the low-pres‐

sure part of the injection system a clean cloth must be wrapped
around the connection and the residual pressure dissipated by



Audi A6 2005 ➤

clamps -arrows-.



filter.

Audi A6 2005 ➤
– Remove bracket (left-side) for connectors -1- and -2- from ple‐
num chamber partition panel.
-2-.

Audi A6 2005 ➤

tion.
wiper shaft.
Caution
a small amount of soap solution to the joint between the wind‐
screen and the cowl panel trim and pull the trim vertically up
windscreen.

Audi A6 2005 ➤
– Unscrew electrical wiring -3-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
it clear.

Audi A6 2005 ➤
WARNING
– Carefully lever out the retaining strap -3- using a screwdriver

electronics box.
Note

electronics box.

lever -80 - 200- .
Caution

– Unscrew nuts -1- evenly on both sides.


Audi A6 2005 ➤

Caution

– respect
Tie to
upthewheel bearing housing using tensioning strap
AG.-T10038-
with correctness of information in this document. Copyright by AUDI
as illustrated.

Audi A6 2005 ➤
Caution
-arrows-.

Caution

Note
Mark installation position of support bracket for selector lever ca‐

ble with a felt-tip pen.
– Push ball socket -1- of selector lever cable off gearbox selector
lever.
– Unbolt cable support bracket from gearbox -arrows-.
– Move selector lever cable clear.

Audi A6 2005 ➤
– Unscrew heat shield -A- for propshaft -arrows-.

– Unscrew bolts at gearbox/propshaft flange.
– Push propshaft back towards rear final drive. The constant
velocity joints can be moved axially.
– Tie propshaft up to side of heat shield -arrow-.

Audi A6 2005 ➤

B5 /10-1 /10-4 /10-5 /10-11
F5 /10-1 /10-4 /10-5 /10-12
B11 /10-1 /10-2 /10-5 /10-8
G11 /10-1 /10-2 /10-5 /10-8
E9 /10-1 /10-3 /10-5 /11-3
D10 /10-1 /10-2 /10-5 /12-1
G14 /10-1 /10-4 /10-5 /10-13
D16 /10-1 /10-3 /10-5 /10-6
only hand-tight.
• Take note of spirit level (bubble gauge). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Place scissor-type assembly platform -VAS 6131 A- under en‐ to the correctness of information in this document. Copyright by AUDI AG.
with respect



Audi A6 2005 ➤
– Place support elements from -VAS 6131/10- and -

VAS 6131/12- at left of gearbox and at tunnel cross member,
as shown in illustration.

VAS 6131/11- on right side of gearbox, as shown in illustration.
– Remove bolts -arrows-permitted

at tunnelunlesscross member.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

a felt-tip pen.
stages.
Note

– Lower engine/gearbox assembly gradually.

– Pull out scissor-type assembly platform -VAS 6131 A- from
under the vehicle.

Audi A6 2005 ➤
3.2 Separating engine from automatic gear‐

box 09L
♦ Adapter -T40058-
Procedure
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
A second mechanic is required for removing the subframe.
Note
The mounting points for engine (front), gearbox and tunnel cross
member remain unchanged.

Audi A6 2005 ➤

B5 1) /10-1 /10-4 /10-5 /10-11
F5 1) /10-1 /10-4 /10-5 /10-12
B8 /10-1 /10-4 /10-5 /10-11
G8 /10-1 /10-4 /10-5 /10-10
E9 1) /10-1 /10-3 /10-5 /11-3
D10 1) /10-1 /10-4 /10-5 /12-1
G14 1) /10-1 /10-4 /10-5 /10-13
D16 1) /10-1 /10-3 /10-5 /10-6
– Position support elements from -VAS 6131/10- on left side of

engine, as shown in illustration.
– Position support elements from -VAS 6131/10- on right side of

engine, as shown in illustration.
– Unplug electrical connector -2- for Lambda probeProtected

2 afterbycat‐
alytic converter -G131- and move wiring clear. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
copyright. Copying for private or commercial purposes, in part or in whole, is not
Note


Audi A6 2005 ➤
Note
Note
Note
Ignore other items.


Note


Audi A6 2005 ➤
Note
Note
Note
Ignore other items.

Note

– Unbolt bracket -arrow- for ATF lines at sump.

Audi A6 2005 ➤
– Unbolt bracket -arrow- for ATF lines at gearbox (bottom).
Note
Lay a cloth under the ATF pipes to catch escaping ATF fluid.
– Remove bolt -arrow-.

– Detach ATF lines from gearbox.
– Unplug electrical connector -arrow- at engine speed sender -

G28- .
– Turn retainer catch anti-clockwise -arrow- and unplug electri‐

cal connector at gearbox.

Audi A6 2005 ➤
– If fitted, unplug electrical connector -1- on right electrohydraul‐

ic engine mounting solenoid valve -N145- .
– Move wiring clear at console for engine mounting.
– Remove bolts -arrows- and detach engine support (right-side).
Note
Shown in illustration without console for engine mounting.
– Detach electrical wires -2- and -3- at starter.

– Remove bolts -1- and -4- and detach starter.
– Insert guide pin of adapter -T40058- with the larger-diameter

section -arrow 1- pointing towards the engine. The smaller-
diameter section -arrow 2- faces the adapter.
– When loosening torque converter bolts, counterhold crank‐

shaft using adapter -T40058- .
Note
Ignore -arrow-.

Audi A6 2005 ➤
– Unscrew the three bolts -arrows- for torque converter, working

through opening of removed starter (turn crankshaft 1/3 turn
each time).
– Loosen clamping bolts -1- on sides of scissor-type assembly

platform -VAS 6131 A- and pull rear section of platform to‐
gether with gearbox towards the rear -arrow-; simultaneously
separate the torque converter from the drive plate through the
opening.
– Secure the torque converter in the gearbox to prevent it falling
out.

♦ Depth gauge -VAS 6082-

Audi A6 2005 ➤
Procedure
Note

work.

– Check installation depth of torque converter: if the torque con‐
verter has been correctly installed, the distance between the
contact surfaces at the threaded holes in the torque converter
and the contact surface on the torque converter bell housing
(with automatic gearbox 09L) is at least 19 mm.
Caution
If the torque converter is not installed correctly, the drive lugs

of the torque converter and the ATF pump will be seriously
damaged when the gearbox is joined to the engine.
– Before bringing engine and gearbox together, turn torque con‐
verter and drive plate on engine so that the holes for one
securing bolt are in line with the opening for the starter motor
-arrow-.
– To secure torque converter on drive plate, use only new ribbed
bolts of the correct type (same as original equipment) as
specified in ⇒ Electronic parts catalogue .

Audi A6 2005 ➤

sleeves.
– Press intermediate plate between engine and gearbox onto
dowel sleeves.
– Bolt gearbox to engine.
Caution
Before and during tightening of bolts on engine/gearbox flange,

continually check that the torque converter behind the drive
plate can be turned. If the converter cannot be turned, it must
be assumed that it has not been installed correctly and the
drive lugs of the ATF pump and consequently the gearbox will
be damaged when the bolts are finally tightened.
Note


Item Bolt Nm
1 M10x100 65 1)
2, 6 M12x120 65
3, 4, 5 M12x105 65
7 M12x130 65
8, 9, 10 M10x80 45
• 1) Bolt strength rating 10.9

the following:
– Secure ATF lines ⇒ Rep. Gr. 37 .
– Install front exhaust pipes: left-side ⇒ page 279 , right-side
⇒ page 284 .
– Prior to assembly, always use a thread tap to remove remain‐
ing locking fluid from the tapped holes in the flange shaft for
the propshaft on the gearbox.

Audi A6 2005 ➤
– Screw spindle for support element (left-side) at engine down‐

wards.
– Unscrew base plate for support element (left-side) at scissor-
– Screw spindle for support element (right-side) at engine down‐

wards.
– Unscrew base plates for support element (right-side) atunless
permitted scis‐authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sor-type assembly platform -VAS 6131 A- . with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
The mounting points for engine (front), gearbox and tunnel cross
member remain unchanged.

coordinates
B5 1) /10-1 /10-4 /10-5 /10-11
F5 1) /10-1 /10-4 /10-5 /10-12
B11 /10-1 /10-2 /10-5 /10-8 2)
G11 /10-1 /10-2 /10-5 /10-8 2)
E9 1) /10-1 /10-3 /10-5 /11-3
D10 1) /10-1 /10-2 /10-5 /12-1
G14 1) /10-1 /10-4 /10-5 /10-13
D16 1) /10-1 /10-3 /10-5 /10-6

Audi A6 2005 ➤
Note
A second mechanic is required for positioning the subframe on

the support elements.


during removal.
bolts only after performing wheel alignment check ⇒ Rep. Gr.
40 .
WARNING

Audi A6 2005 ➤
– Tighten bolts -arrows- for tunnel cross member ⇒ Rep. Gr.

37 .
the following:
– Install selector lever cable and check adjustment if necessary
⇒ Rep. Gr. 37 .
– Install propshaft ⇒ Rear final drive 01R; Rep. Gr. 39 .
Gr. 48 .
Caution


– Install body brace ⇒ Protected
Rep. Gr. 40 . Copying for private or commercial purposes, in part or in whole, is not
by copyright.
– Check oil level ⇒ Maintenance
with respect;toBooklet 405
the correctness .
of information in this document. Copyright by AUDI AG.

Note
♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.

Gr. 48 .
⇒ Rep. Gr. 40 .

Audi A6 2005 ➤
WARNING

Tightening torques
Note

Component Nm
Bolts/nuts M6 9
M8 20
M10 40
M12 65
Drive plate to torque converter 85 1)
Terminal B+ to starter 16
• 1) Renew ribbed bolts; use only genuine bolts (same as
original equipment) ⇒ Electronic parts catalogue .

Audi A6 2005 ➤
4 Securing engine to engine and gearbox support

equipment required
♦ Lifting tackle -2024 A-
♦ Engine and gearbox sup‐
port -VAS 6095- with brack‐
et -VAS 6095/1-5-
♦ Workshop hoist -
VAS 6100-
♦ Lift arm extension (work‐
shop hoist) -VAS 6101-
Procedure
• Engine separated from gearbox
⇒ “1.2 Separating engine from manual gearbox”, page 25 ,
⇒ “2.2 Detaching multitronic gearbox from engine”, page 52 ,
⇒ “3.2 Separating engine from automatic gearbox 09L”, page
80 .
4. Securing engine to engine and gearbox support 93

Audi A6 2005 ➤
– Attach the lifting tackle -2024 A- to engine and workshop hoist

-VAS 6100- with lift arm extension (workshop hoist) -
VAS 6101- as shown in the illustration.
Note
To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.
WARNING
The support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
– If fitted, unplug electrical connector -1- on left electrohydraulic
engine mounting solenoid valve -N144- .

– Remove bolts -arrows- and detach engine support (left-side).
Note
Shown in illustration without console for engine mounting.
Vehicles with manual gearbox or multitronic gearbox:

– Repeat procedure on other side of engine.
All vehicles (continued):

– Using bracket -VAS 6095/1-5- , secure engine to engine and
gearbox support -VAS 6095- as shown in the illustration. Tight‐
ening torque: 40 Nm.

Audi A6 2005 ➤
5 Assembly mountings
5.1 Assembly mountings - exploded view
1 - Stop for torque reaction

support
❑ Must rest at top and bot‐
tom of buffer for torque
reaction support, so that
there is no play
2 - 40 Nm
3 - Torque reaction support
❑ Removing and installing
⇒ page 102
4 - 40 Nm
5 - 75 Nm
6 - Console for engine mount‐
ing (right-side)
⇒ “5.3 Removing and in‐
stalling engine mount‐
ing (right-side)”,
page 99
7 - Engine mounting (right-
side)
⇒ page 99
8 - 40 Nm
9 - 40 Nm
10 - Engine support (right-side)
⇒ page 99
11 - Engine support (left-side)
⇒ page 96
Protected12 - 40 Nm
13 - Engine
with respect mounting
to the correctness (left-side)
❑ Removing and installing ⇒ page 96

14 - Console for engine mounting (left-side)
❑ Removing and installing ⇒ “5.2 Removing and installing engine mounting (left-side)”, page 96
15 - 75 Nm
16 - 40 Nm
17 - 40 Nm
18 - 40 Nm
5. Assembly mountings 95
Audi A6 2005 ➤
5.2 Removing and installing engine mount‐

ing (left-side)
♦ Support bracket -10 - 222 A-
♦ Engine support bracket (basic set) -T40091-
♦ Engine support bracket (supplementary set) -T40093-
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull off engine cover panel (rear)with

-arrows-.

Audi A6 2005 ➤
-2-.
– Set up adapter -10 - 222 A /4- with connecting piece -

T40091/3- and supports -T40093/1- and -T40093/2- on sus‐
pension turrets as illustrated.
• Supports are marked for left and right side of vehicle.
– Attach further components of support bracket -10 - 222 A- , -

T40091- and -T40093- as shown in illustration. Position sup‐
port -T40093/3- onto flange of longitudinal member.
– Engage hook -10 - 222 A /10- at engine lifting eye (left-side).
– Take up weight of engine with spindle.
Audi A6 2005 ➤

– Remove front left wheel.
– Remove front left wheel housing liner ⇒ Rep. Gr. 66 .
– Slacken nut -A- on clamp for corrugated exhaust pipe.

– Remove bolt -B- and detach exhaust silencer with corrugated
exhaust pipes.
All vehicles (continued):

– Remove bolts -1- and -2- for anti-roll bar mounting on both
sides and slightly lower anti-roll bar.
– Remove nut -3-.

– Remove bolts -1- and -2- and take off console for engine
mounting (left-side).
Note
The procedure is illustrated for the console for engine mounting

(right-side).

Audi A6 2005 ➤
– If fitted, unplug electrical connector -1- on left electrohydraulic

engine mounting solenoid valve -N144- .
– Remove bolts -arrows- and detach engine support with engine
mounting.
– Remove nut -arrow- and detach engine mounting from engine

support.
Installing
• Tightening torques ⇒ page 95
Installation is carried out in the reverse order; note the following:
Note
♦ Renew the bolts tightened with specified tightening angle.

– Install subframe and anti-roll bar ⇒ Rep. Gr. 40 .

– On vehicles with auxiliary heater: install exhaust silencer with
corrugated exhaust pipes ⇒ Rep. Gr. 82 .
5.3 Removing andunlessinstalling engine mount‐

permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ing (right-side)

♦ Support bracket -10 - 222 A-
Audi A6 2005 ➤
♦ Engine support bracket (basic set) -T40091-
♦ Engine support bracket (supplementary set) -T40093-
Removing
– Remove air cleaner housing ⇒ Rep. Gr. 24 .
-2-.

Audi A6 2005 ➤
– Set up adapter -10 - 222 A /4- with connecting piece -

T40091/3- and supports -T40093/1- and -T40093/2- on sus‐
pension turrets.
• Supports are marked for left and right side of vehicle.
– Attach further components of support bracket -10 - 222 A- , -

T40091- and -T40093- as shown in illustration. Position sup‐
port -T40093/3- onto flange of longitudinal member.
– Engage hook -10 - 222 A /10- at engine lifting eye (left-side).
– Take up weight of engine with spindle.
– Remove bolts -1- and -2- for anti-roll bar mounting on both
sides and slightly lower anti-roll bar.

Audi A6 2005 ➤
– Remove nut -3-.

– Remove bolts -1- and -2- and take off console for engine
mounting (right-side).
– Unplug electrical connector -1- on right electrohydraulic en‐

gine mounting solenoid valve -N145- .
– Remove bolts -arrows- and detach engine support with engine
mounting.
– Remove nut -arrow- and detach engine mounting from engine

support.
Installing
Note
♦ Renew the bolts tightened with specified tightening angle.

– Install subframe and anti-roll bar ⇒ Rep. Gr. 40 .

– Install air cleaner housing ⇒ Rep. Gr. 24 .
5.4 Removing and installing torque reaction

support
Removing

Audi A6 2005 ➤
– Unscrew bolts -arrows- and detach torque reaction support

from engine.
Installing
– Allow stop for torque reaction support to rest on rubber buffer
for torque reaction support under its own weight, and tighten
bolts.
– Install noise insulation panels ⇒ Rep. Gr. 50 .

Audi A6 2005 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
1.1 Poly V-belt drive - exploded view
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen.
If the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 108
❑ When installing, make
sure it is properly seated
on pulleys.
2 - 20 Nm + 90° further
❑ Renew
3 - 22 Nm
4 - Alternator
⇒ Rep. Gr. 27
5 - Cover cap for idler roller
6 - Idler roller for poly V-belt
❑ Tighten to 40 Nm
7 - 20 Nm
8 - Poly V-belt pulley for cool‐
ant pump
⇒ page 105
9 - 9 Nm
10 - Coolant pump
⇒ page 249
11 - Cover cap for tensioner
12 - Poly V-belt tensioner
13 - 20 Nm
14 - 20 Nm
15 - Bracket for power steering pump
16 - 20 Nm
17 - Power steering pump
❑ Removing and installing ⇒ Rep. Gr. 48
104 Rep. Gr.13 - Crankshaft group

Audi A6 2005 ➤
18 - 20 Nm
19 - Pulley for power steering pump
20 - 20 Nm
21 - 25 Nm
22 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
❑permitted
Pay unless
attention to by
authorised dowel
AUDI AG. sleeves
AUDI AG⇒ Item
does 23 (page
not guarantee 105)anywhen
or accept liability installing
23 - Dowel sleeve
❑ 2x
24 - Bracket for air conditioner compressor
❑ Pay attention to dowel sleeves ⇒ Item 23 (page 105) when installing
25 - Vibration damper
❑ With pulley for poly V-belt
❑ Different versions. Allocation ⇒ Electronic parts catalogue
1.2 Removing and installing coolant pump

pulley
♦ Pin wrench -3212-
Removing
1. Cylinder block (pulley end) 105

Audi A6 2005 ➤

– Remove poly V-belt from coolant pump pulley.
– Release pressure from the tensioner.
– Unbolt belt pulley from coolant pump.

– Use pin wrench -3212- to counterhold pulley when loosening
bolts.
Installing
Installation is carriedProtected
out inbythe reverse
copyright. order;
Copying note
for private the following:
Note
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Start engine and check that belt runs properly.

Tightening torque
Component Nm
Poly V-belt pulley to coolant pump 20
1.3 Removing and installing power steering

pump pulley

Audi A6 2005 ➤
Removing
– To slacken poly V-belt turn Protected

tensioner in direction
by copyright. ofprivate
Copying for -arrow-.
– Remove poly V-belt from power steering
with respect to thepump pulley.
correctness of information in this document. Copyright by AUDI AG.
– Unbolt poly V-belt pulley from power steering pump.

bolts.
Installing
• Installation position: marking “vorne” (front) faces in direction
of travel.
Note

pulleys.

Tightening torque
Component Nm
Poly V-belt pulley to power steering pump 20

Audi A6 2005 ➤
1.4 Removing and installing poly V-belt

Removing
Note


Installing
– Fit poly V-belt onto pulleys as shown in illustration.
1. Alternator
2. Idler roller
3. Coolant pump
4. Power steering pump
5. Air conditioner compressor
6. Tensioner for poly V-belt

7. Vibration damper
Note

pulleys.
1.5 Removing and installing vibration damp‐

er
Note
Different types of vibration dampers are fitted depending on en‐

gine version; for correct allocation refer to ⇒ Electronic parts
catalogue .

Audi A6 2005 ➤
Removing
Note


– Mark position of vibration damper for re-installation.

– Remove vibration damper.
Installing
Tightening torque
Component Nm
Vibration damper to crankshaft 20 +90° 1)
• 1) Renew bolts.
1.6 Renewing sealing flange (pulley end)

with crankshaft oil seal

Audi A6 2005 ➤
♦ Assembly tool -T40048-
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Procedure
– Unbolt belt pulley from coolant pump ⇒ page 105 .
– Remove vibration damper ⇒ page 108 .
– Release sealing flange (pulley end) from bonded joint.
Note
Renew sealing flange (pulley end).
Caution
Make sure that no sealant residue gets into the engine.
WARNING
Wear safety goggles.
– Remove sealant residue from cylinder block and sump (top

section) with rotating plastic brush or similar.
– Clean sealing surfaces; they must be free of oil and grease.

Audi A6 2005 ➤
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (∅ of nozzle approx. 1.5

mm).
– Apply bead of sealant onto clean sealing surface of sealing

flange as illustrated.
• The groove -arrow- on the sealing surface must be completely
filled with sealant.
• The bead of sealant must project 1.5 … 2.0 mm above the
sealing surface.
Note
♦ The sealant bead must not be thicker than specified, otherwise

excess sealant could enter the sump and clog the strainer in
the oil pump.
♦ The sealing flange (pulley end) must be installed within 5 mi‐
nutes after applying silicone sealant.
– Fit assembly aid -T40048/1- onto assembly sleeve -T40048/2-

and slide sealing flange -1- onto assembly sleeve.
– Take off assembly aid.

Audi A6 2005 ➤
– First position sealing flange (with assembly sleeve -T40048/2-

inserted) on crankshaft.
– Keep sealing flange straight while pushing it onto engine seal‐
ing surface. Then bolt on.
the following:
– Install vibration damper ⇒ page 108 .
– Install poly V-belt pulley for coolant pump ⇒ page 105 .
Tightening torque
Component Nm
Sealing flange (pulley end) to cylinder block 9 1)
• 1) Tighten in stages and in diagonal sequence

Audi A6 2005 ➤
2 Cylinder block (gearbox end)
2.1 Dual-mass flywheel on vehicles with manual gearbox - exploded view
Note
Servicing clutch ⇒ Rep. Gr. 30
1 permitted
- Dual-mass flywheel
❑with Removing and installing
⇒ page 113
❑
2 - 60 Nm + 90° further
❑ Renew
3 - Needle bearing
❑ Extracting and driving in
⇒ page 115
4 - Crankshaft oil seal (gearbox
end)
❑ Renewing ⇒ page 122
5 - Crankshaft
2.2 Removing and installing dual-mass fly‐

wheel - vehicles with manual gearbox
2. Cylinder block (gearbox end) 113

Audi A6 2005 ➤
♦ Counterhold tool -10 - 201-
Removing
• Gearbox removed ⇒ Rep. Gr. 34 .
– Remove clutch pressure plate ⇒ Rep. Gr. 30 .
– Mark position of dual-mass flywheel on engine.
– Insert counterhold tool -10 - 201- to slacken bolts.

Audi A6 2005 ➤
Note
To prevent damage to the dual-mass flywheel when removing,

the bolts -B- must not be removed with an impact wrench or sim‐
ilar. The bolts may only be removed by hand using conventional
tools.
– Rotate the dual-mass flywheel -A- so that the bolts align with
the holes -arrows-.
– When unscrewing the bolts, make sure that the bolt heads do
not come into contact with the dual-mass flywheel; the fly‐
wheel will otherwise be damaged as the bolts are screwed out.
Installing
Note
The needle bearing is located in the flywheel and must be instal‐

led accordingly if the flywheel is renewed ⇒ page 115 .
– Use new securing bolts.

– Fit counterhold tool -10-201- the other way round to tighten
bolts.
– Install clutch pressure plate ⇒ Rep. Gr. 30 .
Tightening torque
Component Nm
Flywheel to crankshaft 60 + 90° 1)
• 1) Renew bolts.
2.3 Extracting and driving in needle bearing for dual-mass flywheel - vehicles
with manual gearbox

Audi A6 2005 ➤

equipment required
♦ Centring mandrel -3176-
♦ Punch -3264-
♦ Depth gauge -VAS 6082-
♦ 1 - Internal puller -Kukko
21/2-
♦ 4 - Counter-support -Kukko
22/1-
Procedure
– Remove clutch pressure plate ⇒ Rep.
permitted Gr. 30 by. AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
– Measure and make a note of insertion depth -dimension x- of
needle bearing in dual-mass flywheel, as it will be required
when re-installing the bearing.

Audi A6 2005 ➤
– Remove needle bearing using internal puller -Kukko 21/2- and

counter-support -Kukko 22/1- .
Note
The plastic ring in the dual-mass flywheel is sensitive to knocks.

Renew dual-mass flywheel if plastic ring is damaged.
– Drive needle bearing into dual-mass flywheel using punch

-3264- .
– Use back of centring mandrel -3176- to press needle bearing

in as far as previously measured insertion depth.
– Finally, check insertion depth -dimension x- of needle bearing

in dual-mass flywheel.
– Install clutch pressure plate ⇒ Rep. Gr. 30 .
2.4 Flywheel for vehicles with multitronic gearbox - exploded view

Audi A6 2005 ➤
1 - Damper unit
⇒ page 118
2 - 22 Nm
3 - Flywheel
⇒ page 119
4 - Crankshaft
end)
6 - 60 Nm + 90° further
❑ Renew
2.5 Removing and installing damper unit


Audi A6 2005 ➤
Removing
– Attach counterhold tool -10 - 201- in order to loosen bolts
-arrows-.
– Unscrew bolts -1- and remove damper unit -A- from flywheel
-B-.
Installing
Note
The part number of the damper unit is assigned to the gearbox

code letters; for correct allocation refer to ⇒ Electronic parts
catalogue .
– Align the damper unit -A- and flywheel -B-.

• The two lugs -2- must align.
– Fit bolts -1- hand-tight and tighten in diagonal sequence.
Tightening torque
Component Nm
Damper unit to flywheel 22
2.6 Removing and installing flywheel - vehi‐

cles with multitronic gearbox
♦ Counterhold tool -10 - 201- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi A6 2005 ➤
Removing
– Remove damper unit ⇒ page 118 .
– Mark position of flywheel in relation to crankshaft.
– Attach counterhold tool -10 - 201- in order to loosen bolts
-arrows-.
– Remove bolts and take off flywheel.
Installing
Note
Renew bolts for flywheel.
– Reverse position of counterhold tool -10 - 201- in order to

tighten bolts.
– Install damper unit ⇒ page 118 .
Tightening torque
Component Nm
Flywheel to crankshaft + 90° 1)
60 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• 1) Renew bolts. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2.7 Drive plate on vehicles with automatic gearbox 09L - exploded view

Audi A6 2005 ➤
1 - Drive plate
⇒ page 121
2 - Washer
3 - 60 Nm + 90° further
❑ Renew
4 - Centralising disc
❑ Installation position
⇒ page 122
5 - Crankshaft
end)
2.8 Removing and installing drive plate - ve‐

hicles with automatic gearbox 09L

Audi A6 2005 ➤
Removing
– Insert counterhold tool -10 - 201- to slacken bolts.
– Mark installation position of drive plate on engine.
– Unbolt drive plate.
– Take out centralising disc located behind.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is carried out in the reverse order; notewith
therespect
following:
to the correctness of information in this document. Copyright by AUDI AG.
– Install drive plate with centralising disc -arrow- and washer.

– Use new securing bolts.
– Reverse position of counterhold tool -10-201- in order to tight‐
en bolts.
Tightening torque
Component Nm
Drive plate to crankshaft 60 + 90° 1)
• 1) Renew bolts.
2.9 Renewing crankshaft oil seal (gearbox

end)
♦ Fitting tool -T10122-
♦ Oil seal extractor lever -T20143/2-

Audi A6 2005 ➤
Procedure
• Gearbox removed ⇒ Rep. Gr. 34 or ⇒ Rep. Gr. 37 .
– Vehicles with manual gearbox: remove clutch pressure plate
⇒ Rep. Gr. 30 and dual-mass flywheel ⇒ page 113 .
– Vehicles with multitronic gearbox: Remove damper unit
⇒ page 118 and flywheel ⇒ page 119 .
– Vehicles with automatic gearbox 09L: Remove drive plate
⇒ page 121 .
– Pry out oil seal using oil seal extractor lever -T20143/2- .
– Clean running surface and sealing surface.
– Fit assembly aid -T10122/1- onto assembly sleeve -T10122/2-

and slide oil seal -A- onto assembly sleeve.
– Take off assembly aid -T10122/1- .
– Fit the assembly sleeve -T10122/2- with oil seal -1- onto crank‐
shaft.

Audi A6 2005 ➤
– Press in oil seal uniformly until flush all round using press
sleeve -T10122/3- .
the following:
– Vehicles with manual gearbox: Install dual-mass flywheel
⇒ page 113 and pressure plate ⇒ Rep. Gr. 30 .
– Vehicles with multitronic gearbox: Install flywheel
⇒ page 119 and damper unit ⇒ page 118 .
– Vehicles with automatic gearbox 09L: Install drive plate
⇒ page 121 .

Audi A6 2005 ➤
3 Crankshaft
Note
When performing assembly work, secure engine to engine and

gearbox support -VAS 6095- ⇒ page 93 .
3.1 Crankshaft - exploded view
1 - 9 Nm
❑ Tighten in stages and in
diagonal sequence
2 - Sealing flange (pulley end)
⇒ page 109
3 - Seals
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue
❑ Renew
4 - Crankshaft
❑ Measuring axial clear‐
ance ⇒ page 129
❑ Measuring radial clear‐
ance ⇒ page 130
❑ Do not rotate the crank‐
shaft when checking the
radial clearance
❑ Crankshaft dimensions
⇒ page 129
5 - Dowel sleeve
❑ authorised
permitted unless 4x by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Inserting in retaining
frame ⇒ page 127

6 - Retaining frame
❑ To remove, detach
guide rail
⇒ Item 26 (page 161)
for drive chain for valve
gear
❑ Applying sealant
⇒ page 127
❑ Tightening sequence for securing bolts ⇒ page 127
7 - Bolt
❑ For sealing surfaces: cylinder block/retaining frame
❑ Differing bolt lengths and bolt heads
❑ Tightening sequence ⇒ page 127
8 - Bolt (long, large collar)
❑ For retaining frame (inner row)
9 - Bolt (short, small collar)
❑ For retaining frame (outer row)
3. Crankshaft 125
Audi A6 2005 ➤

10 - Thrust washer
❑ Only fitted on 3rd crankshaft bearing
❑ Oil grooves face outwards
❑ Make sure it engages in retaining frame
❑ Measuring axial clearance of crankshaft ⇒ page 129
11 - Bearing shell
❑ For retaining frame (without oil groove)
❑ Mark used bearing shells for re-installation but not on bearing surface
❑ Bearing shells worn down to the base layer must be renewed
❑ Note installation position
❑ Install new bearing shells for retaining frame with correct coloured markings ⇒ page 129
12 - Centralising disc
❑ For vehicles with automatic gearbox 09L ⇒ page 126
13 - Thrust washer
❑ Only fitted on 3rd crankshaft bearing
❑ Oil grooves face outwards
❑ Make sure it engages in retaining frame
❑ Measuring axial clearance of crankshaft ⇒ page 129
14 - Bearing shell
❑ For cylinder block (with oil groove)
❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ page 128
15 - O-ring or seal
❑ Depending on version ⇒ Electronic parts catalogue
❑ Renew
16 - Cylinder block
Centralising disc for drive plate on vehicles with automatic gear‐

box 09L
Note
In vehicles with automatic gearbox 09L the drive plate is bolted

to the crankshaft with a centralising disc -arrow-.

Audi A6 2005 ➤
Applying sealant to retaining frame, position of dowel sleeves

– Clean sealing surfaces, they must be free of oil and grease at
top and bottom.
– Apply the beads of sealant -arrows- onto the clean sealing
surfaces of the retaining frame as illustrated.
• The groove on the sealing surface must be completely filled
with sealant.
• The beads of sealant must project 1.5 … 2.0 mm above the
sealing surface.
– Fit seals -1 … 3-.
Note
On some versions the seals -2- and -3- are connected together.
– Check that dowel sleeves -4 ... 7- are inserted in retaining

frame at positions shown in illustration.
Installing retaining frame

– Renew bolts -1 … 16- for retaining frame.
– Install long bolts in inner row on retaining frame.
– Tighten bolts in 3 stages in the sequence shown:
Stag Bolts Tightening torque/tightening angle
e
1. -1 … 16- 50 Nm
2. -1 … 16- turn 90° further
3. -17 … 31- 23 Nm
3. Crankshaft 127
Audi A6 2005 ➤
Matching crankshaft bearing shells to bearings in 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 bearing positions in
the cylinder block is indicated by a code letter at the relevant
bearing on the retaining frame.
To engine No. AUK 028 000 or BKH 033 000:
For engines up to engine number AUK 028 000 orProtected
BKH 033 000,
please note that on bearing No. 1 (front) the code letters ontothe
with respect the correctness of information in this document. Copyright by AUDI AG.
retaining frame and the corresponding colour codes for the bear‐
ing shells are not the same as for the other bearings:
Bearing No. Code letter on retaining Colour coding of bear‐
frame ing
1 G = Red
B = Yellow
S = Blue
2…4 G = Yellow
B = Blue
S = Black
From engine No. AUK 028 001 or BKH 033 001:
Code letter on retaining frame Colour coding of bearing
R = Red
G = Yellow
B = Blue
S = Black

Audi A6 2005 ➤
Matching crankshaft bearing shells to bearings in retaining frame

♦ Bearing shells of the correct thickness are matched to the
bearings in the retaining frame at the factory. Coloured dots
on the side of the bearing shells are used to identify the bear‐
ing shell thickness.
♦ The allocation of the bearing shells to the bearing positions in
the retaining frame is indicated by a sequence of letters on the
flywheel flange on the crankshaft. The first letter in the se‐
quence stands for bearing “1”, the second letter for bearing
“2”, etc.
To engine No. AUK 028 000 or BKH 033 000:
For engines up to engine number AUK 028 000 or BKH 033 000,
please note that on bearing No. 1 (front) the code letters on the
crankshaft and the corresponding colour codes for the bearing
shells are not the same as for the other bearings:
Bearing No. Letter on crankshaft Colour coding of bear‐
ing
1 G = Red
B = Yellow
S = Blue
2…4 G = Yellow
B = Blue
S = Black
From engine No. AUK 028 001 or BKH 033 001:
Letter on crankshaft Colour coding of bearing
R = Red
G = Yellow
B = Blue
S = Black
3.2 Crankshaft dimensions

Honing di‐ Crankshaft main bear‐ Crankshaft conrod jour‐
mension ing journal ∅ nal ∅
mm mm
Basic di‐ 65.00 – 0.022 56.00 – 0.022
mension – 0.042 – 0.042
3.3 Measuring axial clearance

♦ Universal dial gauge bracket -VW 387-
3. Crankshaft 129
Audi A6 2005 ➤
♦ Dial gauge -VAS 6079-
Procedure
– Bolt dial gauge -VAS 6079- with universal dial gauge bracket
-VW 387- onto cylinder block and set it against 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: 0.15 ... 0.25 mm
3.4 Measuring radial clearance

♦ Plastigage
Procedure
Note
♦ Mark used bearing shells for re-installation, but not on bearing

surface.
♦ Bearing shells worn down to the base layer must be renewed.
– Remove retaining frame and clean bearing journals.

– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or bearing shell.
• The Plastigage must be positioned in the centreProtected
of thebybearing
copyright. Copying for private or commercial purposes, in part or in whole, is not
shell permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Fit retaining frame and tighten to 30 Nm. Do not rotate crank‐
shaft.
– Remove retaining frame once more.
– Compare width of Plastigage with measurement scale:
• Radial clearance (new): 0.015 ... 0.055 mm.
• Radial clearance (wear limit): 0.08 mm.

Audi A6 2005 ➤
4 Pistons and conrods
Note
Oil spray jet for piston cooling ⇒ page 134 .
4.1 Pistons and conrods - exploded view
1 - 30 Nm + 90° further
❑ Renew
❑ Lubricate threads and
contact surface
2 - Conrod bearing cap
❑ Do not interchange
❑ Mark cylinder allocation
with a coloured pen -B-
⇒ page 133
❑ Note when fitting bear‐
ing cap: the wide con‐
tact shoulder -A- must
point towards same side
on conrod and conrod
bearing cap
❑ Installation position of
conrod pairs
⇒ page 134by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
3 - Bearing shell
Different types may be fitted,

depending on version:
❑ Lower bearing shell (for
bearing cap); identifica‐
tion: shell is a dark col‐
our. Upper bearing shell
(for conrod): more wear-
resistant material; iden‐
tification: shell is a light
colour.
Or
❑ Bearing shells are the
same: no special identi‐
fication
❑ Ensure that retaining
lugs are securely seated.
4 - Conrod
❑ Only renew as a complete set
❑ Mark cylinder allocation in colour -B- ⇒ page 133
❑ Note when fitting bearing cap: the wide contact shoulder -A- must point towards same side on conrod
and conrod bearing cap
❑ Installation position of conrod pairs ⇒ page 134
❑ Measuring radial clearance ⇒ page 134
4. Pistons and conrods 131

Audi A6 2005 ➤
5 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift -VW 222 A-
6 - Circlip
❑ Renew
7 - Piston
❑ Installation position and allocation of piston/cylinder ⇒ page 133
❑ Arrow on piston crown points to pulley end
❑ Checking ⇒ page 133
❑ Install using piston ring clamp
❑ Piston and cylinder dimensions ⇒ page 134
❑ Checking cylinder bore ⇒ page 133
8 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install
❑ Marking “TOP” or side with identification mark must face piston crown
❑ Checking ring gap ⇒ page 132
❑ Checking ring-to-groove clearance ⇒ page 132
Checking 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. Use a piston without rings to push ring into bore.
Piston ring new Wear limit
mm mm
1st compression ring 0.20 … 0.35 0.8
2nd compression ring 0.50 … 0.70 1.0
Oil scraper ring 0.20 … 0.40 0.8
Checking ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring new Wear limit
mm mm
Compression rings 0.02 … 0.08 0.20
Oil scraper ring 0.02 … 0.08 0.15

Audi A6 2005 ➤
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: 0.04 mm.
Nominal dimension
⇒ “4.2 Piston and cylinder dimensions”, page 134 .
Checking cylinder bore

– Use 50 ... 100 mm internal dial gauge to take measurements
at 3 points in transverse direction -A- and longitudinal direction
-B-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Maximum deviation from nominal dimension: 0.08 mm.
Nominal dimension
⇒ “4.2 Piston and cylinder dimensions”, page 134 .
Piston installation position and piston/cylinder allocation

– Use chalk or waterproof felt-tip pen to mark installation posi‐
tion and cylinder allocation on piston crown.
Note
Do not use a centre punch or scriber, as this would damage the

coating of the piston crown.
• Installation position: Arrow on piston crown points to pulley

end.
Marking conrods
Note
♦ Only renew conrods as a complete set.

♦ Do not interchange conrod bearings.
– Prior to removal, use a coloured pen to mark conrod and con‐

rod bearing cap relative to one another, as well as to cylinder
-arrow-.
4. Pistons and conrods 133

Audi A6 2005 ➤
Conrod installation position

• The cast lugs -arrows- at ground surfaces of conrod pairs 1
and 2, 3 and 4, and 5 and 6 must face one another.
Oil spray jet for piston cooling

1- Apply locking fluid when installing bolt (tightening torque
9 Nm); refer to ⇒ Electronic parts catalogue
2- Oil spray jet with spray nozzle valve
Caution
♦ Do not bend oil spray jets.

♦ Always renew bent oil spray jets.
4.2 Piston and cylinder dimensions

Honing dimension Piston ∅ Cylinder bore ∅
(in mm)
Basic dimension 84.51
84.49 1)permitted unless authorised
by AUDI AG. AUDI AG does not guarantee or accept any liability
• 1) with respect to the correctness of information in this document. Copyright by AUDI AG.
Dimensions including coating (thickness 0.02 mm). The
coating will wear down in service.
4.3 Checking radial clearance of conrod

bearings
♦ Plastigage
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
bearing on the bearing journal or bearing shell.
– Fit conrod bearing cap and tighten to 30 Nm. Do not rotate
crankshaft.
– Remove conrod bearing caps once more.
– Compare width of Plastigage with measurement scale:
• Radial clearance (new): 0.010 ... 0.052 mm
• Radial clearance: wear limit: 0.12 mm
– Renew bolts for conrod bearings.

Audi A6 2005 ➤
15 – Cylinder head, valve gear

1 Chain drive
1.1 Timing chain covers - exploded view
1 - M6: 9 Nm; M8: 20 Nm

❑ Observe tightening se‐
quence: vehicles up to
04.2005 ⇒ page 145 ,
vehicles from 05.2005
⇒ page 147 05.2005
⇒ page 147
end) with respect to the correctness of information in this document. Copyright by AUDI AG.

3 - Dowel sleeve
❑ 2x
4 - Timing chain cover (bottom)
⇒ page 139
5 - Cylinder head gasket (left-
side)
6 - 5 Nm + 90° further
❑ Renew
❑ Note correct sequence
when tightening
⇒ page 139
7 - Timing chain cover (left-
side)
⇒ page 135
8 - 16 Nm
❑ For vehicles from
05.2005
❑ Renew
❑ Note correct sequence
when tightening ⇒ page 139
10 - Timing chain cover (right-side)
11 - Cylinder head gasket (right-side)
12 - Dowel sleeve
❑ 2x
1.2 Removing and installing timing chain

covers (left and right)
1. Chain drive 135

Audi A6 2005 ➤

♦ Safety goggles
Removing
Note
All cable ties which are released or cut open when removing must
be refitted in the same position when installing.
Timing chain cover (left-side):

– Unplug electrical connector for coolant shortage indicator
switch -F66- at bottom of expansion tank and move expansion
tank to one side with coolant hoses -1- and -2- attached.
– Unplug electrical connectors -1 ... 3-.

– Unscrew nut -arrow-.
– Remove bracket for electrical connector -3-.
– Unscrew centre hex stud located beneath the bracket.
– Remove bracket for electrical connectors -1- and -2-.
136 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 2005 ➤
– Unscrew bolts -arrows- and unplug electrical connectors at ig‐

nition coils.
Note
Disregard -items 1 ... 4-.
– Move wiring clear.
– Remove bolts with
-1 ... 8- and
respect to therelease
correctnesstiming chain
of information cover
in this (left-side)
from bonded joint.
Timing chain cover (right-side):

clamps -arrows-.
– Unplug electrical connector -1-.

– Remove bolt -arrow- and detach bracket for electrical connec‐
tor.
1. Chain drive 137

Audi A6 2005 ➤
– Remove bolts -1 ... 8- and release timing chain cover (right-

side) from bonded joint.
Installing
Note
Fit all cable ties in the original positions when installing.
WARNING
– Remove remaining sealant on timing chain covers and cylin‐

der block / cylinder head using rotating plastic brush or similar.
Caution
Note

– Cut off nozzle of tube at front marking
permitted unless (∅ of nozzle
authorised by AUDIapprox.
AG. AUDI AG 1 does not guarantee or accept any liability
mm). with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
The timing chain covers must be installed within 5 minutes after

applying sealant.
– Apply sealant bead -arrow- onto the clean sealing surface of

the timing chain cover (left-side) as illustrated.
with sealant.
sealing surface.

Audi A6 2005 ➤
– Fit timing chain cover (left-side) and tighten bolts in sequence

-1 ... 8-.
– Apply sealant bead -arrow- onto the clean sealing surface of

the timing chain cover (right-side) as illustrated.
with sealant.
sealing surface.
– Fit timing chain cover (right-side) and tighten bolts in sequence

-1 ... 8-.
The remaining installation steps are carried out in the reverse se‐
quence.
Tightening torques
Component Nm
Timing chain covers (left and right) to engine 5 +90° 1)
Bracket for electrical connectors to cylinder 9
head
• 1) Renew bolts.
1.3 Removing and installing timing chain

cover (bottom)
1. Chain drive 139

Audi A6 2005 ➤

♦ Safety goggles
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 405 .
Note
WARNING
Make sure that the lock carrier is installed and the torque re‐
action support is secured on the vehicle before performing the
following steps.

⇒ page 121 .
– Unplug electrical connectors -1 ... 3-.
– Unscrew nut -arrow-.
– Remove bracket for electrical connector -3-.
– Unscrew centre hex stud located beneath the bracket.
– Remove bracket for electrical connectors -1- and -2-.
– Remove bolts -1 ... 8- and release timing chain cover (left-side)

from bonded joint.

Audi A6 2005 ➤

– Remove bolt -arrow- and detach bracket for electrical connec‐
tor.
– Remove bolts -1 ... 8- and release timing chain cover (right-

side) from bonded joint.
– byUnscrew
Protected sealing
copyright. Copying cap or-arrow-
for private for
commercial oil filter
purposes, housing.
in part or in whole, is not
with–respect
Remove oil filterof information
to the correctness element.in this document. Copyright by AUDI AG.
– Extract engine oil from oil filter housing using used oil collec‐
tion and extraction unit -V.A.G 1782- .
Note
Place a cloth below the oil filter housing to catch escaping oil.
– Unplug electrical connector at oil pressure switch -F1-

-arrow-.
– Unscrew oil pressure switch.
1. Chain drive 141

Audi A6 2005 ➤

– Remove oil filter housing.
Vehicles up to 04.2005:
– Remove bolts -1 ... 8- and release timing chain cover (bottom)
from bonded joint.
Vehicles from 05.2005:

– Remove bolts -1 ... 9- and release timing chain cover (bottom)
from bonded joint.
All vehicles:
– Press out crankshaft oil seal (rear) from timing chain cover
(bottom).
Installing
Note
♦ Renew gaskets, seals and O-rings.


Audi A6 2005 ➤
– Pull dowel sleeve (top right) out of cylinder block.

– Bevel the dowel sleeve with a file, as illustrated.
• 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.
Note
Bevelling the dowel sleeve makes it easier to fit the timing chain
cover (bottom) with the cylinder head installed.
WARNING
– Remove remaining sealant on timing chain cover and cylinder

block / cylinder head using rotating plastic brush or similar.
Caution
– Clean any old sealing compound from the bores -arrow- in the
cylinder head gaskets.
Note
With the cylinder head installed the holes in the cylinder head
gasket are only half visible.
Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
The cylinder head gasket must not to be bent more than a small
amount. If the cylinder head gasket has been bent and kinked
it must be renewed.
1. Chain drive 143

Audi A6 2005 ➤
– Carefully bend the ends of the cylinder head gaskets down

very slightly -arrows-, just far enough to be able to clean the
upper sealing surface on the gasket and cylinder head.
– Clean both cylinder head gaskets (top and bottom); they must
be free of oil and grease.
Note
– Cut off nozzle of tube at front marking (∅ of nozzle approx. 2

mm).
Note
♦ The sealant must be applied at several points on the engine

as described below.
♦ The timing chain cover must be installed within 5 minutes after
applying sealant.
Caution
The cylinder head gasket must not to be bent more than a small
amount. If the cylinder head gasket has been bent and kinked
it must be renewed.
– Apply a small amount of sealant to sealing surfaces of cylinder

head gaskets (top and bottom). To do so, you again have to
bend cylinder head gaskets down very slightly.
– Use a flat object (e.g. a feeler gauge) to apply sealant to area
between cylinder head and gasket.

Audi A6 2005 ➤
– Fill cleaned holes -arrow- in cylinder head gasket with sealant.
Vehicles up to 04.2005:
– Apply the beads of sealant -1 ... 6- onto the clean sealing sur‐
faces of the timing chain cover (bottom) as illustrated.
with sealant.
sealing surface.
• The sealant -item 3- must be applied in a continuous bead as
shown in the illustration (although the groove is not continu‐
ous).
– Insert the O-ring -arrow- in the groove in the bottom timing
chain cover.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Apply a small amount
with respect toof
thesealant
correctnessto
of hold O-ring
information in this in position.
– Fit timing chain cover (bottom), guiding it towards the sealing

surface on cylinder block and cylinder head at an angle and
from below.
– Take care not to damage the cylinder head gaskets when fit‐
ting the cover. Renew gaskets if damaged.
– Tighten bolts in 4 stages as follows:
e
1. -arrows- Apply locking fluid when installing,
5 Nm
2. -1 … 8- 9 Nm in diagonal sequence
3. -arrows- 9 Nm
4. -6, 7, 8- 20 Nm
– Install oil filter housing immediately ⇒ page 234 .
1. Chain drive 145

Audi A6 2005 ➤
Vehicles from 05.2005:

faces of the timing chain cover (bottom) as illustrated.
with sealant.
sealing surface.
• The sealant -item 2- must be applied in a continuous bead as
shown in the illustration (although the groove is not continu‐
ous).
– Insert seals -arrows- in grooves on timing chain cover (bot‐
tom).

Audi A6 2005 ➤
– Fit timing chain cover (bottom), guiding it towards the sealing

surface on cylinder block and cylinder head at an angle and
from below.
– Take care not to damage the cylinder head gaskets when fit‐
ting the cover. Renew gaskets if damaged.
– Tighten bolts in 5 stages as follows:
e
1. -arrows- Apply locking fluid when installing,
5 Nm
2. -1 … 9- 9 Nm in diagonal sequence
3. -arrows- 9 Nm
4. -7, 8, 9- 20 Nm
5. -3- 16 Nm
All vehicles:
the following:
– Install timing chain covers (left and right) ⇒ page 138 .
– Install oil filter housing ⇒ page 234 .
– Install crankshaft oil seal (gearbox end) ⇒ page 122 .
– Vehicles withauthorised
permitted unless multitronic
by AUDIgearbox:
AG. AUDI AG Install
does notflywheel
⇒ page 119toand
with respect damperof unit
the correctness ⇒ page
information in this 118 . Copyright by AUDI AG.
document.

⇒ page 121 .
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
405 .
Tightening torques
Component Nm
Timing chain cover (bottom) to engine M6 9 1)
M7 16
M8 20
Timing chain covers (left and right) to engine 5 +90° 2)
Bracket for electrical connectors to cylinder 9
head
• 1) Install securing bolts between cylinder head and timing
chain cover (bottom) using locking fluid; locking fluid ⇒
Electronic parts catalogue .
• 2) Renew bolts.
1. Chain drive 147

Audi A6 2005 ➤
1.4 Camshaft timing chains - exploded view
Note
♦ The crankshaft and camshafts must only be turned with the

chain drive mechanism fully installed. Otherwise the valves
may strike the pistons, causing damage to valves and piston
crowns.
♦ Mark rotation direction of camshaft chain with paint before re‐
moving. If a used chain rotates in the opposite direction when
it is refitted, this can cause breakage.
Camshaft timing chain (left-side)
1 - Camshaft adjuster for ex‐

haust camshaft
❑ Identification “Exhaust”
⇒ “1.5 Detaching timing
chains from camshafts,
removing and installing
chain tensioners”,
page 150
2 - Bolt for camshaft
❑ Renew
❑ Pre-tightening torque:
40 Nm
❑ Final tightening torque:
80 Nm + 90°
❑ Renew
40 Nm
80 Nm + 90°
4 - Camshaft adjuster for inlet
camshaft
❑ Identification “Intake”
page 150
5 - Camshaft timing chain (left-
side)
⇒ page 150
6 - 9 Nm
7 - Chain tensioner for camshaft timing chain (left-side)
⇒ “1.5 Detaching timing chains from camshafts, removing and installing chain tensioners”, page 150
8 - Oil strainer
❑ Inserted in chain tensioner
❑ Watch position of locking lug on outer circumference

Audi A6 2005 ➤
9 - Gasket
❑ Renew
❑ Clipped onto chain tensioner
10 - Bearing bracket for drive sprocket
11 - 8 Nm + 45° further
❑ Renew
❑ Lubricate with oil before installing
12 - Drive chain sprocket for camshaft timing chain (left-side)
13 - Thrust washer for drive sprocket
14 - 6 Nm + 60° further
❑ Renew
Camshaft timing chain (right-side)
1 - Drive chain sprocket for

camshaft timing chain (right-
side)
2 - Bearing mounting for drive
sprocket
3 - 30 Nm + 90° further
4 - Camshaft timing chain
(right-side)
⇒ page 150
❑ Renew
40 Nm
80 Nm + 90°
6 - Camshaft adjuster for inlet
camshaft
❑ Identification “Intake”
page 150
7 - Chain tensioner for cam‐
shaft timing chain (right-side)
page 150 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Oil strainer permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Inserted in chain tensioner
❑ Installation position: locating lug on outer circumference
9 - Gasket
❑ Renew
1. Chain drive 149

Audi A6 2005 ➤
❑ Clipped onto chain tensioner

10 - 9 Nm
11 - Camshaft adjuster for exhaust camshaft
❑ Identification “Exhaust”
⇒ “1.5 Detaching timing chains from camshafts, removing and installing chain tensioners”, page 150
❑ Renew
❑ Pre-tightening torque: 40 Nm
❑ Final tightening torque: 80 Nm + 90°
13 - Thrust washer for drive sprocket
1.5 Detaching timing chains from camshafts, removing and installing chain ten‐
sioners

equipment required
♦ Counterhold tool -T10172-
with pin -T10172/2-
♦ Locking pin -T40069-
♦ Camshaft clamp -T40070-
(2x)
♦ Locking pin -T40071- (2x)

Audi A6 2005 ➤
♦ Special wrench -T10035-
Removing
Note
In the following procedure the camshaft timing chains remain on

the engine. If you want to detach the camshaft timing chains com‐
pletely you must also remove the timing chain cover (bottom)
⇒ page 139 .
– Remove cylinder head cover: left-side ⇒ page 178 , right-side

⇒ page 182 .
– Remove timing chain covers (left and right) ⇒ page 135 .
– Insert guide pin of adapter -T40058- with the larger-diameter
section -arrow 1- pointing towards the engine. The smaller-
diameter section -arrow 2- faces the adapter.
– Using adapter -T40058- turn the crankshaft in the normal di‐

rectionCopying
Protected by copyright. of rotation -arrow-
for private to TDC.
1. Chain drive 151

Audi A6 2005 ➤
• The threaded holes -arrows- in the camshafts must face up‐

wards.
– Fit camshaft clamps -T40070- to both cylinder heads and

tighten bolts -arrows- to 20 Nm.
• The camshaft clamp -T40070- is positioned correctly if the
holes for the cylinder head bolts remain free.
– Unscrew plug -arrow- from cylinder block.
– Screw locking pin -T40069- into bore -1- (tightening torque: 10

Nm); if necessary, turn crankshaft backwards and forwards
slightly to fully centralise locking pin.

Audi A6 2005 ➤
– Mark running direction of camshaft timing chain (left-side) with

paint.
– Unscrew bolts -1- and -2- for camshaft adjusters using special
wrench -T10035- .
– Remove both camshaft adjusters.
– Unscrew bolts -1- and -2- and remove chain tensioner.
– Mark running direction of camshaft timing chain (right-side)

with paint.
– Unscrew bolts -1- and -2- for camshaft adjusters using special
wrench -T10035- .
– Remove both camshaft adjusters.
– Unscrew bolts -1- and -2- and remove chain tensioner.

Installing
Note

as seals and gaskets.
♦ The crankshaft must not be at TDC at any cylinder when the
camshaft is turned. Otherwise, there is a risk of damage to
valves and piston crowns.
1. Chain drive 153

Audi A6 2005 ➤
• Drive chain for valve gear installed ⇒ page 161

• Crankshaft locked in TDC position with locking pin -T40069- .
• Camshaft clamps -T40070- installed on both cylinder heads

and tightened to 20 Nm.
– First completely release guide rail of chain tensioners for cam‐

shaft timing chains (left and right) -arrow-.
• The piston -1- of the tensioning element must be fully exten‐
ded, so that the locking device is released (only possibly when
chain tensioner is removed).
Note
Note the correct installation position if the tensioning element has

been removed from the chain tensioner: drilling in base of housing
faces chain tensioner and piston faces tensioner rail.
– Press guide rails of chain tensioners for camshaft timing

chains (left and right) inwards in direction of -arrow- as far as
the stop. Then lock chain tensioners by inserting locking pin -
T40071- .

Audi A6 2005 ➤
– If necessary, clean oil strainer -3- in both chain tensioners.

– Fit new gasket -2- to rear of chain tensioner -1-.
– Install chain tensioner on cylinder head (left-side) and position

camshaft timing chain as shown in the illustration.
– Tighten bolts -1- and -2-.
– Renew the camshaft bolts.
– Position camshaft timing chain on drive chain sprocket and
camshaft adjusters and loosely screw in bolts -1- and -2-.
• It should just be possible to turn both camshaft adjusters on
the camshaft without axial movement.
– Remove locking pin -T40071- .
– Install chain tensioner on cylinder head (right-side) and posi‐

tion camshaft timing chain as shown in the illustration.
– Tighten bolts -1- and -2-.
1. Chain drive 155

Audi A6 2005 ➤
– Renew the camshaft bolts.

– Position camshaft timing chain on drive chain sprocket and
camshaft adjusters and loosely screw in bolts -1- and -2-.
• It should just be possible to turn both camshaft adjusters on
the camshaft without axial movement.
– Fit counterhold tool -T10172- with pin -T10172/2- onto cam‐

shaft adjuster of inlet camshaft (left-side).
– Pretension camshaft timing chain by pressing counterhold tool
in direction of -arrow-.
– At the same time pre-tighten camshaft bolt using special
wrench -T10035- and torque wrench.
• Tightening torque: 40 Nm.
– Maintain tension on inlet camshaft and permitted
pre-tighten bolt -1-byon
unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
exhaust camshaft. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Tighten camshaft bolts -1- and -2- at cylinder head (left-side)

to final torque.
• Tightening torque: 80 Nm + turn 90° further.
– Fit counterhold tool -T10172- with pin -T10172/2- onto cam‐

shaft adjuster of exhaust camshaft (right-side).
– Pretension camshaft timing chain by pressing counterhold tool
in direction of -arrow-.
– At the same time pre-tighten camshaft bolt using special
wrench -T10035- and torque wrench.
– Maintain tension on exhaust camshaft and pre-tighten bolt
-1- on inlet camshaft.

Audi A6 2005 ➤
– Tighten camshaft bolts -1- and -2- at cylinder head (right-side)

to final torque.
• Tightening torque: 80 Nm + turn 90° further.
– Remove camshaft clamps -T40070- from both cylinder heads.

– Using adapter -T40058- , turn crankshaft two rotations in nor‐

mal direction of rotation -arrow- until crankshaft is at TDC
again.
Note
If you turned the crankshaft beyond TDC, turn it back approx. 30°
and set to TDC again.
1. Chain drive 157

Audi A6 2005 ➤
• The threaded holes -arrows- in the camshafts must face up‐

wards.
– Fit camshaft clamps -T40070- to both cylinder heads and

tighten bolts -arrows- to 20 Nm.
– Screw the locking pin -T40069- directly into the hole.

• The locking pin -T40069- must engage in the locating hole in
crankshaft -1-. If it does not, reset valve timing.

Audi A6 2005 ➤
– Remove camshaft clamps from both cylinder heads.

– Remove locking pin.
– Screw plug for the TDC mark into cylinder block with a new
seal.
the following:
– Install cylinder head cover: left-side ⇒ page 178 , right-side
⇒ page 182 .
Tightening torques
Component Nm
Chain tensioner to cylinder head 9
Camshaft bolts Protected by copyright. Copying for private or80 +90° 1)
commercial purposes, in part or in whole, is not
Screw plug in cylinder block
with respect to the correctness of information 14 2)document. Copyright by AUDI AG.
in this
• 1) Renew bolts.
• 2) Install with new seal.
1.6 Drive chain for valve gear - exploded view
1. Chain drive 159

Audi A6 2005 ➤
1 - Bearing mounting for drive

sprocket
2 - 30 Nm + 90° further
❑ Renew
3 - Bolt
❑ Renew
❑ Types and tightening
torque differ depending
on version ⇒ page 161
❑ Renew
5 - Thrust washer for drive
sprocket
6 - Bush
❑ Depending on version
⇒ page 161
7 - Drive chain sprocket for Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
camshaft timing chain (left- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
side) with respect to the correctness of information in this document. Copyright by AUDI AG.
8 - Bolt
❑ Renew
❑ Types and tightening
torque differ depending
on version ⇒ page 161
9 - Drive chain for valve gear
running direction with
paint
10 - Guide rail
11 - Bolt
❑ Renew
❑ Types and tightening torque differ depending on version ⇒ page 161
12 - Bush
❑ Depending on version ⇒ page 161
13 - 8 Nm + 45° further
❑ Renew
❑ Lubricate with oil before installing
14 - Bearing bracket for drive sprocket
15 - Bush
16 - Thrust washer
17 - Drive chain sprocket for camshaft timing chain (right-side)
18 - Bush
19 - Bolt
❑ Renew
20 - O-ring
❑ Renew

Audi A6 2005 ➤
21 - Chain tensioner
22 - 6 Nm + 45° further
❑ Renew
23 - Guide rail for chain tensioner
24 - Crankshaft
25 - Bush
26 - Guide rail
27 - Bolt
❑ Renew
Different types of bolts securing guide rails

Depending on version, different bolt types are used when secur‐
ing the timing chain guide rails:
1- Bolt with shaft
♦ Renew
♦ 10 Nm + 30° further
2- Bolt with bush -6- with collar

♦ Renew
3- Bolt with bush -4- and washer -5-

♦ Renew
1.7 Removing and installing drive chain for

valve gear
1. Chain drive 161

Audi A6 2005 ➤
Removing
WARNING
following steps.

⇒ page 121 .
– Remove timing chain cover (bottom) ⇒ page 139 .
– Remove camshaft timing chains from camshafts
⇒ page 150 .
– Remove drive chain for auxiliary drives: vehicles up to 04.2006
⇒ page 164 , vehicles from 04.2006 onwards ⇒ page 169 .
– Press guide rail of chain tensioner for drive chain in direction
of arrow and lock chain
Protected tensioner
by copyright. Copying forby inserting
private locking
or commercial pinin-part or in whole, is not
purposes,
T40071- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Mark running direction of chain with paint.
– Remove bolts -2- and -3- and detach chain sprockets together
with drive chain and guide rail -1-.

Audi A6 2005 ➤
Installing
• Crankshaft -1- locked in TDC position with locking pin -
T40069- .
– First install sprocket for camshaft timing chain (left-side) -2-.

– Install guide rail -1- with drive chain fitted.
– Now install sprocket for camshaft timing chain (right-side)
-3-.
– Press guide rail of chain tensioner for drive chain in direction
of -arrow- and pull locking pin -T40071- out of chain tensioner.
– Install drive chain for auxiliary drives: vehicles up to 04.2006
– Install camshaft timing chains ⇒ page 153 .
– Install timing chain cover (bottom) ⇒ page 139 .


⇒ page 121 .
405 .
Tightening torques
Component Nm
Drive chain sprocket (left-side) to bearing brack‐ 6 +60° 1)
et
Drive chain sprocket (right-side) to cylinder 30 +90° 1)
block
Screw plug in cylinder block 14 2)
• 1) Renew bolts.
1.8 Drive chain for auxiliary drives on vehicles up to 04.2006 - exploded view
1. Chain drive 163

Audi A6 2005 ➤
1 - Drive chain for auxiliary

drives
paint
⇒ page 164
2 - Drive chain sprocket for oil
pump
❑ Installation position:
Side with lettering faces
engine
3 - 30 Nm + 90° further
❑ Renew
4 - Compression spring
5 - Crankshaft
6 - 15 Nm + 90° further
❑ Renew
7 - Chain sprocket for balance
shaft
❑ Installation position: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Side with lettering faces permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
gearbox
❑ Renew
9 - Chain tensioner
❑ With guide rail
10 - Seal
❑ Depending on version
❑ Renew

auxiliary drives on vehicles up to
04.2006

Audi A6 2005 ➤
♦ Locating pins -T40116-
Removing
WARNING
following steps.

⇒ page 121 .
1. Chain drive 165

Audi A6 2005 ➤
Caution
Risk of damage to drive chain if thread of bolt exceeds speci‐

fied length.
♦ Use bolts with a maximum thread length -a- of 22 mm to
attach special wrench -T40049- .
♦ If no suitable bolts are available, position suitable washer
(s) under bolt head so that remaining thread length does
not exceed 22 mm.
– Attach special wrench -T40049- at rear end of crankshaft us‐

ing 2 bolts -arrows-.
– Unscrew plug -arrow- from cylinder block.

– Turn crankshaft in normal direction of rotation to TDC position.
– Screw locking pin -T40069- into bore (tightening torque:

20 Nm); if necessary, turn crankshaft backwards and forwards
– Mark running direction of drive chain for auxiliary drives with
paint.

Audi A6 2005 ➤
– Press guide rail of chain tensioner in direction of -arrow- and

lock chain tensioner by inserting locking pin -T40071- .
– Remove bolts -1 ... 3- and take out chain tensioner, balance
shaft sprocket and chain.
Installing
T40069- .
1. Chain drive 167

Audi A6 2005 ➤
– Install chain tensioner with chain and balance shaft sprocket.

– Lock balance shaft in TDC position using locating pin -
T40116- .
• The elongated holes in the balance shaft sprocket must be
aligned centrally over the threaded holes in the balance shaft.
If necessary move chain one tooth further.
– Tighten bolts for chain tensioner.
– Screw in bolts -1- for chain sprocket, but do not tighten.
• It should just be possible to turn the sprocket on the balance
shaft without axial movement.
– Pull locking pin -T40071- out to release chain tensioner.
– Press against guide rail of chain tensioner -arrow- using a
screwdriver, and at the same time tighten bolts -1- securing
chain sprocket.
– Pull locating pin -T40116- out of balance shaft.
the following:
– Vehicles
with with
respectautomatic gearbox 09L:in this
Install drive plateby AUDI AG.
to the correctness of information document. Copyright
⇒ page 121 .
405 .
Tightening torques
Component Nm
Chain tensioner to cylinder block 6 +45° 1)
Chain sprocket for balance shaft to balance 15 +90° 1)
weight
• 1) Renew bolts.
1.10 Drive chain for auxiliary drives on vehicles from 04.2006 - exploded view

Audi A6 2005 ➤
1 - Crankshaft
2 - Drive chain for auxiliary
drives
paint
⇒ page 169
3 - Drive chain sprocket for oil
pump
engine
4 - 30 Nm + 90° further
❑ Renew
6 - 15 Nm + 90°Protected
further by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew
7 - Chain sprocket for balance

shaft
gearbox
8 - Chain tensioner
❑ With guide rail
9 - 10 Nm + 45° further
❑ Renew

auxiliary drives on vehicles from
04.2006
1. Chain drive 169

Audi A6 2005 ➤
Removing
WARNING permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
following steps.

⇒ page 121 .
Caution
Risk of damage to drive chain if thread of bolt exceeds speci‐

fied length.
♦ Use bolts with a maximum thread length -a- of 22 mm to
attach special wrench -T40049- .
♦ If no suitable bolts are available, position suitable element
under bolt head so that remaining thread length does not
exceed 22 mm.

Audi A6 2005 ➤
– Attach special wrench -T40049- at rear end of crankshaft us‐

ing 2 bolts -arrows-.
– Unscrew plug -arrow- for “TDC” marking from sump (top sec‐
tion).
– Turn crankshaft in normal direction of rotation to “TDC” posi‐
tion.
– Screw locking pinunless
permitted -T40069-
authorisedinto bore
by AUDI AG.(tightening
AUDI AG does not torque:
20 Nm); if necessary, turn crankshaft backwards and forwards
– Mark running direction of drive chain for auxiliary drives with

paint.
– Press guide rail of chain tensioner in direction of -arrow- and
lock chain tensioner by inserting locking pin -T40071- .
– Unscrew bolts -3- and detach chain sprocket from balance
shaft.
– Remove bolts -1- and -2- and take off chain tensioner with
chain.
1. Chain drive 171

Audi A6 2005 ➤
Installing
• Crankshaft -1- locked in “TDC” position with locking pin -
T40069- .
– Install chain tensioner with chain and balance shaft sprocket.

– Lock balance shaft in TDC position using locating pin -
T40116- .
• The elongated holes in the balance shaft sprocket must be
aligned centrally over the threaded holes in the balance shaft.
If necessary move chain one tooth further.
– Tighten bolts for chain tensioner.
– Fit bolts -1- for chain sprocket without tightening.
• It should just be possible to turn the sprocket on the balance
shaft without axial movement.
– Pull locking pin -T40071- out to release chain tensioner.
– Press against guide rail of chain tensioner -arrow- using a
screwdriver, and at the same time tighten bolts -1- securing
chain sprocket.
– Pull locating pin -T40116- out of balance shaft.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Vehicles with automatic gearbox 09L:
permitted unlessInstall drive
authorised plate
by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 121 . with respect to the correctness of information in this document. Copyright by AUDI AG.
405 .
Tightening torques
Component Nm
Chain tensioner to cylinder block 10 +45° 1)
Chain sprocket for balance shaft to balance 15 +90° 1)
weight
• 1) Renew bolts.

Audi A6 2005 ➤
1.12 Balance shaft - exploded view
1 - Balance shaft
⇒ page 173
2 - 60 Nm
❑ Use locating pin -
T40116- as counterhold
when loosening and
tightening
3 - Balance weight (gearbox
end)
❑ Can only be fitted on
balance shaft in one po‐
sition.
4 - Bearing plate
5 - 13 Nm
6 - Balance weight (pulley end)
❑ Can only be fitted on
balance shaft in one po‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
sition.
7 - 60 Nm
❑ Use locating pin -
T40116- as counterhold
when loosening and
tightening
1.13 Removing and installing balance shaft

Removing
1. Chain drive 173

Audi A6 2005 ➤
WARNING
following steps.

⇒ page 121 .
– Remove sealing flange (pulley end) ⇒ page 109 .
– Remove drive chain for auxiliary drives: vehicles up to 04.2006
– Use locating pin -T40116- to lock balance shaft -1- in position
at rear of engine.
– Unscrew bolt -2- andunless
permitted detach balance
authorised weight
by AUDI AG. AUDIfrom
AG doesbalance
not guarantee or accept any liability
shaft. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew bolt -2- (counterhold balance weight -1- with a suit‐

able pin) and detach balance weight at front of engine from
balance shaft.
– Unscrew bolts -arrows- and remove bearing plate for balance

shaft at rear of engine.
– Pull balance shaft out of cylinder block towards rear.

Audi A6 2005 ➤
Installing
T40069- .
Note
Balance weights can only be fitted on balance shaft in one posi‐

tion.
– Install drive chain for auxiliary drives: vehicles up to 04.2006

– Install sealing flange (pulley end) ⇒ page 109 .
– Vehicles with multitronic gearbox: Install flywheel permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 119 and damper unit ⇒ page 118 . with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 121 .
405 .
Tightening torques
Component Nm
Bearing plate to cylinder block 9
Balance weight to balance shaft 60
1. Chain drive 175

Audi A6 2005 ➤
2 Cylinder head
2.1 Cylinder head - exploded view
Note
♦ Illustration shows left cylinder head.

♦ Both cylinder heads can be removed and installed with the engine still installed.
1 - High-pressure pump
⇒ Rep. Gr. 24
2 - 9 Nm
3 - 20 Nm
4 - Lifting eye
5 - O-ring
❑ Renew
6 - Hall sender for inlet cam‐
shaft
❑ Cylinder bank 1 (right-
side) Hall sender -G40-
❑ Cylinder bank 2 (left-
side) Hall sender 2 - with respect to the correctness of information in this document. Copyright by AUDI AG.
G163-
❑ Renew
8 - O-ring
❑ Renew
9 - Solenoid valve for camshaft
control (inlet side)
❑ Cylinder bank 1 (right-
side) camshaft control
valve 1 -N205-
❑ Cylinder bank 2 (left-
side) - camshaft control
valve 2 -N208-
10 - 2.5 Nm
11 - Seal
❑ Renew if damaged or
leaking
12 - Filler cap
13 - O-ring
❑ Renew
14 - Solenoid valve for camshaft control (exhaust side)
❑ Cylinder bank 1 (right-side) - exhaust camshaft control valve 1 -N318-
❑ Cylinder bank 2 (left-side) - exhaust camshaft control valve 2 -N319-

Audi A6 2005 ➤
15 - 2.5 Nm
16 - Special bolt, 9 Nm
❑ Renew if damaged or leaking
❑ Note correct sequence when tightening ⇒ page 180
17 - Cylinder head cover
❑ Removing and installing cylinder head cover (left-side) ⇒ page 178
❑ Removing and installing cylinder head cover (right-side) ⇒ page 182
18 - Gasket for cylinder head cover
❑ Renew if damaged or leaking
19 - Cylinder head bolt
❑ Renew
❑ Note correct sequence when loosening ⇒ page 192
❑ Note correct sequence when tightening ⇒ page 193
20 - O-ring
❑ Renew
21 - 8 Nm + 90° further
❑ Renew
22 - Hall sender for exhaust camshaft
❑ Cylinder bank 1 (right-side) Hall sender 3 -G300-
❑ Cylinder
with respect bank
to the correctness 2 (left-side)
of information Hall sender
in this document. 4 -G301-
Copyright by AUDI AG.
23 - Cylinder head
❑ Removing ⇒ page 188
❑ Checking for distortion ⇒ page 177
❑ Machining limit ⇒ page 178
❑ Installing ⇒ page 192
❑ If renewed, change coolant and engine oil
24 - Cylinder head gasket
❑ Renewing ⇒ “2.6 Removing and installing cylinder head”, page 188
❑ Installation position: Part No. towards cylinder head
❑ If renewed, change coolant and engine oil
Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure for distortion
at several points.
• Max. distortion: 0.05 mm
2. Cylinder head 177

Audi A6 2005 ➤
Cylinder head machining limit

Machining of the cylinder head (surface grinding) is only permis‐
sible down to the minimum dimension -a-.
• Minimum dimension: -a- = 139.20 mm
2.2 Removing and installing cylinder head

cover (left-side)
♦ Puller -T40039-
Removing

Audi A6 2005 ➤

– Unplug electrical connectors.

1- Variable intake manifold position sender -G513-
2- Fuel pressure sender for low-pressure -G410- (if fitted)

1- Hall sender 2 -G163-
2- Inlet camshaft control valve 2 -N208-
3- Exhaust camshaft control valve 2 -N319-
nition coils.
– Move wiring harness clear.
– Pull ignition coils out with puller -T40039- .

Audi A6 2005 ➤
– Detach crankcase breather hose -arrow-.

– Unscrew cylinder head cover bolts (left-side) in the sequence
-12 ... 1-.
– Remove cylinder head cover.
Installing
Note
♦ Renew cylinder head cover gaskets if damaged.

♦ Renew cylinder head cover bolts if gasket is damaged.

– Tighten bolts for cylinder head cover in the sequence
-1 ... 12-.
Tightening torque
Component Nm
Cylinder head cover to cylinder head 9

cover (left-side) - USA vehicles
♦ Puller -T40039-
Removing

Audi A6 2005 ➤

– Unplug electrical connector
Protectedfor coolantCopying
by copyright. shortage indicator
for private or commercial purposes, in part or in whole, is not
switch -F66- at bottom of expansion
permitted tank and
unless authorised move
by AUDI expansion
AG. AUDI AG does not guarantee or accept any liability

1- Variable intake manifold position sender -G513-
2- Fuel pressure sender for low-pressure -G410- (if fitted)

2- Inlet camshaft control valve 2 -N208-
3- Exhaust camshaft control valve 2 -N319-
nition coils.

Audi A6 2005 ➤
– Unscrew cylinder head cover bolts (left-side) in the sequence

-12 ... 1-.
Note
Ignore -arrow-.
Caution
Do not disconnect crankcase permitted
breather hose
unless on USA
authorised by AUDImodels.
AG. AUDI AG does not guarantee or accept any liability
– Detach cylinder head cover and move clear to one side (crank‐
case breather hose remains connected).
Installing
Note


– Tighten bolts for cylinder head cover to final setting in the se‐
quence -1 ... 12-.
Tightening torque
Component Nm

cover (right-side)

Audi A6 2005 ➤
♦ Puller -T40039-
Removing


Audi A6 2005 ➤

clamps -arrows-.

1- Coolant temperature sender -G62-
2- Variable intake manifold flap change-over valve -N239-
Note
Disregard -item 3-.

1 - Exhaust camshaft control valve 1 -N318-
3 - Hall sender -G40-
4 - Intake manifold flap potentiometer -G336-
5 - Hall sender 3 -G300-
Note
Disregard -item 2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
nition coils.

Audi A6 2005 ➤
– Unscrew cylinder head cover bolts (right-side) in the sequence

-12 ... 1-.
– Detach crankcase breather hose -arrow-.
– Remove cylinder head cover.

Installing
Note


quence -1 ... 12-.
Tightening torques
Component Nm

cover (right-side) - USA vehicles
♦ Puller -T40039-

Audi A6 2005 ➤
Removing


clamps -arrows-.

Audi A6 2005 ➤

1- Coolant temperature sender -G62-
2- Variable intake manifold flap change-over valve -N239-
Note
Disregard -item 3-.

1 - Exhaust camshaft control valve 1 -N318-
3 - Hall sender -G40-
4 - Intake manifold flap potentiometer -G336-
5 - Hall sender 3 -G300- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
Disregard -item 2-.

nition coils.

Audi A6 2005 ➤
– Unscrew cylinder head cover bolts (right-side) in the sequence

-12 ... 1-.
Note
Ignore -arrow-.
Caution
Do not disconnect crankcase breather hose on USA models.
– Detach cylinder head cover and move clear to one side (crank‐
case breather hose remains connected).
Installing
Note


quence -1 ... 12-.
Tightening torques
Component Nm

Audi A6 2005 ➤
Removing
• Engine in vehicle.
Note
The following
permitted description
unless authorised shows
by AUDI AG. AUDI the
AG removal and installation
does not guarantee of
or accept any liability
the cylinder
with respect head (left-side).
to the correctness The procedure
of information forCopyright
in this document. the other
by AUDIside
AG. is
identical.
WARNING
The fuel system operates under high pressure. The pressure

in the high-pressure part of the injection system must be re‐
duced to a residual pressure prior to opening the system ⇒
Rep. Gr. 24 .
– Drain off coolant ⇒ page 243 .

– Remove front exhaust pipe: left-side ⇒ page 279 , right-side
⇒ page 284 .
– Remove poly V-belt ⇒ page 108 .
– Remove coolant pipe (front) ⇒ page 253 .
– Remove power steering pump ⇒ Rep. Gr. 48 .
Note
To remove the cylinder head (right-side) you must first remove

the exhauster pump for brake servo ⇒ Rep. Gr. 47 .
– Remove intake manifold (top section) ⇒ Rep. Gr. 24 .

– Remove intake manifold (bottom section) ⇒ Rep. Gr. 24 .
– Detach electrical connectors at injectors.

Audi A6 2005 ➤
– Unplug electrical connector -1- for Lambda probe before cat‐

alytic converter and move wiring clear towards bottom of
vehicle.
Note
Disregard -item 2-.
– Remove oil filter housing ⇒ page 234 .
– Disconnect fuel line -arrow-.
– Remove low-pressure pipe by unscrewing bolts and union

nuts -1 ... 6-.
– Remove large lifting eye -arrows- (if fitted).

Audi A6 2005 ➤
– Unplug electrical connectors -1- and -2-.

– Remove high-pressure pump from cylinder head (left-side)
-arrows- (only necessary if you are planning to carry out further
repairs to cylinder head).
– Remove bolt -arrow- and lift out guide tube for oil dipstick.
⇒ page 182 .
⇒ page 150 .
– Unscrew bolts -arrows- at rear of cylinder head.

♦ Cylinder head (left-side): 3 bolts
♦ Cylinder head (right-side): 4 bolts

Audi A6 2005 ➤
– Loosen cylinder head bolts in the sequence -1 ... 8-.

– Carefully remove the cylinder head.
Installing
Note
♦ Renew the cylinder head bolts.

work.
as seals and gaskets.
♦ If repairing, carefully remove any remaining gasket material
from the cylinder head and cylinder block. Ensure that no long
scores or scratches are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive material.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ Checking cylinder head for distortion ⇒ pageCopying
Protected by copyright. 177 .for private or commercial purposes, in part or in whole, is not
♦ Do not remove new cylinder head gasket
with respect from
to the packaging
correctness untilin this document. Copyright by AUDI AG.
of information
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
♦ Position cylinder head gasket on dowel sleeves. The word
“oben” (top) or the Part No. should face towards the cylinder
head.
♦ When installing an exchange cylinder head with fitted cam‐
shafts, the contact surfaces between roller rocker fingers and
cams must be oiled after installing the head.
♦ The plastic protectors fitted to protect the open valves should
not be removed until the cylinder head is ready to be fitted.
♦ After fitting a new cylinder head or cylinder head gasket,
change the coolant and engine oil.
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations by hand to ensure that none of the valves
make contact when the starter is operated.
– Before fitting cylinder head set crankshaft and camshafts to

TDC. To do so, fit camshaft clamps -T40070- to both cylinder
heads and tighten to 20 Nm.

Audi A6 2005 ➤
• The locking pin -T40069- must be screwed into the crankshaft.
– Fit cylinder head gasket.

• Note position of centering pins -arrows- in cylinder block.
• Check installation position of cylinder head gasket: the word
“oben” (top) or the Part No. should face towards the cylinder
head.
– Fit the cylinder head.
– Insert new cylinder head bolts and tighten finger-tight.

– Tighten cylinder head in 3 stages in the following sequence:
1. Tighten to 40 Nm.
2. Turn 90° further.
3. Turn 90° further.
Note
Cylinder head bolts do not have to be torqued down again later

after repairs.

Audi A6 2005 ➤
– Tighten bolts -arrows- to 9 Nm.

♦ Cylinder head (left-side): 3 bolts
♦ Cylinder head (right-side): 4 bolts
the following:
⇒ page 182 .
– Install high-pressure pump ⇒ Rep. Gr. 24 .
– Install oil filter housing ⇒ page 234 .
– Install intake manifold (bottom section) with high-pressure and
low-pressure lines ⇒ Rep. Gr. 24 .
– Install intake manifold (top section) ⇒ Rep. Gr. 24 .
– Install vacuum pump for brake servo ⇒ Rep. Gr. 47 .
– Install power steering pump ⇒ Rep. Gr. 48 .
– Install coolant pipe (front) ⇒ page 253 .
– Install front exhaustProtected
pipe together with catalytic converter: left-
side ⇒ page 279 , right-side
with respect⇒topage 284 . of information in this document. Copyright by AUDI AG.
the correctness

– Change engine oil ⇒ Maintenance ; Booklet 405 .
– Fill cooling system with fresh coolant ⇒ page 243 .
Gr. 48 .
Tightening torques
Component Nm
Guide tube for dipstick to cylinder head 9
2.7 Checking compression

Audi A6 2005 ➤

equipment required
♦ Spark plug socket and ex‐
tension -3122 B-
♦ Compression tester -
V.A.G 1763-
♦ Puller -T40039-
Procedure
• Engine oil temperature at least 30 °C.
• Batterypermitted
voltage at authorised
unless least 12.5 V AG. AUDI AG does not guarantee or accept any liability
by AUDI
– Switch off ignition.

Audi A6 2005 ➤


clamps -arrows-.


Audi A6 2005 ➤

nition coils on cylinder head (left-side).
Note

nition coils on cylinder head (right-side).
Note
– Unplug electrical connector -3- leading to injectors at rear of

cylinder head (left-side).
Note
Disregard items marked -1-, -2- and -arrow-.

Audi A6 2005 ➤
– Unplug electrical connector -1- leading to injectors at rear of

cylinder head (right-side).
Note
Ignore -arrow-.
– Remove spark plugs with spark plug socket -3122 B- .

– Test the compression pressure with the compression tester -
V.A.G 1763- .
Note
Using the compression tester ⇒ Operating instructions .
– Have a 2nd mechanic press down the accelerator pedal com‐

pletely and simultaneously operate the starter until the pres‐
sure no longer increases on the tester display.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 11.0 … 14.0
Wear limit 10.0
Difference between cylinders 3.0 (maximum)
Assembly is carried out in the reverse order; note the following:
– Install spark plugs ⇒ Maintenance ; Booklet 405 .
– Faults are stored in engine control units because connectors
were unplugged: “Generate readiness code” in “Guided Func‐
tions” ⇒ Vehicle diagnosis, testing and information system
VAS 5051.
Tightening torque
Component Nm

Audi A6 2005 ➤
3 Valve gear
Note
♦ Cylinder heads which have cracks between the valve seats or

between a valve seat insert and the spark plug thread can be
re-installed without reducing service life, provided the cracks
are only slight and do not exceed a maximum of 0.3 mm in
width, and no more than the first 4 turns of the spark plug
threads are cracked.
♦ After installing camshafts, wait for approx. 30 minutes before
starting engine. Hydraulic valve compensation elements have
to settle (otherwise valves will strike pistons).
♦ The following illustration shows the left-side cylinder head.
3.1 Valve gear - exploded view
1 - Exhaust valve
catalogue
❑ Do not machine, only
grinding-in is permitted
❑ Mark installation posi‐
tion for re-installation
❑ Valve dimensions
⇒ page 216
❑ Checking valve guides
⇒ page 216
2 - Sealing plugs
❑ Apply sealant when in‐
stalling; refer to ⇒ Elec‐
tronic parts catalogue
3 - Cylinder head Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Checking valve guides with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 216
4 - Hydraulic valve compensa‐
tion element
❑ Lubricate contact sur‐
face
5 - Securing clip
❑ Check for firm attach‐
ment
6 - Inlet camshaft
⇒ page 201
❑ Measuring axial clear‐
ance ⇒ page 200
3. Valve gear 199

Audi A6 2005 ➤
❑ Runout: max. 0.04 mm

7 - Retaining frame
❑ With integrated camshaft bearings
❑ Removing and installing ⇒ “3.4 Removing and installing camshafts”, page 201
❑ Renew
9 - Exhaust camshaft
❑ Measuring axial clearance ⇒ page 200
❑ Runout: max. 0.04 mm
10 - Roller rocker finger
❑ Check roller bearings for ease of movement
❑ Lubricate contact surface
11 - Valve cotters
12 - Valve spring plate
13 - Valve spring
❑ Installation position: the narrow spring coils face the cylinder head
14 - Valve stem oil seal
❑ Renewing (cylinder head installed) ⇒ page 207
❑ Renewing (cylinder head removed) ⇒ page 211
15 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Mark installation position for re-installation
❑ Valve dimensions
Protected ⇒ page
by copyright. Copying 216 or commercial purposes, in part or in whole, is not
for private
❑ Checking valveauthorised
permitted unless guidesby ⇒ page
AUDI 216AG does not guarantee or accept any liability
AG. AUDI
3.2 Measuring axial clearance of camshafts

♦ Universal dial gauge bracket -VW 387-

Audi A6 2005 ➤
Procedure
– Remove roller rocker fingers and hydraulic compensation el‐
ements
⇒ “3.4 Removing and installing camshafts”, page 201 .
– Secure universal dial gauge bracket -VW 387- with dial gauge
-VAS 6080- to cylinder head.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
• Axial clearance: 0.100 ... 0.191 mm
3.3 Measuring radial clearance of cam‐
shafts
♦ Plastigage
Procedure
– Remove roller rocker fingers
– Clean bearing and bearing journal.
bearing on the bearing journal or bearing shell to be measured.
• The Plastigage must be positioned in the centre of the bearing.
– Fit retaining frame and tighten to torque (do not turn further)
without rotating camshafts ⇒ page 206 .
– Remove retaining frame again.
– Compare width of Plastigage with measurement scale.
Radial clearance:
• Bearing (∅ 24 mm): 0.024 ... 0.066 mm.
• Bearing (∅ 36 mm): 0.100 ... 0.325 mm.
3.4 Removing and installing camshafts
3. Valve gear 201

Audi A6 2005 ➤

equipment required
♦ Impact extractor attach‐
ment -T10133/3- from tool
set for FSI engines -
T10133-
(2x)
♦ Electric drill with plastic
brush attachment
♦ Safety goggles
♦ Sealant ⇒ Electronic parts
catalogue
Removing
⇒ page 182 .
⇒ pageProtected
150 . by copyright. Copying for private or commercial purposes, in part or in whole, is not
– To remove
with the camshafts
respect (right-side)
to the correctness of informationyou
in thismust firstCopyright
document. remove by AUDI AG.
the exhauster pump for brake servo ⇒ Rep. Gr. 47 .

Audi A6 2005 ➤
– Slacken retaining frame bolts in the sequence -22 ... 1-.
Note
Illustration shows retaining frame of left-side cylinder head.
– Carefully release retaining frame from bonded joint.

– Mark and remove camshafts.
Note
To enable the locating pins -T40116- to be attached during in‐

stallation on engines fitted with dowel pins -arrows- for retaining
frame , drive out dowel pins using a suitable drift.
Installing
Note
Renew gaskets and seals.
• Crankshaft -1- locked in position with locking pin -T40069- .
WARNING
– Remove remaining sealant from cylinder head and retaining

frame using rotating plastic brush or similar.
Caution
Make sure that no sealant residue gets into the cylinder head
or the bearings.

– Lubricate running surfaces of camshafts.
– Lay retaining frame aside onto workbench, on a soft surface.
3. Valve gear 203

Audi A6 2005 ➤
– Insert camshafts into retaining frame.

• Camshafts must be in correct position in axial bearings
-arrows- in retaining frame.
• The ends of the piston rings -1- and -2- must point up or down,
never to the side.
– Turn retaining frame upside down with camshafts inserted,
keeping hold of the camshafts in the retaining frame.
– Turn the camshafts until the threaded holes -arrows- point up‐
wards.
– Check that camshafts are still in correct position in axial bear‐
ings in retaining frame.
– Fit camshaft clamp -T40070- as shown in illustration and tight‐

en bolts -arrows- to 20 Nm.
Note

mm).
– Turn retaining frame back up.

Audi A6 2005 ➤
Vehicles up to approx. 08.2004:

faces of the retaining frame as illustrated.
• The grooves on the sealing surface must be completely filled
with sealant.
sealing surface.
Note
The beads of sealant must be applied exactly according to these

instructions, otherwise excess sealant can get into the camshaft
bearings.
Vehicles from approx. 08.2004:

– Apply a small amount of sealant in groove for gasket -3- in
area of opening for camshaft control solenoid valve -arrows-.
– Press gasket into retaining frame and wipe off excess sealant
from gasket and retaining frame.
– Apply the beads of sealant -1-, -2- and -4- onto the clean seal‐
ing surfaces of the retaining frame as illustrated.
• Width of sealant bead: 1.0 mm.
Note
The beads of sealant must be applied exactly according to these
instructions, otherwise excess sealant can get into the camshaft
bearings.
All vehicles:
Note
The retaining frame must be installed within 5 minutes after ap‐

plying sealant.
– Fit retaining frame onto cylinder head.

– Insert locating pins -T40116- in retaining frame and cylinder
head.
3. Valve gear 205

Audi A6 2005 ➤
– Fit retaining frame onto cylinder head without delay.

– Tighten retaining frame bolts in the sequence -1 ... 22- evenly,
initially only hand-tight.
• The retaining frame should make contact with the cylinder
head over the full surface.
– Tighten retaining frame bolts to final torque in the sequence
-1 ... 22-.
Note
♦ Illustration shows retaining frame of left-side cylinder head.

♦ After installing the retaining frame, wait about Protected
30 minutes for Copying for private or commercial purposes, in part or in whole, is not
by copyright.
the sealant to dry. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Clean bore for sealing plug in cylinder head; it must be free of

oil and grease.
– Coat outer circumference of sealing plug -arrow- with sealant;
for sealant refer to ⇒ Electronic parts catalogue .
– Drive in sealing plug until flush.

Audi A6 2005 ➤
– Use impact extractor attachment -T10133/3- to pull out locat‐

ing pins -T40116- .
the following:
Note

– Install vacuum pump for brake servo ⇒ Rep. Gr. 47 .

⇒ page 182 .
Tightening torque
Component Nm
Retaining frame to cylinder head 8 +90° 1)
• 1) Renew bolts.
3.5 Renewing valve stem oil seals (cylinder head installed)
3. Valve gear 207

Audi A6 2005 ➤

equipment required
♦ Spark plug socket and ex‐
tension -3122 B-
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Removal / installing device
for valve cotters -VAS
5161- with guide plate -
VAS 5161/19 A-
Procedure
– Remove camshafts ⇒ page 201 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place on a clean surface.
– Remove spark plugs with spark plug socket -3122 B- .
– Apply drift -VAS 5161/3- to valve spring plate and knock valve
cotters loose using a plastic hammer.

Audi A6 2005 ➤
– Fit guide plate -VAS 5161/19B- onto cylinder head.

– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw adapter -T40012- with seal hand-tight into the corre‐
sponding spark plug thread and apply a steady pressure.
• Air pressure: at least 6 bar
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/8- into guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
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.
– Release the pressure fork.
– Remove assembly cartridge.
– Detach guide plate and turn to one side.
• The compressed air hose remains connected.
– Remove valve spring with valve spring plate.
– Remove valve stem oil seals using the valve stem seal puller
-3364- .
If the 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 -3364- using a drift and remove
the extractor attachment.
3. Valve gear 209

Audi A6 2005 ➤
– Attach lower part of puller -3364- to valve stem oil seal.

– Secure -3364- with drift or roll-pin drift -1- as shown in the il‐
lustration.
– Apply an assembly lever to puller -3364- and pull out valve
stem oil seal -arrow-.
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- ontowiththe valve
respect to thestem to prevent
correctness damage
to the new valve stem oil seal -B-.
– Lightly lubricate sealing lip of valve stem oil seal.
– Slip valve stem oil seal over plastic sleeve.
– Carefully press the valve stem oil seal onto valve guide using
fitting tool -3365- .
– Remove the plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

need to be put into insertion device for valve cotters -
VAS 5161/18- first.
• Larger diameter of valve cotters faces upwards.
– Install valve spring and valve spring plate.

• The closely spaced spring coils -arrow- face the cylinder head.

Audi A6 2005 ➤
– Screw guide plate back onto cylinder head.

– Insert assembly cartridge into guide plate.
– Push pressure fork down and pull knurled screw upwards
while turning to left and right – this will insert the valve cotters.
– Release the pressure fork with knurled screw still in pulled po‐
sition.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers contact the ends of the
valve stems correctly and are clipped onto their respective hy‐
draulic compensation elements.
– Install camshafts ⇒ page 201 .
– Install spark plugs ⇒ Maintenance ; Booklet 405 .
Note

least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
3.6 Renewing valve stem oil seals (cylinder head removed)
3. Valve gear 211

Audi A6 2005 ➤

equipment required
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Removal / installing device
for valve cotters -VAS
5161-
♦ Engine and gearbox sup‐
port -VAS 6095-
♦ Cylinder head tensioning
device -VAS 6419-
Procedure
– Remove camshafts ⇒ page 201 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place on a clean surface.
– Insert cylinder head tensioning device -VAS 6419- into engine
and gearbox support -VAS 6095- .
– Secure cylinder
permittedhead
unless in cylinder
authorised head
by AUDI tensioning
AG. AUDI AG does notdevice,
guaranteeas
or accept any liability
illustrated. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Connect cylinder head tensioning device to compressed air.
– 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.

Audi A6 2005 ➤
– Apply drift -VAS 5161/3- to valve spring plate and knock valve
cotters loose using a plastic hammer.
– Fit guide plate -VAS 5161/19B- onto cylinder head.

– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw snap-inwithdevice -VAS
respect to 5161/6-
the correctness with engaging
of information fork Copyright
in this document. - by AUDI AG.
VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/8- into guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
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.
– Release the pressure fork.
– Remove assembly cartridge.
– Detach guide plate and turn to one side.
– Remove valve spring with valve spring plate.
– Remove valve stem oil seals using the valve stem seal puller
-3364- .
3. Valve gear 213

Audi A6 2005 ➤
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto the valve stem to prevent damage
to the new valve stem oil seal -B-.
– Lightly lubricate sealing lip of valve stem oil seal.
– Slip valve stem oil seal over plastic sleeve.
– Carefully press the valve stem oil seal onto valve guide using
fitting tool -3365- .
– Remove the plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

need to be put into insertion device -VAS 5161/18- first.
• Larger diameter of valve cotters faces upwards.
– Install valve spring and valve springwith
plate.
• The closely spaced spring coils -arrow- face the cylinder head.
– Screw guide plate back onto cylinder head.

– Insert assembly cartridge into guide plate.
– Push pressure fork down and pull knurled screw upwards
while turning to left and right – this will insert the valve cotters.
– Release the pressure fork with knurled screw still in pulled po‐
sition.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers contact the ends of the
valve stems correctly and are clipped onto their respective hy‐
draulic compensation elements.
– Install camshafts ⇒ page 201 .

Audi A6 2005 ➤
3.7 Checking hydraulic valve compensation

elements
Note
♦ The hydraulic compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge
Procedure
– Start engine and let it run until the radiator fan has switched
on once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
Note
If the irregular valve noises stop but recur repeatedly during short
trips, renew the oil retention valve. The oil retention valve is lo‐
cated in the oil filter housing - version up to 04.2005
⇒ Item 6 (page 232) , from 05.2005 ⇒ Item 7 (page 233) .
If the hydraulic compensation elements are still noisy, locate the

defective element as follows:
⇒ page 182 .
– Turn crankshaft until cams of compensation element to be
tested are at top:
♦ Vehicles with manual gearbox: push vehicle forwards with 4th
gear engaged and ignition switched off.
♦ Vehicles with multitronic gearbox or automatic gearbox 09L:
Turn crankshaft clockwise at central bolt for poly V-belt pulley.
– Determine clearance between cam and roller rocker finger.
– Press roller rocker finger down using a screwdriver -arrow-.
If it is possible to insert a feeler gauge of 0.20 mm between cam‐
shaft and roller rocker finger:
– Renew hydraulic valve compensation element
Note

least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
3. Valve gear 215

Audi A6 2005 ➤
3.8 Valve dimensions
Note
Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.0 ± 0.2 101.9 ± 0.2
α ∠° 45 45
WARNING
♦ Care must be taken when disposing of old sodium-cooled

exhaust valves.
♦ The valves must be sawn in two with a metal saw between
the centre of the stem and valve head. When doing so, the
valves must not come into contact with water. After pre‐
paring the valves, throw a maximum of ten into a bucket
of water. Then step away immediately, since a chemical
reaction will occur in which the sodium filling burns.
♦ After performing these steps the valves can be disposed
of in the normal way.
3.9 Checking valve guides

Special tools and workshop equipment required Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Universal dial gauge bracket -VW 387- with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi A6 2005 ➤
Procedure
– Insert valve into valve guide. Only insert inlet valve into inlet
guide and exhaust valve into exhaust guide, as the stem di‐
ameters are different.
• End of valve stem must be flush with valve guide.
– Determine amount of sideways play.
• Wear limit: 0.8 mm.
Note
♦ If the valve has to be renewed as part of a repair, use a new

valve for the measurement.
♦ If the wear limit is exceeded, repeat the measurement with
new valves. Renew cylinder head if wear limit is still exceeded.
3.10 Checking valves

– Visually inspect for scoring on valve stem and on surface of
seat.
If scoring is clearly visible:
– Renew the relevant valve.
3. Valve gear 217

Audi A6 2005 ➤
17 – Lubrication
1 Lubrication system
Note
♦ If large quantities of metal shavings or particles are found in

the engine oil when repairing the engine, the oil passages
must be cleaned carefully, and the engine oil cooler must be
renewed in order to prevent further damage occurring later.
♦ The oil level must not be above the max. mark – otherwise the
catalytic converter can be damaged.
♦ Refer to ⇒ Maintenance tables for engine oil capacity, oil
specifications and viscosity grades.
♦ Oil spray jet for piston cooling ⇒ page 134 .
1.1 Sump (bottom section), sump (top section), oil pump, engine oil cooler -
exploded view
1 - 9 Nm
❑ Bolt or nut (depending
on version)
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
2 - Oil level and oil temperature
sender -G266-
⇒ page 220
3 - Oil drain plug, 30 Nm
4 - 9 Nm
5 - Baffle plate (bottom)
6 - 16 Nm
❑ Tighten in stages and in
diagonal sequence
7 - Sump (top section)
⇒ page 225
8 - O-ring
❑ Renew
9 - 9 Nm
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
10 - Baffle plate (top)
11 - Gasket
❑ Renew
218 Rep. Gr.17 - Lubrication

Audi A6 2005 ➤
12 - Gasket
❑ Renew
13 - 9 Nm
14 - Engine oil cooler
❑ See note ⇒ page 218
❑ With oil cooler bypass valve
15 - 9 Nm
16 - Oil pump drive shaft
18 - Mounting bracket
19 - 9 Nm
20 - Chain sprocket for oil pump

❑ Can only be fitted in one position on drive shaft
21 - 30 Nm + 90° further
❑ Renew
❑ To loosen, use pin wrench -3212- to counterhold chain sprocket
22 - O-ring
❑ Renew
23 - O-rings
❑ Renew
24 - 20 Nm
25 - Oil pump
❑ Do not dismantle
❑ With pressure relief valve for cold condition (11 bar) and pressure control valve (4.3 bar)
26 - Bolt
Sump (bottom section), aluminium version:
❑ 9 Nm
❑ Tighten in stages and in diagonal sequence
Sump (bottom section), sheet-metal version:
❑ Renew
❑ 5 Nm + 90° further
❑ Tighten in stages and in diagonal sequence
27 - Sump (bottom section)
❑ Different versions available ⇒ Electronic parts catalogue
28 - Seal
❑ Renew
1. Lubrication system 219

Audi A6 2005 ➤
1.2 Removing and installing oil level and oil

temperature sender -G266-
Removing
– Remove nuts or bolts -1- and detach oil level and oil temper‐
ature sender -G266- -item 4-.
Installing
Note
Renew seal -2-.
405 .
Tightening torque
Component Nm
Oil level and oil temperature sender -G266- to 9
sump (bottom section)
1.3 Removing and installing engine oil cooler

Audi A6 2005 ➤

equipment required
♦ Used oil collection and ex‐
traction unit -V.A.G 1782-
-VAS 6208-
to 25 mm -3094-
Removing
WARNING


Audi A6 2005 ➤
– Clamp off coolant hoses -1- and -2- using hose clamps -3094- .
– Disconnect coolant hoses at engine oil cooler and drain off
coolant.
below engine.
– Unscrew bolts -arrows- and detach engine oil cooler.
Installing
Note
♦ Renew seals and gaskets.

405 .
Tightening torques
Component Nm
Engine oil cooler to sump (top section) 9
Oil drain plug 30
1.4 Removing and installing sump (bottom

section)
♦ Electric drillunless
permitted withauthorised
plasticbybrush attachment
AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Safety goggles
Removing
– Unscrew bolts -arrows- and detach engine oil cooler with cool‐
ant hoses -1- and -2- attached.

Audi A6 2005 ➤
– Unplug electrical connector -1- at oil level and oil temperature

sender -G266- -arrow- and move wiring clear.
– Release sump (bottom section) from bonded joint, taking care
not to bend sump (sheet-metal version).
Installing
Note
♦ Renew seals and gaskets.

♦ On the sheet-metal version, the sump (bottom section) must
be renewed if its coating is damaged or if it is bent.
WARNING
– Remove remaining sealant on sump (bottom and top sections)

with a rotating plastic brush or similar.
Note
On the sheet-metal version, take care not to damage the coating

on the sump (bottom section).

mm).

Audi A6 2005 ➤
– Apply bead of sealant -arrow- onto clean sealing surface of

sump (bottom section) as illustrated.
• The bead of sealant should be approx. 1.5 mm wide.
Note
♦ The bead of sealant must not be thicker than specified, other‐

wise excess sealant can enter the sump (bottom section) and
obstruct the strainer in the oil intake pipe.
♦ The sump (bottom section) must be installed within 5 minutes
after applying sealant.
– Fit sump (bottom section) and tighten all bolts initially to 5 Nm

in diagonal sequence.
– Tighten bolts on sump (bottom section) in diagonal sequence
– Install engine oil cooler ⇒ page 220 .
405 .
Tightening torques
Component Nm
Engine oil cooler to sump (top section) 9
Sump (bottom section), aluminium version to 9 1)
sump (top section)
Sump (bottom section), sheet-metal version to 5 +90° 1)2)
sump (top section)
Oil drain plug 30
• 1) Tighten in diagonal sequence.
• 2) Renew bolts.

Audi A6 2005 ➤
1.5 Removing and installing oil pump

Removing
– Remove sump (bottom section) ⇒ page 222 .
– Detach oil pump from drive shaft by pulling it to front, move
drive shaft slightly to rear if necessary.
Installing
Note
Renew O-rings.
– Fit oil pump onto drive shaft and

Protected tightenCopying
by copyright. bolts.
for private or commercial purposes, in part or in whole, is not
– Install sump (bottom section) ⇒ page
with respect to the 222 . of information in this document. Copyright by AUDI AG.
correctness
405 .
Tightening torque
Component Nm
Oil pump to sump (top section) 20
1.6 Removing and installing sump (top sec‐

tion)
♦ Pneumatic jig-saw -VAS 5108-
♦ Universal mole grips, 300 mm -VAS 5433-
♦ Safety goggles

Audi A6 2005 ➤

Removing
• Engine secured to engine and gearbox stand -VAS 6095-
⇒ page 93 .
⇒ page 121 .
– Remove sump (bottom section) ⇒ page 222 .
– Remove oil pump ⇒ page 225 .
– Unscrew bolts -arrows- and remove baffle plate (bottom).
– Unscrew bolts -1 ... 4- from timing chain cover (bottom).

Audi A6 2005 ➤
– Remove bolts -1 … 6- for sump (top section).

– Carefully release sump (top section) from bonded joint and pry
sump off dowel pins on cylinder block.
Installing
Note
Renew gaskets, seals and O-rings.
– Remove old sealant from grooves on sump (top section) and

on timing chain cover (bottom) -arrows- using a small screw‐
driver.
WARNING
– Remove sealant residue on sump (top section) using rotating

plastic brush or similar.

Audi A6 2005 ➤
– Mask oil return channel with adhesive tape -1-.

– Cover cylinder block with a cloth -2- to protect against metal
shavings.
– Also mask open threaded holes with adhesive tape to protect
against metal shavings.
– Secure a strip of sheet metal (2.5 mm thick and approx. 65 x

100 mm) -item 1- next to dowel sleeve using universal mole
grips (300 mm) -VAS 5433- .
Note
The metal strip serves as a stop when sawing; at the same time
it protects the sealing surface of the retaining frame.
WARNING
– Saw off dowel sleeve so it is flush with metal strip using pneu‐
matic jig-saw -VAS 5108- .
– Repeat procedure for second dowel sleeve.
– Deburr both dowel sleeves.
– Chamfer both holes for dowel sleeves (1.5 mm) on sump (top
section) using countersink.
– Clean sealing surfaces on sump (top section) and timing chain
cover (bottom); they must be free of oil and grease.
Note

mm).

Audi A6 2005 ➤
– Apply bead of sealant -arrow- onto clean sealing surface of

sump (top section) as illustrated.
• The grooves -arrows- on the sealing surfaces must be com‐
pletely filled with sealant.
sealing surface.
– Apply sealant bead -arrow- onto clean sealing surface of tim‐

ing chain cover (bottom), as illustrated.
with sealant.
sealing surface.
• Apply sealant bead all the way into corners.
Note
♦ The sealant bead must not be thicker than specified, otherwise

excess sealant could enter the sump and clog the strainer in
the oil pump.
♦ The sump (top section) must be installed within 5 minutes after
applying sealant.
– Fit seal -1- and O-ring -2- in retaining frame.

Audi A6 2005 ➤
– Fit sump (top section), paying attention to dowel sleeves, and

tighten bolts -1 ... 6- in diagonal sequence initially to 5 Nm.
– Pre-tighten bolts -1 ... 4- in diagonal sequence to 5 Nm.
– Tighten bolts -1 ... 6- in diagonal sequence.

Audi A6 2005 ➤
– Tighten bolts -1 ... 4- in diagonal sequence.

the following:
– Install oil pump ⇒ page 225 .
– Install sump (bottom section) ⇒ page 222 .
⇒ page 121 .
– After installing engine, fill up with engine oil and check oil level
⇒ Maintenance ; Booklet 405 .
Tightening torques
Component Nm
Sump (top section) to cylinder block 16 1)
Timing chain cover (bottom) to engine M6 9
M8 20
Baffle plate (top) to sump (top section) 9 2)
Baffle plate (bottom) to sump (top section) 9
• 1) Tighten in diagonal sequence.
• 2)Apply locking fluid when installing; refer to ⇒ Electronic
parts catalogue for locking fluid.
1.7 Oil filter housing - exploded view

Vehicles up to 04.2005

Audi A6 2005 ➤
1 - 13 Nm
2 - Oil pressure switch - F1-
❑ Black insulation
❑ Checking
⇒ “1.12 Checking oil
pressure”, page 238
⇒ page 237
3 - 13 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Sleeve
5 - Rubber grommet
6 - Oil filter housing
❑ With filter bypass valve,
3.0 bar
❑ With oil retention valve
❑ The oil retention valve
cannot be renewed
⇒ page 234
7 - O-ring
❑ Renew
8 - Sealing cap, 25 Nm
9 - Seal
❑ Renew
⇒ page 233
10 - Oil filter element
⇒ Maintenance ; Booklet 405
11 - Gasket
❑ Renew
12 - Seal with earth wire
❑ Renew
Vehicles from 05.2005

Audi A6 2005 ➤
1 - 13 Nm
2 - Oil pressure switch - F1-
❑ Black insulation
⇒ page 237
❑ Checking
⇒ “1.12 Checking oil
pressure”, page 238
3 - Multi-point socket flange
nut, 13 Nm
4 - 13 Nm
5 - Sleeve
6 - Rubber grommet
7 - Oil filter housing
❑ With filter bypass valve,
3.0 bar
❑ With oil retention valve
❑ The oil retention valve
cannot be renewed
8 - O-ring
❑ Renew
9 - Sealing cap, 25 Nm
10 - Seal
❑ Renew
❑ Removing andunless
installing
permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 233
11 - Oil filter element

❑ Removing and installing ⇒ Maintenance ; Booklet 405
12 - Stud, 16 Nm
13 - Seal
❑ Renew
14 - Seal with earth wire
❑ Renew
Renewing seal on sealing cap

– Take hold of tab -arrow A- and pull seal -2- out of sealing cap
-1-.
– Fit new seal with semi-circular profile in groove -arrow B- in
sealing cap.
• The tab -arrow A- must face upwards.

Audi A6 2005 ➤
Installing O ring on oil filter housing

– Install O-ring -2- in groove -arrow- on oil filter housing -1-.
1.8 Removing and installing oil filter housing

Removing
– Pull off engine cover panel (rear)permitted
-arrows-.


Audi A6 2005 ➤
Note
In the following illustrations the steps to perform are shown from

the rear and with the engine removed.
– Unscrew sealing cap -arrow- for oil filter housing.

– Remove oil filter element.
– Extract engine oil from oil filter housing using used oil collec‐
tion and extraction unit -V.A.G 1782- .
Note
– Unplug electrical connector at oiltopressure
with respect switch
the correctness -F1- in this document. Copyright by AUDI AG.
of information
-arrow-.

– On engines from 05.2005, also remove multi-point socket
flange nut ⇒ Item 3 (page 233) .
– Remove oil filter housing.
Installing
Note
Renew gaskets, seals and O-rings.
405 .
Tightening torques
Component Nm
Oil filter housing to engine 13
Oil pressure switch to oil filter housing 20
Sealing cap on oil filter housing 25
1.9 Oil retention valves, oil separator - exploded view

Audi A6 2005 ➤
1 - O-ring
❑ Renew
2 - Oil retention valve, 20 Nm
❑ For oil supply to cylinder
head (right-side)
3 - 9 Nm
4 - Oil separator
❑ Bolted into cover
from below
5 - Gasket
❑ Renew
6 - Cover
❑ With connection for
crankcase breather
❑ To remove, first remove
intake manifold (top
section) ⇒ Rep. Gr. 24
and intake manifold (left
and right bottom sec‐
tions) ⇒ Rep. Gr. 24
7 - O-ring
❑ Renew
8 - Gasket
❑ Renew
9 - 6 Nm
10 - Crankcase breather hoses
⇒ page 237
Caution
Do not disconnect crank‐

case breather hose on
USA models.
11 - 9 Nm
12 - Oil retention valve, 20 Nm
❑ For oil supply to cylinder head (left-side)
13 - O-ring
❑ Renew

Audi A6 2005 ➤
1.10 Removing and installing crankcase

breather hoses - not applicable for USA
vehicles
Removing
Note

– Disconnect crankcase breather hoses -arrows- from cylinder
head covers.
– Move the crankcase breather hoses clear.
– Unscrew bolt -1- and take out hose connection with crankcase
breather hoses.
Installing
Note
♦ Renew gaskets, seals and O-rings. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Tightening torque
Component Nm
Hose connection for crankcase breather hoses 6
to cover
1.11 Removing and installing oil pressure

switch -F1-
Removing

Audi A6 2005 ➤

Note
– Unplug electrical connector at oil pressure switch -F1-

-arrow-.
Installing
Renew seal.

Tightening torque
Component Nm
Oil pressure switch to oil filter housing 20
1.12 Checking oil pressure

Audi A6 2005 ➤

equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Voltage tester -
V.A.G 1527 B-
♦ Auxiliary measuring set -
V.A.G 1594 C-
Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch ⇒ page 237 .

Audi A6 2005 ➤
– Connect oil pressure tester -V.A.G 1342- to threaded hole for

oil pressure switch.
– Screw oil pressure switch -2- into oil pressure tester -
V.A.G 1342- .
Checking oil pressure switch
– Connect brown wire -1- of oil pressure tester to earth (–).
– Connect voltage tester -V.A.G 1527 B- with test leads from
auxiliary measuring set -V.A.G 1594 C- to oil pressure switch
and battery positive (+).
• LED should not light up.
If LED lights up now:
– Renew oil pressure switch.
– Start engine.
Note
Observe oil pressure tester and LED while starting, as switching

point of oil pressure switch may already be exceeded when start‐
ing.
• LED should light up at 1.2 ... 1.6 bar.
If LED does not light up:
– Renew oil pressure switch.
Checking oil pressure
– Start engine.
• Minimum oil pressure at idling speed: 1.2 bar
• Minimum oil pressure at 2000 rpm: 3.4 bar.
Assembling
– Install oil pressure switch ⇒ page 237 .
1.13 Engine oil

Refer to ⇒ Maintenance tables for viscosity grades, oil specifi‐
cations and engine oil capacity.
1.14 Checking oil level

Check oil level ⇒ Maintenance ; Booklet 405 .

Audi A6 2005 ➤
19 – Cooling
1 Cooling system
WARNING
Hot steam can escape when opening cap on expansion tank;

cover filler cap with a cloth and open carefully.
Note
♦ The cooling system is under pressure when the engine is hot.

If necessary, relieve pressure before commencing repair work.
♦ Renew gaskets and seals.
♦ The arrow markings on coolant pipes and on ends of hoses
must align.
1.1 Diagram of coolant hose connections
1. Cooling system 241

Audi A6 2005 ➤
1 - Radiator
⇒ page 220
❑ If renewed, refill system
with fresh coolant
2 - Coolant pump
⇒ page 249
3 - Thermostat
⇒ page 251
4 - Heat exchanger
with fresh coolant
5 - Bleeder screw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Expansion tank with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ With filler cap

❑ Checking pressure re‐
lief valve in filler cap
⇒ page 268
7 - Engine oil cooler
with fresh coolant
⇒ page 220
8 - Continued coolant circula‐
tion pump -V51-
❑ Only on vehicles equip‐
ped for a hot climate
242 Rep. Gr.19 - Cooling

Audi A6 2005 ➤
1.2 Draining and filling cooling system

equipment required
♦ Adapter for cooling system
tester -V.A.G 1274/8-
♦ Pipe for cooling system
tester -V.A.G 1274/10-
♦ Cooling system charge unit
-VAS 6096-
-VAS 6208-
♦ Refractometer -T10007-
Draining
Note
Collect drained coolant in a clean container for re-use or disposal.
WARNING



Audi A6 2005 ➤
Note
Disregard -item 2-.

Audi A6 2005 ➤

Filling
• Ignition off.
Note
♦ The cooling system is filled all year round with a mixture of

water and radiator antifreeze/anti-corrosion agent.
♦ Use only the radiator antifreeze/anti-corrosion agent approved
for this engine ⇒ Electronic parts catalogue . Other coolant
additives could seriously impair in particular the anticorrosion
properties. The resulting damage could lead to loss of coolant
and consequently to serious engine damage.
♦ The specified radiator antifreeze/anti-corrosion agent pre‐
vents frost and corrosion damage and stops scaling. Such
additives also raise the boiling point of the coolant. For these
reasons the cooling system must be filled all year round with
the correct antifreeze and anticorrosion additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Frost protection is required down to about –25 °C (in countries
with arctic climate: down to about –35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
antifreeze concentration must be at least 40 %.
♦ If greater frost protection is required in very cold climates, the
concentration of radiator antifreeze/anti-corrosion agent can
be increased, but only up to 60% (this gives frost protection to
about –40 °C). If the concentration exceeds 60%, frost pro‐
tection decreases again and cooling efficiency is also im‐
paired.
♦ Use only clean tap water for mixing coolant.
♦ Do not use drained coolant again if:
♦ the radiator, heat exchanger for heater, cylinder head, cylinder
head gasket or cylinder block have been renewed.
♦ the coolant is contaminated or dirty.
♦ For checking anti-freeze protection in cooling system, use re‐
fractometer -T10007- .
– Close
Protected drain
by copyright. plugfor-1-.
Copying private or commercial purposes, in part or in whole, is not
Note
Disregard -item 2-.

Audi A6 2005 ➤
– Connect coolant hose to engine oil cooler -arrow-.
– Fill reservoir -VAS 6096/1- with at least 12 litres of premixed

coolant (based on recommended ratio):
• Radiator antifreeze/anti-corrosion agent (40 %) and water (60
%) for frost byprotection
Protected to –25
copyright. Copying °C. or commercial purposes, in part or in whole, is not
for private
• Radiator
withantifreeze/anti-corrosion agent
respect to the correctness of information in this(50 %) and
document. water
Copyright (50AG.
by AUDI
%) for frost protection to –35 °C.
• Radiator antifreeze/anti-corrosion agent (60 %) and water (40
%) for frost protection to -40 °C.
• Radiator antifreeze/anti-corrosion agent ⇒ Electronic parts
catalogue
– Run vent hose -1- into a small container -2-. (The vented air
draws along a small amount of coolant, which should be col‐
lected.)
– Close the two valves -A- and -B- by setting lever at right angle
to direction of flow.
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar.

Audi A6 2005 ➤
– Open valve -B- by setting lever in direction of flow.

The suction jet pump generates a partial vacuum in the cooling
system.
• The needle on the gauge should move into the green zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on reservoir -VAS 6096/1- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The with
suction jet pump will continue generating a vacuum in the
cooling system.
• The needle on the gauge should remain in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
If the needle does not reach the green zone, repeat the process.
If the vacuum level drops, there is a leak in the cooling system.
– Detach compressed air hose.
– Open valve -A-.
The partial vacuum in the cooling system causes the coolant to
be drawn up out of the reservoir -VAS 6096/1- ; the cooling system
is then filled.
– Detach cooling system charge unit -VAS 6096- from expan‐
sion tank.
– Fit pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .
-2-.

Audi A6 2005 ➤
– Open bleeder screw -arrow-.

– Fill up with coolant until it flows out at bleeder hole in coolant
hose.
– Close the bleeder screw.
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Tighten filler cap on expansion tank.
– Start engine.
– Set temperature to “HI” in all zones.
– Switch off air conditioner compressor (press ECON button).
– Run the engine for 3 minutes at 2000 rpm.
– Allow the engine to run at idling speed until the two large cool‐
ant hoses at main radiator become warm.
– Run the engine for 1 minute at 2000 rpm.
– Switch off ignition and allow engine to cool down.
– Check coolant level.

• The coolant level must be at the MAX marking when the en‐
gine is cold.
• The coolant level can be above the MAX marking when the
engine is warm.
1.3 Thermostat, coolant pump and connection - exploded view

Audi A6 2005 ➤
1 - 9 Nm
2 - 20 Nm
3 - Poly V-belt pulley for cool‐
ant pump
4 - Coolant pump
❑ With seal
⇒ page 249
5 - 9 Nm
6 - Connection
❑ For coolant hose
7 - Gasket
❑ Renew
8 - Gasket
catalogue
❑ Renew permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
9 - Thermostat
⇒ page 251
10 - 9 Nm
1.4 Removing and installing coolant pump


Audi A6 2005 ➤
Removing
Note


– Remove poly V-belt from coolant pump.

bolts.
– Prise off cap.

– Unscrew bolt -arrow- and detach idler roller.

Audi A6 2005 ➤
– Unscrew bolts -arrows- for coolant pump and detach coolant

pump.
Installing
Tightening torques
Component Nm
Coolant pump to cylinder block 9
Idler roller to cylinder block 40
1.5 Removing and installing thermostat

Removing
– Remove coolant pipe (front) ⇒ page 253 .
Note
Place a cloth underneath to catch any escaping coolant.

– Detach thermostat with hose connection.
Installing
Note
Renew seals and gaskets.
– Install coolant pipe (front) ⇒ page 253 .

Tightening torque
Component Nm
Coolant thermostat with hose connection to cyl‐ 9
inder block
1.6 Checking thermostat Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Heat removed thermostat in water bath.
Starts to open Fully open Opening travel
approx. 87 °C approx. 102 °C 1) at least 8 mm

Audi A6 2005 ➤
Starts to open Fully open Opening travel

• 1) Cannot be tested.
1.7 Coolant pipes - exploded view
1 - Coolant pipe (left-side)

❑ Remove and install to‐
gether with
⇒ page 255
2 - 9 Nm
3 - O-ring
❑ Renew
4 - Connecting hose
5 - 9 Nm
6 - Coolant pipe (front)
⇒ page 253
7 - 9 Nm
8 - O-ring
❑ Renew
9 - Coolant temperature send‐
er -G62-
⇒ page 252
10 - Retaining clip
11 - Seal
❑ Renew
12 - O-ring
❑ Renew
13 - Coolant pipe (top)
⇒ page 258
14 - 9 Nm
15 - Seal
❑ Renew
16 - Coolant pipe (left-side)
❑ Remove and install together with ⇒ Item 1 (page 252) ⇒ page 255
17 - 9 Nm
1.8 Removing and installing coolant temper‐

ature sender -G62-
Removing with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi A6 2005 ➤
– Unplug electrical connector -2- at coolant temperature sender

-G62- .
– Pull off retaining clip -1- and detach coolant temperature send‐
er -G62- .
Installing
Note
Renew O-ring.
1.9 Removing and installing coolant pipe

(front)

Audi A6 2005 ➤
Removing

Note



bolts.

Audi A6 2005 ➤

– Detach coolant hoses -arrows- from coolant pipe (front).
– Unscrew bolts -1-, -2-, -4- and -5- and remove coolant pipe
(front).
Installing
Note
♦ Renew seals and O-rings.

– Before installing, clean and smoothen sealing surface for O-

ring.
– Lubricate new O-ring with coolant and slide onto coolant pipe.
Tightening torques
Component Nm
Coolant pipe (front) to engine 9
1.10 Removing and installing coolant pipes

(left-side)
♦ Drip tray for workshop hoist -VAS 6208-

Audi A6 2005 ➤
Removing


WARNING

off coolant.

Audi A6 2005 ➤

WARNING
Note


side of vehicle.
– Remove bolts -arrows- and detach bracket for AC compres‐

sor.

Audi A6 2005 ➤

– Disconnect coolant pipes from coolant hoses -1- and -2-.
Note
Shown in illustration with power steering pump removed.
Installing
Note
♦ Renew O-rings.

ring.
Tightening torque
Component Nm
Coolant pipes to engine 9 by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
1.11 Removing and installing coolant pipe (top)

Audi A6 2005 ➤

equipment required
♦ Socket, 14 mm -3150-
♦ Torque wrench -V.A.G
1331-
♦ Ratchet -V.A.G 1331/1-
♦ Ring insert (open-end; 17
mm) -V.A.G 1331/2-
♦ Ring insert (open-end; 14
mm) -V.A.G 1331/8-
♦ Socket, 17 mm -T40055-
Removing
Note

WARNING
The fuel system operates under high pressure. The pressure

in the high-pressure part of the injection system must be re‐
duced to a residual pressure prior to opening the system ⇒
Rep. Gr. 24 .

Audi A6 2005 ➤
Rest-of-world vehicles:
– Disconnect crankcase breather hoses -arrows- from cylinder
head covers.
– Move the crankcase breather hoses clear.
– Unscrew bolt -1- and take out hose connection with crankcase
breather hoses.
USA models:
Caution
Do not disconnect crankcase breather hose on USA models.
– Detach cylinder head cover (left-side) and move clear to one

side (crankcase breather hose remains connected)
⇒ page 178 .
All vehicles:
– Remove high-pressure pipe by unscrewing bolts and union
nuts -1 … 6-.
– Lay a cloth under coolant pipe to catch escaping coolant.

– Detach coolant hose -3- from coolant pipe.
– Unscrew bolts -1- and -2- and pull coolant pipe out of cylinder
block towards the rear -arrow-.
Installing
Note
♦ Renew O-ring.

ring.

Audi A6 2005 ➤
– First hand-tighten union nuts -1-, -4- and -5- for high-pressure
pipes, then hand-tighten pipe mountings -2-, -3- and -6-.
– Ensure that high-pressure pipes are not under tension.
– To
with secure high-pressure
respect to the pipe (14
correctness of information in thismm) to fuel
document. rail,byuse
Copyright AUDI torque
AG.
wrench -V.A.G 1331- with ring insert (open-end, 14 mm) -
V.A.G 1331/8- .
– To secure high-pressure pipe (17 mm) to fuel rail, use torque

wrench -V.A.G 1331- with ring insert (open-end, 17 mm) -
V.A.G 1331/2- .
– To secure high-pressure pipe (17 mm) to high-pressure pump,

use torque wrench -V.A.G 1331- with ratchet -V.A.G 1331/1-
and socket, 17 mm -T40055- .
– Install high-pressure pipes ⇒ Rep. Gr. 24 .
Tightening torques
Component Nm
Coolant pipe to engine 9
Hose connection for crankcase breather hoses 6
to cover
1.12 Removing and installing radiator


Audi A6 2005 ➤
♦ Engine bung set -VAS 6122- for vehicles with multitronic gear‐
box/automatic gearbox 09L
♦ Drip tray for workshop hoist -VAS 6208-

Removing
Note
If there are slight impressions on the fins, refer to ⇒ page 6 .

Audi A6 2005 ➤
WARNING


– Remove front wheel housing liners (right and left) ⇒ Rep. Gr.
66 .
– Remove bumper cover (front) ⇒ Rep. Gr. 63 .
–Protected
Then disconnect
by copyright. Copyingcoolant
for private hose -2- from
or commercial radiator.
purposes, in part or in whole, is not
– Disconnect coolant hose -arrow- (bottom left) from radiator (lift

retaining clip).
– Detach coolant hose (top) -arrow on right- from radiator.
Note
Ignore -arrow on left side of illustration-.

Audi A6 2005 ➤
Vehicles with multitronic gearbox or automatic gearbox 09L:

Note


– Detach ATF pipes (top -arrow- and bottom) from radiator: ⇒
Rep. Gr. 37 .
All vehicles:
– Unscrew bolts -3- and detach air duct.
– Unscrew bolts -4- and remove bracket for horns; electrical wir‐
ing remains attached.
– Unscrew brackets -2- and -5- for headlights.
– Unscrew nuts -1- and -6- and remove bumper.
– Unclip ambient temperature sensor -G17- -arrow- from brack‐

et.
– Unscrew bolts -1- and -2- for power steering cooling pipe; the
hydraulic hoses remain attached. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Detach air ducts (left and right) from radiator.
WARNING

Audi A6 2005 ➤

Note
To prevent damage to the air conditioner compressor and refrig‐

erant pipes/hoses, ensure that the pipes and hoses are not
stretched, kinked or bent.
– Pivot condenser downwards with pipes/hoses attached.
– Release two retaining pins for radiator and pull out upwards
-arrows-.
– Swivel radiator forwards and lift off.
Installing
Note
Secure all hose connections with the correct type of hose clips
– Install ATF pipes ⇒ Rep. Gr. 37 .

– Install bumper cover (front) ⇒ Rep. Gr. 63 .
– Install front wheel housing liners (right and left) ⇒ Rep. Gr.
66 .
– Remove old O-ring -2- from coolant hose -3-.

– Lubricate new O-ring with coolant additive and fit O-ring in
coolant hose.
– Press coolant hose onto radiator -1- until it engages with a
click.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
Note
The coolant in the entire system must be changed if the radiator

is renewed.

Tightening torques
Component Nm
Condenser to lock carrier 6
Power steering cooling pipe to condenser 9
Bracket for horns to lock carrier 8

Audi A6 2005 ➤
1.13 Removing and installing radiator cowl

Removing

– Remove front noise insulation ⇒ Rep. Gr. 50 .
– Unplug electrical connector -1- going to radiator fan.

– Unscrew bolts -arrows- and lift out radiator cowl.
Installing
Install in reverse order.
Tightening torques
Component Nm
Radiator cowl to M6 11
Lock carrier Panel bolt 2
1.14 Removing and installing radiator fan

Removing
– Remove radiator cowl ⇒ page 266 .
– Move wiring clear.

Audi A6 2005 ➤
– Remove bolts -1 ... 5-.

– Detach radiator fan with control unit.
Installing
– Install radiator cowl ⇒ page 266 .
Tightening torque
Component Nm
Radiator fan Single fan 3
to radiator cowl Dual fan 4.5
1.15 Checking cooling system for leaks

♦ Cooling system tester -V.A.G 1274
Protected B- Copying for private or commercial purposes, in part or in whole, is not
by copyright.
♦ Adapter for cooling system tester -V.A.G 1274/8-

Audi A6 2005 ➤
♦ Adapter for cooling system tester -V.A.G 1274/9-
Procedure
• Engine must be warm.
WARNING


– Attach cooling system tester -V.A.G 1274 B- with adapter -
V.A.G 1274/8- topermitted
expansion tank. by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
– Use hand pump on cooling system tester to create a pressure
of approx. 1.0 bar.
If the pressure drops:
– Trace leak and repair.
Checking pressure relief valve in filler cap

– Attach cooling system tester -V.A.G 1274 B- with adapter -
V.A.G 1274/9- to filler cap.
– Use hand pump on cooling system tester to create pressure.
• The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
If the pressure relief valve does not open as described:
– Renew filler cap.

Audi A6 2005 ➤
26 – Exhaust system
1 Exhaust system
Note
After working on the exhaust system, ensure that the system is

not under stress and that it has sufficient clearance from the body.
If necessary, loosen clamps and align silencers and exhaust
pipes so that sufficient clearance is maintained to the body at all
points and the mountings are evenly loaded.
1.1 Exhaust system on vehicles with front-wheel drive - exploded view
1 - 23 Nm
2 - Mounting
❑ Renew if damaged
3 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes
❑ Cutting point
⇒ page 277
❑ Align exhaust system so
it is free of stress
⇒ page 293
4 - Exhaust manifold
❑ Removing and instal‐
ling: left-side
⇒ page 289 , right-side
⇒ page 291
5 - Gasket
❑ Renew
6 - 23 Nm
❑ Renew
7 - Front exhaust pipe with cat‐
alytic converter and front si‐
lencer
❑ For cylinder bank 2 (left-
side)Copying for private or commercial purposes, in part or in whole, is not
Protected by copyright.
❑ toWith
with respect flexibleof joint;
the correctness do innot
information this document. Copyright by AUDI AG.
bend flexible joint more
than 10° – otherwise it
can be damaged
❑ Protect against knocks
and impact
❑ Components of exhaust pipe mountings: vehicles with manual gearbox ⇒ page 271 , vehicles with mul‐
titronic gearbox ⇒ page 272
❑ Align exhaust system so it is free of stress ⇒ page 293
1. Exhaust system 269

Audi A6 2005 ➤
8 - Lambda probe after catalytic converter

9 - Clamps (front)
❑ Installation position ⇒ page 271
❑ Before tightening bolt connections, align exhaust system so it is free of stress ⇒ page 293
❑ Tighten bolt connections evenly
10 - 23 Nm
11 - Front exhaust pipe with catalytic converter and front silencer
❑ For cylinder bank 1 (right-side)
❑ With flexible joint; do not bend flexible joint more than 10° – otherwise it can be damaged
❑ Protect against knocks and impact
❑ Components of exhaust pipe mountings: vehicles with manual gearbox ⇒ page 272 ; vehicles with mul‐
titronic gearbox ⇒ page 272
12 - Rear silencer with tailpipe
❑ Left side of vehicle
❑ Combined as one unit with centre silencer as original equipment
❑ Centre silencer, rear silencer and tailpipe can be renewed separately as required
❑ Cutting point: centre silencer / rear silencer ⇒ page 277
❑ Cutting point: rear silencer / tailpipe ⇒ page 278
13 - 23 Nm
❑ Renew
14 - Mounting
15 - 23 Nm
16 - Mounting
❑ Right side of vehicle
18 - Bracket
19 - 23 Nm
20 - Clamps (rear)
❑ For separate replacement of centre
Protected by copyright. Copyingand rearorsilencers
for private commercial purposes, in part or in whole, is not
❑ Position clamp sowiththat it aligns with centre of cutting location

270 Rep. Gr.26 - Exhaust system

Audi A6 2005 ➤
Installation position of front clamps

– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp.
• Bolt connections face to right.
Installation position of rear clamps
bottom of clamp.
• Bolt connections face outwards.
Components of exhaust pipe mountings (left-side) for vehicles

with manual gearbox
1- Bolt
2- Washer
3- Compression spring
4- Spacer sleeve
5- Nut, 23 Nm
6- Spacer sleeve
7- Bracket
8- Buffer
9- Spacer sleeve
10 - Bolt, 23 Nm

Audi A6 2005 ➤

with multitronic gearbox
1- Nut, 23 Nm
2- Spacer sleeve
3- Buffer
4- Spacer sleeve
5- Bolt
6- Bolt, 23 Nm
7- Bolt
8- Washer
10 - Spacer sleeve
Components of exhaust pipe mountings (right-side) for vehicles

with manual gearbox
1- Nut, 23 Nm
2- Spacer sleeve
3- Bracket
4- Buffer
5- Spacer sleeve
6- Bolt, 23 Nm
7- Bolt
8- Washer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9- Compression spring with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Spacer sleeve

with multitronic gearbox
1- Nut, 23 Nm
2- Bolt, 23 Nm
3- Spacer sleeve
4- Bracket
5- Buffer
6- Spacer sleeve
7- Bolt
8- Washer
10 - Spacer sleeve

Audi A6 2005 ➤
Mounting components for centre bracket for front exhaust pipes

1- 23 Nm
2- Bracket
3- 23 Nm
4- 23 Nm
1.2 Exhaust system on vehicles with four-wheel drive - exploded view
1 - 23 Nm
2 - Mounting
3 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes
❑ Cutting point
⇒ page 278
❑ Align exhaust system so
it is free of stress
⇒ page 293
ling: left-side
⇒ page 291
5 - Gasket
❑ Renew
6 - 23 Nm
❑ Renew
7 - Front exhaust pipe with cat‐
alytic converter and front si‐
lencer
side)
❑ With flexible joint; do not
can be damaged
and impact
❑ Mounting components ⇒ page 275
8 - Lambda probe after catalytic converter

Audi A6 2005 ➤
9 - Clamps (front)
10 - 23 Nm
11 - Front exhaust pipe with catalytic converter and front silencer
❑ For cylinder bank 1 (right-side)
❑ With flexible joint; do not bend flexible joint more than 10° – otherwise it can be damaged
❑ Protect against knocks and impact
❑ Left side of vehicle
13 - 23 Nm
❑ Renew
14 - Mounting
15 - 23 Nm
16 - Mounting
❑ Right side of vehicle
18 - Bracket
19 - 23 Nm
20 - Clamps (rear)
❑ For separate replacement of centre and rear silencers
❑ Position clamp so that it aligns with centre of cutting location

Audi A6 2005 ➤
Installation position of front clamps

bottom of clamp.
• Bolt connections face to right.
Installation position of rear clamps

bottom of clamp.

with manual gearbox and automatic gearbox 09L
1- Bolt
2- Washer
4- Spacer sleeve
5- Nut, 23 Nm
6- Spacer sleeve
7- Bracket
8- Buffer
9- Spacer sleeve
10 - Bolt, 23 Nm

Audi A6 2005 ➤

with manual gearbox
1- Nut, 23 Nm
2- Spacer sleeve
3- Bracket
4- Buffer
5- Spacer sleeve
6- Bolt, 23 Nm
7- Bolt
8- Washer
10 - Spacer sleeve

with automatic gearbox 09L
1- Nut, 23 Nm
2- Sleeve
3- Spacer sleeve
5- Washer
6- Bolt
7- Bolt, 23 Nm
8- Spacer sleeve
9- Buffer
10 - Bracket
11 - Spacer sleeve
Mounting components for centre bracket for front exhaust pipes

1- 23 Nm
2- Bracket
3- 23 Nm
4- 23 Nm
1.3 Separating centre and rear silencers

♦ The connecting pipe can be cut through at the cutting point
provided in order to renew the centre and rear silencers sep‐
arately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.

Audi A6 2005 ➤
♦ Chain-type pipe cutter -VAS 6254-
Procedure on vehicles with front-wheel drive

– Cut through exhaust pipes at right angles at the position
marked -arrow- using chain-type pipe cutter -VAS 6254-
– When installing, position centre of clamps -arrows- over cut‐

ting location.

bottom of clamp.

Audi A6 2005 ➤
Procedure on vehicles with four-wheel drive

– Cut through exhaust pipes at right angles at the position
marked -arrow- using chain-type pipe cutter -VAS 6254-
– When installing, position centre of clamps -arrows- over cut‐

ting location.

bottom of clamp.
1.4 Renewing tailpipe

♦ Chain-type pipe cutter -VAS 6254-

Audi A6 2005 ➤
Procedure
– Cut through old tailpipe -1- at a right angle at cutting point
-C- using chain pipe cutter -VAS 6254- .
– Push on tailpipe -3- as far as marking -A-. Slot on tailpipe
should align with marking -B-.
– Fit clip -2-.
Tightening torque
Component Nm
Clip 25
1.5 Removing and installing front exhaust

pipe (left-side) with catalytic converter
Removing
Note

– Unplug electrical wire for coolant shortage indicator switch -
F66- at bottom of expansion tank and move expansion tank to
one side with coolant hoses -1- and -2- attached.

Audi A6 2005 ➤

alytic converter -G131- and move wiring clear (downwards).
Note
Disregard -item 1-.
– permitted
Unscrew nut
unless -2- (accessible
authorised from
by AUDI AG. AUDI AG above) connecting
does not guarantee or acceptfront ex‐
any liability
haust pipeto to
with respect the exhaust manifold.
correctness of information in this document. Copyright by AUDI AG.
Note
Shown from rear with engine removed for illustration purposes.
– Remove front left wheel.
Note
Secure brake disc with one wheel bolt.
– Unbolt heat shield -arrows- for drive shaft (left-side).

Audi A6 2005 ➤
– Unbolt cross piece for subframe -arrows-.
Disconnect exhaust system at clamp (left-side) -2-.

Disregard -item 1-.
Note
– Remove bolts -1- on bracket (rear) for front exhaust pipe.
Note

Audi A6 2005 ➤
Vehicles with manual gearbox or automatic gearbox 09L:

Note
♦ Illustration shows vehicle with manual gearbox.

Vehicles with multitronic gearbox:

– Remove bolts -1- and -2-.
– Remove bracket (left-side) for front exhaust pipe.

Audi A6 2005 ➤
All vehicles:
– Unscrew nuts -1- and -3- (accessible from below) connecting
front exhaust pipe to exhaust manifold.
Note
Shown in illustration with engine removed.
– Remove front exhaust pipe with catalytic converter.

Installing
Note
♦ Renew gaskets and self-locking nuts.

♦ 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.

Note
Components of exhaust pipe mountings: vehicles with manual

gearbox, vehicles with multitronic gearbox ⇒ page 272 , vehicles
with automatic gearbox 09L ⇒ page 275 .
Tightening torque
Component with respect to the correctness of information in this document.Nm
Copyright by AUDI AG.
Front exhaust pipe with catalytic converter to 23 1)2)

exhaust manifold
Mounting bracket to: Front exhaust 23
pipe
Gearbox 23
Front exhaust pipe to centre bracket 23
Drive shaft heat shield to gearbox 23
• 1) Renew nuts.
• 2)Grease with high-temperature paste; refer to ⇒ Electronic
parts catalogue for high-temperature paste

Audi A6 2005 ➤
1.6 Removing and installing front exhaust

pipe (right-side) with catalytic converter
Removing
Note

clamps -arrows-.

lytic converter -G130- and move wiring clear (downwards).
Note
Disregard -item 1-.

Audi A6 2005 ➤
– Unscrew nut -2- (accessible from above) connecting front ex‐

haust pipe to exhaust manifold.
Note
Shown from rear with engine removed for illustration purposes.
– Remove front right wheel.
Note
Secure brake disc with one wheel bolt.
– Unbolt heat shield -arrow- for drive shaft (right-side).
– Unbolt cross piece for subframe -arrows-.

Audi A6 2005 ➤
Disconnect exhaust system at clamp (right-side) -1-.
Note
Disregard -item 2-.
Note
The flexible joint in front exhaust pipe must not be bent more than
10° – damage can otherwise occur.
– Remove bolts -2- on bracket (rear) for front exhaust pipe.
Note
Vehicles with manual gearbox or automatic gearbox 09L:

Note
♦ Illustration shows vehicle with manual gearbox.


Audi A6 2005 ➤
Vehicles with multitronic gearbox:

– Remove nuts -1- and bolts -2-.
– Remove bracket (right-side) for front exhaust pipe.

Audi A6 2005 ➤
All vehicles:
– Unscrew nuts -1- and -3- (accessible from below) connecting
front exhaust pipe to exhaust manifold.
Note
Shown in illustration with engine removed.
– Remove front exhaust pipe with catalytic converter.

Installing
Note
♦ Renew gaskets, O-ring and self-locking nuts.

♦ 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.

Note
Components of exhaust pipe mountings: vehicles withpermitted

manual
gearbox ⇒ page 276 , vehicles with multitronic gearboxwith respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 272 , vehicles with automatic gearbox 09L ⇒ page 276 .
Tightening torques
Component Nm
Front exhaust pipe with catalytic converter to 23 1)2)
exhaust manifold
Mounting bracket to front exhaust pipe 23
Front exhaust pipe to: Gearbox 23
Centre bracket 23
Drive shaft heat shield to gearbox 23
• 1) Renew nuts.
• 2)Grease with high-temperature paste; refer to ⇒ Electronic
1.7 Exhaust manifold - exploded view

Audi A6 2005 ➤
1 - 25 Nm
❑ Renew
❑ Coat with high-tempera‐
ture paste; for high-tem‐
perature paste refer to
⇒ Electronic parts cata‐
logue
❑ Note tightening se‐
quence ⇒ page 291 and
⇒ page 292
2 - Bracket for heat shield
ling: left-side
⇒ page 291
4 - Gasket
❑ Renew
5 - Heat shield
6 - 10 Nm
7 - Lambda probe before cata‐
lytic converter
⇒ Rep. Gr. 24 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Front exhaust pipe permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
side)
❑ With flexible joint; do not
can be damaged
and impact
9 - 23 Nm
❑ Renew
❑ Coat with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
10 - Gasket
❑ Renew
1.8 Removing and installing exhaust mani‐

fold (left-side)
Removing
– Remove front exhaust pipe (left-side) together with catalytic
converter ⇒ page 279 .

Audi A6 2005 ➤
– Unplug electrical connector -1- for Lambda probe 2 -G108-

and move wiring clear.
Note
Disregard -item 2-.
Note


– Remove poly V-belt from pulley for AC compressor.

WARNING
Note
To prevent damage to the refrigerant lines,permitted
ensure that
unless the pipes
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
and hoses are not stretched, kinked or bent.with respect to the correctness of information in this document. Copyright by AUDI AG.

side of vehicle.

Audi A6 2005 ➤
– Unscrew bolts -1 ... 4- and remove heat shield.
– Remove nuts -1- and -8- and detach bracket for heat shield.
– Unscrew nuts -2 ... 7- and -9- and remove exhaust manifold.
Installing
Note
Renew gaskets and self-locking nuts.
– Tighten exhaust manifold in 2 stages in the following se‐

quence:
1. Initially tighten to 15 Nm.
2. Tighten to 25 Nm.
– Install front exhaust pipe (left-side) together with catalytic con‐
verter ⇒ page 279 .
Tightening torques
Component Nm
Exhaust manifold to cylinder head 25 1)2)
Heat shield to bracket for heat shield 10
• 1) Renew nuts.
• 2) Grease with high-temperature paste; refer to ⇒ Electronic
1.9 Removing and installing exhaust mani‐

fold (right-side)
Removing
– Remove front exhaust pipe (right-side) together with catalytic

Audi A6 2005 ➤
– Unplug electrical connector -1- for Lambda probe -G39- and

move wiring clear.
Note
Disregard -item 2-.
– Unscrew bolts -1 ... 4- and remove heat shield.
– Remove nuts -7-
withand -9-
respect and
to the detachof bracket
correctness for
information in thisheat shield.
– Unscrew nuts -1 ... 6- and -8- and remove exhaust manifold.

Installing
Note
Renew gaskets and self-locking nuts.
– Tighten exhaust manifold in 2 stages in the following se‐

quence:
1. Initially tighten nuts to 15 Nm.
2. Tighten nuts to 25 Nm.
– Install front exhaust pipe (right-side) together with catalytic
Tightening torques
Component Nm
Exhaust manifold to cylinder head 25 1)2)
Heat shield to bracket for heat shield 10
• 1) Renew nuts.
• 2) Grease with high-temperature paste; refer to ⇒ Electronic

Audi A6 2005 ➤
1.10 Stress-free alignment of exhaust system
Note
The exhaust system must be aligned when it is cool.
Vehicles without clamps between centre silencer and rear silenc‐

er
– Loosen bolt connections for clamps ⇒ Item 9 (page 270) .
– Push exhaust system towards front of vehicle -arrow-, so that
mountings (right-side) for rear silencers are preloaded by -a-
= 5 ... 9 mm.
– Tighten bolt connections of clamps evenly to 23 Nm.
– Align tailpipes ⇒ page 294 .
Vehicles with clamps between centre silencer and rear silencer
Note
On vehicles with clamps fitted between centre silencer and rear

silencer, it is also necessary to align the centre silencer.
– Loosen bolts on clamps ⇒ Item 9 (page 270) and

⇒ Item 20 (page 274) .
– Push front section of exhaust system towards front of vehicle

-arrow-, so that mountings for centre silencer are preloaded
by -a- = 5 ... 9 mm.
– Tighten bolt connections for clamps (front)
⇒ Item 9 (page 270) evenly to 23 Nm.
– Push rear section of exhaust system towards front of vehicle

-arrow-, so that mountings (rear) for rear silencers are preloa‐
ded by -a- = 5 ... 9 mm.
– Align rear silencers so they are horizontal.
– Tighten bolt connections for clamps (rear)
⇒ Item 20 (page 274) evenly to 23 Nm.
– Align tailpipes ⇒ page 294 .

Audi A6 2005 ➤
Aligning tailpipes
– Check clearance between tailpipes and bumper on both sides.
• Dimension -x- (left-side) = dimension -x- (right-side)
If necessary, correct dimension “x” as follows:

– Slacken bolt connection -arrow- on brace between exhaust
pipes.
– Adjust the distance between the rear silencers.
– Tighten bolt connection to 25 Nm.
– Check distances -y- and -z- between tailpipes and bumper:

• Dimension -y- = 17 ... 19 mm.
• Dimension -z- = 0 ... 2 mm.
– If necessary, check whether the exhaust system is aligned free
of stress ⇒ page 293 .
1.11 Checking exhaust system for leaks

– Start engine and run at idling speed.
– Plug tailpipe (e. g. with rags or stopper) and leave plugged until
the check is complete.
– Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
any leaks.
– Repair any leaks that are found.

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Service Department. Technical Information

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Copyright © 2015 Audi AG, Ingolstadt A005A601120

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2.9 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1.8 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

♦ The engine number (“engine code” and “serial number”) can

2 Rep. Gr.00 - Technical data

The fuel system operates at extremely high pressure. This can

– Procedure before opening high-pressure section of injection

To prevent damage to the electronic components when dis‐

– Disconnect battery ⇒ Rep. Gr. 27 .

Hot steam/hot coolant can escape - risk of scalding.

Note the following if testers and measuring instruments have to

Accidents can be caused if the driver is distracted by test

3.1 Procedure before opening high-pres‐

♦ The injection system consists of a high-pressure section

4 Rep. Gr.00 - Technical data

4 General repair instructions

4.1 Rules for cleanliness when working on

4.2 Checking fuel system for leaks

4.3 Foreign particles in engine

♦ In the event of mechanical damage to one of the cylinder

4.4 Contact corrosion!

4. General repair instructions 5

4.5 Routing and attachment of pipes, hoses

4.6 Installing radiators and condensers

4.7 Checking vacuum system

6 Rep. Gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

♦ Hose clamps for hoses up

1. Removing and installing engine - vehicles with manual gearbox 7

♦ Hose clip pliers -VAS 6362-

♦ Tensioning strap -T10038-

gearbox and subframe (with lock carrier installed).

Before removing the engine secure the vehicle against tipping

8 Rep. Gr.10 - Removing and installing engine

Observe notes on procedure for disconnecting the battery ⇒

– With ignition switched off, disconnect battery earth cable

– Pull off engine cover panel (front) -arrows-.

– Pull off engine cover panel (rear) -arrows-.

Hot steam or hot coolant can escape when expansion tank is

– Open filler cap on coolant expansion tank.

1. Removing and installing engine - vehicles with manual gearbox 9

Before removing, mark direction of rotation of poly V-belt with

– To slacken poly V-belt turn tensioner in direction of -arrow-.

Secure brake discs with wheel bolts.

– Remove noise insulation panels ⇒ Rep. Gr. 50 .

– Disconnect coolant hose -arrow- at engine oil cooler and drain

10 Rep. Gr.10 - Removing and installing engine

– Unplug electrical connector -1- for magnetic clutch on air con‐

The air conditioner refrigerant circuit must not be opened.

– Unscrew air conditioner compressor from bracket -arrows-.