6-Cylinder Direct Injection Engine (Evo) With Supercharger (3 0 LTR 4-Valve TFSI)

Service
6-cylinder direct injection engine (evo) with

supercharger (3.0 ltr. 4-valve TFSI)
Engine ID
CRE CRE CTD
C D A
Edition 06.2015
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt D4B8043D074

Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
6-cylinder direct injection engine (evo) with supercharger (3.0 ltr. 4-valve TFSI) - Edition 06.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine identification number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 2
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.3 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.1 Exploded view - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.2 Removing and installing poly V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.3 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.5 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.3 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.5 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.6 Checking sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1 Exploded view - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents i
71
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.3 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.4 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Exploded view - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.1 Exploded view - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.2 Exploded view - drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.3 Exploded view - drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.4 Removing camshaft timing chain from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.5 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.6 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.7 Removing and installing drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.3 Measuring radial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.5 Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.6 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.7 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.4 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 158
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Exploded view - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.1 Exploded view - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.3 Removing and installing hose for crankcase breather system . . . . . . . . . . . . . . . . . . . . . . 164
4 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.1 Exploded view - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
ii Contents
4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 167

4.3 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.4 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 168
4.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.6 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 170
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.1 Exploded view - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.3 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.7 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 191
2.8 Removing and installing temperature sender for engine temperature regulation G694 . . 192
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4 Radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.1 Exploded view - radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.3 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 211
4.4 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.5 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1 Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.1 Exploded view - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.2 Exploded view - magnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.3 Exploded view - rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.4 Removing and installing supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.5 Checking supercharger for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.6 Removing and installing magnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.7 Removing and installing pulley for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.8 Removing and installing drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.9 Removing and installing rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.10 Renewing drive shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1.11 Securing supercharger to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1.12 Removing and installing sender 1 for turbocharger speed G688 . . . . . . . . . . . . . . . . . . . . 251
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.4 Removing and installing charge pressure sender G31 / G447 . . . . . . . . . . . . . . . . . . . . . . 257
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
1.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Contents iii
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4.1 Exploded view - intake manifold (bottom section) with fuel rail . . . . . . . . . . . . . . . . . . . . . . 272
4.2 Removing and installing intake manifold (bottom section) with fuel rail . . . . . . . . . . . . . . . . 274
4.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
4.4 Removing and installing regulating flap control unit J808 . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.5 Removing and installing fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
5.1 Exploded view - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
5.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
5.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
5.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
6.1 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
6.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
6.3 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 293
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
7.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
7.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
9.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
1.2 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.3 Removing and installing front silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
1.4 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2.1 Exploded view - emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3.1 Exploded view - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

3.2 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 325
3.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
4.1
3.4 Exploded
Removingview
and -installing
exhaust combination
manifold . .valve . . . . . . . .. .. .. .. .. .. .. .. .. .. ......... .. .. .. .. .. .. .. .. .. .. . . . . . . . . . . 331
327
4.2
4 Removing and installing
Exhaust manifolds . . . .exhaust
. . . . . . .manifolds
. . . . . . . . .. .. .. .. .. .. .. .. .. .. .. .. ......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 332
331
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
1.1 Exploded view - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
iv Contents
1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

1.3 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.4 Removing and installing knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.5 Removing and installing Hall senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Contents v
vi Contents
00 – Technical data
1 Identification
(ARL004319; Edition 06.2015)
⇒ “1.1 Engine identification number/engine data”, page 1
1.1 Engine identification number/engine da‐

ta
Engine number
Note
The engine cover panel must be removed to make the engine

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

be found on top of the cylinder block at the front -arrow-.
♦ Starting with the letter “C”, the engine codes consist of 4 let‐
ters.
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped on the cylinder block, together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine, and is determined by the engine control unit.
Note
♦ The 4-character engine code can be found on the type plate

(in versions for some countries only) and on the vehicle data
sticker and the engine control unit.
♦ Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 811 ; ⇒ Main‐
tenance ; Booklet 812 or ⇒ Maintenance ; Booklet 818 .
1. Identification 1
2 Safety precautions
⇒ “2.1 Safety precautions when working on the fuel supply sys‐
tem”, page 2
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 2
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “2.4 Safety precautions when working on the cooling system”,
page 3
⇒ “2.5 Safety precautions when working on the ignition system”,
page 3
⇒ “2.6 Safety precautions when working on the subframe”,
page 4
⇒ “2.7 Safety precautions when working on the exhaust system”,
page 4
2.1 Safety precautions when working on the fuel supply system

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

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

Risk of injury - engine may start unexpectedly
On vehicles with the start/stop system activated, the engine may
start unexpectedly. If the start/stop system is activated, this is in‐
dicated by a message on the dash panel insert.
– Deactivate start/stop system by switching off ignition.
2 Rep. gr.00 - Technical data

2.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or
– Have a second mechanic operate test equipment on the rear
seat.
2.4 Safety precautions when working on the cooling system

Risk of scalding as hot coolant can escape
The cooling system is under pressure when the engine is hot. Hot
steam/hot coolant can escape - risk of scalding.
– Wear protective gloves.
– Wear safety goggles.
– Release pressure (cover filler cap on coolant expansion tank
with a cloth and open carefully).
2.5 Safety precautions when working on the ignition system

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

Washing the engine or connecting/disconnecting electrical wiring
may result in components being damaged if the engine is running.
– Switch off ignition before connecting/disconnecting electrical
wiring.
– Switch off ignition before cleaning engine.
2. Safety precautions 3
2.6 Safety precautions when working on the

subframe
When working on the subframe note the following warnings:
Caution
Risk of damage to running gear components.

♦ The vehicle must NOT be lowered onto its wheels if the
engine/gearbox mountings, steering rack or subframe
cross brace are not properly installed.
♦ The vehicle must NOT be supported by applying a trolley
jack or similar to the subframe or subframe cross brace.
2.7 Safety precautions when working on the

exhaust system
When working on the exhaust system please note the following:
Caution
Risk of damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.

3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 Foreign particles in engine”, page 5
⇒ “3.3 Contact corrosion”, page 5
⇒ “3.4 Routing and attachment of pipes, hoses and wiring”, page
6
⇒ “3.5 Installing radiators and condensers”, page 6
3.1 Rules for cleanliness

Even small amounts of dirt can cause malfunctions. For this rea‐
son, please observe the following rules when working on the fuel
supply system, injection system and supercharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy 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.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
3.2 Foreign particles in engine

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

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
used.
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 .
3. Repair instructions 5
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.
3.4 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.
♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐
cient clearance from all moving or hot components in engine
compartment (little space in engine compartment).
3.5 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.

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 7
⇒ “1.2 Separating engine and gearbox”, page 24
⇒ “1.3 Securing engine to engine and gearbox support”,
page 30
⇒ “1.4 Installing engine”, page 32
1.1 Removing engine
Special tools and workshop

equipment required
♦ Stepladder - VAS 5085-
♦ Engine bung set - VAS
6122-
♦ Scissor-type assembly
platform - VAS 6131 B-
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Hose clip pliers - VAS
6340-
6362-
1. Removing and installing engine 7

♦ Support set for Audi - VAS 6131/10-
♦ Support set, Audi A8 >2002 - VAS 6131/11-

♦ Supplementary set, Audi Q7 >2005 - VAS 6131/13-
♦ Used oil collection and extraction unit - VAS 6622A-
♦ Special wrench 12 mm -T40252-
8 Rep. gr.10 - Removing and installing engine

Procedure
Note
♦ The engine is removed from underneath together with the

gearbox and subframe (with lock carrier installed).
♦ Re-install all cable ties in the same locations when installing.
♦ All bolts on running gear components with bonded rubber
bushes must be tightened with suspension in unladen position
(vehicle unladen).
♦ Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension compo‐
nents with bonded rubber bushes must be brought into a
position corresponding to the normal position while driving
(unladen position). Otherwise, the bush would be subject to
torsion loading and its service life shortened.
♦ Before starting work, use measuring tape or similar to meas‐
ure distance -a- from centre of wheel to lower edge of wheel
housing.
♦ This measurement must be taken with the suspension in the
unladen position (vehicle unladen).
♦ Note down measurement. This will be needed when tightening
the bolts/nuts on the suspension.
WARNING
Make sure the vehicle cannot tip over when the engine is re‐
moved.
♦ Secure the vehicle, to do so, the luggage compartment
must be empty.
Note
Move the selector lever to position “N” and release the electro‐
mechanical parking brake before disconnecting the battery, so
that the propshaft can be turned during removal.
– Set front wheels to straight-ahead position.
Caution
Electronic components are susceptible to damage.

♦ Observe notes on procedure for disconnecting the battery.
– Switch off ignition.

– Disconnect earth wire from battery terminal ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .

– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Removing and installing attach‐
ments .
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 coolant
expansion tank with cloth and open carefully.
– Open filler cap on coolant expansion tank.

– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres .
– Remove wheel housing liners (front left and front right) ⇒
General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Removing and installing wheel housing liner (front) .
– Remove noise insulation panels ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– Remove propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
– Place drip tray for workshop hoist - VAS 6208- underneath.

– Release hose clips -2-, disconnect coolant hoses from coolant
pipes (front left) and drain off coolant.
– Remove bolt -1-.

– Remove drain plug -1- and drain off coolant.

– Lift retaining clip -2- and disconnect coolant hose from radia‐
tor.
– Unplug electrical connector -3- from charge air cooling pump

- V188- and move clear electrical wiring.
Note
Disregard -items 1, 2-.
– Position used oil collection and extraction unit - VAS 6622A-

below connection point.
– Mark position of ATF lines -1- and -2- for re-installation and
disconnect ATF lines.
– Seal off open lines and connections with clean plugs from en‐
gine bung set - VAS 6122- .
Note
Disregard -arrow-.
– Unplug electrical connectors -1- and -2- for radiator fan (push
retainer to the rear -arrow- and press down release catch).
– Move clear electrical wiring harness.

– Unplug electrical connector -2- at secondary air pump motor -

V101- and move electrical wiring clear.
– Press release tabs, disconnect secondary air hose -1- and
move hose clear.
Note
Disregard -item 3-.
– Remove bolt -1- and nut -3- on both sides and detach strut
-2- for lock carrier.
– Unscrew nut -arrow- on longitudinal member (right-side) and

move earth cables clear.
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Remove bolts -arrows- for air duct -1- and intermediate flange
-2-.

– Move fuel hose -1- and hose -2- from activated charcoal filter
clear at air pipe.
– Detach vacuum hose -3- from connection on air pipe.
– Remove air pipe. To do so, release hose clip -4- and clamps
-arrows-.
– Press release tabs, detach air cleaner housing and disconnect

secondary air hose -arrow- on reverse side.
– Disconnect vacuum hose -1- on rear side of plenum chamber

partition panel and detach vacuum connection -2- from ple‐
num chamber partition panel.
– Unplug electrical connector -3- at activated charcoal filter sol‐
enoid valve 1 - N80- and detach vacuum hose -4-.
– Detach activated charcoal filter solenoid valve 1 - N80- from
bracket and move it clear to the side with hoses still attached.
NAR vehicles:
– Disconnect vacuum hose leading to fuel system diagnostic
pump - V144- -arrow-.

All vehicles (continued):
Caution
Take care to keep components clean.

♦ Observe rules for cleanliness when working on the fuel
supply system ⇒ page 5 .
– Open retaining clips and move fuel hose -1- clear.
WARNING
The fuel system is pressurised.

Risk of injury as fuel may spray out.
• Wear safety goggles.
• Wear protective gloves.
• Release pressure (wrap clean cloth around connection
and open connection carefully).
– Disconnect fuel hose -1- ⇒ Fuel supply system; Rep. gr. 20 ;

Plug-in connectors; Disconnecting plug-in connectors .
– Keep release tabs depressed and detach hose connector.
– Seal off open lines and connections with plugs (thoroughly
cleaned) from engine bung set - VAS 6122- .
– Press release tabs on both sides and disconnect secondary

air hose -arrow-.
– Lift retaining clip -2- and detach coolant hose leading to heat
exchanger at plenum chamber partition panel.
Note
Disregard -item 1-.

– Lift retaining clip -arrow- and detach coolant hose (front right)
from coolant pipe (front).
– Lift retaining clip -arrow- and disconnect coolant line.

– Move coolant line clear and push to left side.
– Lift retaining clip and detach coolant hose -arrow- from coolant
pipe (front).
– Remove bolt -2- for coolant pipe (front left).
Note
Disregard -item 1-.

– Release retainer -arrow A- and open cover -arrow B-.
– Remove nuts -1- for electrical wiring.

– Detach electrical connector -2- from bracket and unplug.
– Remove bolt -3- and detach terminal 30 wiring junction 2 -
TV22- from body brace -arrow-.
– Working from wheel housing, release catches using a 5.5 mm

ring spanner -item 1- and remove wiring protector -2- from
above.
– Release wiring harness -3- leading to alternator and starter
using removal lever - 80 - 200- and move clear.
– Release catch -arrow- to open wiring duct -1- and move wiring
harness clear.

– Remove nut -1- and swivel filler neck -2- for washer fluid res‐
ervoir slightly upwards -arrow A-.
– Pull filler neck with filler pipe out of washer fluid reservoir and
through opening in body -arrow B-.
– Remove bolts -1- and nuts -2- and detach body brace -3-.
– Remove bolts -arrows- and detach cover for electronics box in

engine compartment.
– Remove nut -1- and move electrical wiring clear.
– Release catches -arrows A- and take out engine control unit

-arrow B-.

– If fitted, unplug electrical connector -2-.

– Unplug electrical connectors -4- and unscrew nut -3- for wiring.
– Release catches -arrow- and detach relay carrier with fuse
holder -1-.
– Disengage engine wiring harness at electronics box in engine
compartment and move clear.
– Unplug electrical connector at brake servo pressure sensor -

G294- -arrow-.
– Release catches -arrows A- and lift off wiring protector -2-

-arrow B-.
– Place wiring harness on engine and secure engine control unit
to prevent it from dropping.
Note
Disregard -item 1-.
– To slacken poly V-belt, turn tensioner in clockwise direction

-arrow-.
– Remove poly V-belt from pulley of air conditioner compressor
and release tensioner.
Note
Ignore -10060 A- .

– Unplug electrical connector -arrow- and move wiring clear.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Remove air conditioner compressor from bracket and tie up to

left side ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor; Detaching and attaching air conditioner
compressor at bracket .
– Unplug electrical connectors -1- at front wheel speed sensors

-2- on both sides.
– If fitted, unplug electrical connector -1- from front left vehicle

level sender - G78- and front right vehicle level sender - G289-
and move wiring clear -arrow-.
– Remove brake caliper and tie up in wheel housing with wire
(brake hose remains attached) ⇒ Brake system; Rep. gr. 46 ;
Front brakes; Removing and installing brake caliper .
Caution
Risk of damage to brake pistons.

♦ Do not operate brake pedal with brake caliper removed.
– Remove nut -2- and pull out bolt -1-.

– Pull upper suspension links upwards out of wheel bearing
housing -arrows-.
– Perform the same work steps on the other side of the vehicle.

– Remove bolt -1- for anti-roll bar on both sides.

– Remove nut -3- on both sides.
Note
The bolts -2- are removed at a later stage.
– Audi A5 Cabriolet/Sportback: Remove diagonal struts ⇒ Run‐

ning gear, axles, steering; Rep. gr. 42 ; Subframe; Exploded
view - subframe .
– Remove subframe cross brace ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Subframe; Removing and installing subframe
cross brace .
Caution
Risk of damage to running gear components.

♦ The vehicle must NOT be lowered onto its wheels if the
engine/gearbox mountings, steering rack or subframe
cross brace are not properly installed.
– Unplug electrical connector -2- at power steering control unit

- J500- (release retainer -arrow- and press down release
catch).
Note
Disregard -item 1-.
– If fitted, remove bolts -arrows- on both sides and detach heat

shield -1-.

– Unscrew nuts -arrows- for front silencer on both sides using

special wrench -T40252- .
Caution
Risk of damage to flexible joints in front silencer.

♦ Do NOT bend the flexible joint in the front silencer more
than 10°.
– Loosen and push back clamps -1- and -2- and detach front
silencers on both sides.
– Detach intermediate steering shaft from steering rack and
move clear by telescoping upwards ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and instal‐
ling intermediate steering shaft .
Setting up scissor-type assembly platform

– Set up scissor-type assembly platform - VAS 6131 B- with
support set for Audi - VAS 6131/10- , support set -VAS
6131/11- and supplementary set -VAS 6131/13- as follows:
Platform Parts of support set for Audi - VAS 6131/10- and
coordinates supplementary set -VAS 6131/13-
B4 /13-4 /10-4 /10-5 /13-1
G4 /13-4 /10-4 /10-5 /13-1
B6 /10-1 /10-2 /10-5 /10-11
G6 /10-1 /10-2 /10-5 /10-11
A8+C8 /13-6 – – /13-2
F8+H8 /13-6 – – /13-2
C14 /10-1 /10-3 /10-5 /10-13
F14 /10-1 /10-3 /10-5 /10-10
– Initially hand-tighten the support elements on the scissor-type
assembly platform.
– Position scissor-type assembly platform - VAS 6131 B- hori‐
zontally.
• Take note of spirit level (bubble gauge).
– Position scissor-type assembly platform - VAS 6131 B- below
engine/gearbox assembly.

WARNING
Accident risk if subframe mountings are detached.

♦ Subframe bolts -2- and -3- must not be loosened at this
stage.
– Remove subframe bolt -1- on both sides.
– Position support elements from -VAS 6131/10- and -VAS

6131/13- at front left and right of subframe as shown.
– Make sure that threaded spindles are screwed in completely.
– Position support elements from -VAS 6131/10- (rear left and

right) at front attachment points of subframe cross brace as
shown.
– Position support elements from -VAS 6131/13- under left and

right wheel bearing housings as shown.

– Position support elements from -VAS 6131/10- and -VAS

6131/11- (rear left and right) at tunnel cross member as
shown.
– Turn all spindles for support elements upwards until all locat‐
ing lugs make contact with mounting points.
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform - VAS 6131 B- .
– Mark installation position of subframe and tunnel cross mem‐

ber on longitudinal members with felt-tip pen.
– Unscrew subframe bolts -2, 3- on both sides in several stages.
– Remove bolts -arrows- for tunnel cross member.
– Remove bolt -2- on both sides.
Caution
Danger of damage to hoses, pipes and wiring connections and

to engine compartment.
♦ Check that all hoses and wiring connections between en‐
gine, gearbox, subframe and body have been detached.
♦ Carefully guide out engine/gearbox assembly with sub‐
frame from engine compartment when lowering.

– Lower engine/gearbox assembly using scissor-type assembly

platform - VAS 6131 B- initially only as far as distance -a-.
• Dimension -a- = 100 mm (maximum).
– Pry ball socket -2- of selector lever cable off gearbox selector
lever using removal lever - 80 - 200- .
– Press off securing clip -1- and remove selector lever cable
from gearbox.
Note
Take care not to bend or kink selector lever cable.
– Lower engine/gearbox assembly further.

– Pull out scissor-type assembly platform - VAS 6131 B- with
engine/gearbox assembly from underneath vehicle.
1.2 Separating engine and gearbox

Special tools and workshop equipment required
♦ Support set for Audi - VAS 6131/10- , support -VAS 6131/13-7-
and gearbox support - VAS 6131/14-
♦ Adapter - T40058-

Procedure
• Engine/gearbox assembly removed and secured to scissor-
type assembly platform - VAS 6131 B-
– Remove poly V-belt tensioner for supercharger ⇒ page 54 .
– Take electrical connector -2- for Lambda probe 2 after catalytic
converter - G131- out of bracket, unplug and move wiring
clear.
Note
Disregard -item 1-.
– Remove nuts -arrows- and bolt -1- and detach catalytic con‐
verter (left-side).
Caution
Risk of irreparable damage to gearbox control unit (mecha‐

tronic unit) because of static discharge.
♦ Before unplugging or plugging in electrical connector, me‐
chanic must discharge static electricity. To do so, touch
vehicle earth, heater radiator, or lifting platform, with your
hand.
♦ Do NOT touch connector contacts in gearbox connector
with your hands.
– Turn retainer catch anti-clockwise -arrow- and unplug electri‐

cal connector at gearbox.
– Move clear electrical wiring harness at gearbox.

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

lytic converter - G130- from bracket and unplug connector.
– Remove bolts -3- and move bracket clear to one side.
Note
Disregard -item 2-.
– Remove bolt -1- and nuts -arrows- and detach catalytic con‐
verter (right-side).
– Unplug electrical connector -2- at engine speed sender - G28-

and move wiring clear.
Note
Disregard -item 1-.
– Unplug electrical connector -1- at power steering control unit

- J500- (release retainer -arrow- and press down release
catch).
Note
Disregard -item 2-.
– Unbolt drive shaft (left and right) from gearbox flange shafts
⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Removing and installing drive shaft .

– Detach bottom cover -1- from gearbox -arrow-.
– Insert guide pin of adapter -T40058- as follows:

• The larger-diameter section -arrow 1- faces towards the en‐
gine.
• The smaller-diameter section -arrow 2- faces the adapter.
– Counterhold crankshaft using adapter - T40058- and angled

ring spanner when loosening bolts for torque converter.
Note
When performing the next step, turn the crankshaft only in the
normal direction of rotation -arrow-.
– Remove 6 bolts -arrow- for clutch module, turning crankshaft

60° in normal direction of rotation each time.

– Remove bolt -arrow- for ATF lines.
Note
Note
Lay a cloth under the separating point to catch escaping ATF.
– Unscrew bolts -arrows -, detach ATF lines -1, 2- from ATF-filter

housing and tie up ATF lines.
– Remove bolt -arrow- and move coolant circulation pump - V50-

clear to one side.

– Set up scissor-type assembly platform - VAS 6131 B- with

support set for Audi - VAS 6131/10- , support -VAS 6131/13-7-
and gearbox support - VAS 6131/14- as follows:
Note
The other support elements remain unchanged.
Platform Parts from support set for Audi - VAS 6131/10- ,

coordinates support -VAS 6131/13-7- and gearbox support -
VAS 6131/14-
F2 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5
– Secure support -VAS 6131/13-7- at tapped hole for poly V-belt

tensioner for air conditioner compressor at front of engine
(right-side) as illustrated.
– Secure support -VAS 6131/13-7- to scissor-type assembly
platform and tighten to 20 Nm.
– Position support elements from -VAS 6131/10- and gearbox

support - VAS 6131/14- at front of gearbox, as illustrated.
– Screw spindles on both sides upwards until gearbox support
- VAS 6131/14- makes full contact with gearbox.
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform - VAS 6131 B- .
– Remove bolts -1- and -2- for starter.

– Separate starter from gearbox and leave in position.
– Unscrew remaining bolts -3 ... 10- securing engine to gearbox.
Note
Disregard -item A-.

– Loosen clamping bolts -1- on sides of scissor-type assembly

platform - VAS 6131 B- , pull rear section of platform together
with gearbox towards rear -arrow-, and at the same time dis‐
connect coolant hose from engine oil cooler.
1.3 Securing engine to engine and gearbox support

equipment required
♦ Lifting tackle - 2024 A-
♦ Engine and gearbox sup‐
port - VAS 6095- with uni‐
versal mounting - VAS
6095/1- and bracket for V6
FSI engine, Audi A6 - VAS
6095/1-5-
♦ Workshop hoist -
VAS 6100-
♦ Lift arm extension (work‐
shop hoist) - VAS 6101-

Procedure
WARNING
Risk of accident.
♦ The engine can only be transported with the gearbox re‐
moved using the method described.
• Engine/gearbox assembly removed and secured to scissor-

type assembly platform - VAS 6131 A- (with engine detached
from gearbox) ⇒ page 24 .
• Engine secured with support -VAS 6131/13-7- .
– Attach lifting tackle - 2024 A- to engine lifting eyes and work‐

shop hoist - VAS 6100- with lift arm extension (workshop hoist)
- VAS 6101- as shown in 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
Risk of accident.
♦ The support hooks and retaining pins on the lifting tackle
must be secured with locking pins -arrows-.
– Take up weight of engine with workshop hoist, but do not lift.
– Remove bolt -1- for engine mounting on both sides.

– Remove nut -2- and move bracket with electrical wiring clear.
– Take electrical connector (right-side) -arrow- out of bracket
and unplug.
– Remove support -VAS 6131/13-7- from engine.

– Lift engine off engine cross member.

– Unscrew bolts -arrows- and remove engine support (left-side).
– Remove nut -1- and move earth wire clear at engine support.
– Unscrew bolts -arrows- and remove engine support (right-
side).
– Tie up starter on engine.
– Secure engine with universal mounting - VAS 6095/1- and

support bracket for V6 FSI engine, Audi A6 - VAS 6095/1-5-
to engine and gearbox support - VAS 6095- as shown in
illustration and tighten to 40 Nm.
1.4 Installing engine


♦ Ring spanner insert AF 16 - V.A.G 1332/14-
♦ Transport lock - T40170-
Tightening torques
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 de-greased parts.
♦ Tolerance for tightening torques: ± 15 %.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40

Component Nm
M12 65
♦ Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 40
♦ Engine to gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Tightening torques for gearbox
Procedure
Note
♦ Renew bolts tightened with specified tightening angle.

♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings after removal.
♦ Do not remove plugs or protective caps until you are ready to
fit the relevant line.
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
♦ To secure the air hoses at their connections, spray rust re‐
mover onto the worm thread of the used hose clips before
installing.
• Engine/gearbox assembly positioned on scissor-type assem‐

bly platform - VAS 6131 B- .
• Engine secured with support -VAS 6131/13-7- .
– Before installing gearbox, remove residue from threaded holes
for engine/gearbox bolts in cylinder block using a thread tap.
– Install engine supports and engine mountings ⇒ page 40 .
– The following preparations are required before joining engine
and gearbox.
– Insert assembly aid - T40169- into gearbox housing between
clutch module and gearbox housing from below, as illustrated.
• The assembly aid must engage in the semi-circular recess
-1- and in the inspection hole -2-.
Note
There is only one inspection hole on the circumference; turn the

clutch module accordingly.
– Insert pin of assembly aid into hole on gearbox housing.

– Insert transport lock - T40170- into gearbox housing and clutch

module from below and clamp onto flange shaft -1-.
– Check whether dowel sleeves -A- for centring engine and

gearbox are fitted in cylinder block; install missing dowel
sleeves.
– Check whether aluminium bolts securing engine to gearbox
can be reused; if so, apply marking ⇒ Rep. gr. 34 ; Removing
and installing gearbox; Tightening torques for gearbox .
– Bring gearbox into position on engine (pay attention to starter).
– Bring gearbox into position on engine and tighten bolts
-1, 6 … 10-.
– Remove transport lock - T40170- and assembly aid - T40169- .
Note
The following step is necessary to ensure that the clutch module

is straight and that it makes even contact with the drive plate.
– Using assembly lever -1-, press clutch module -2- slightly

against drive plate -3- -arrow-.
– Bolt clutch module onto drive plate as follows:
Note
Use ring spanner insert AF 16 - V.A.G 1332/14- to tighten bolts.
– Hand-tighten first bolt -arrow- (2 Nm).


gine.
– Use adapter - T40058- and angled ring spanner to turn crank‐

shaft 180° further in direction of engine rotation -arrow-.
– Tighten bolt accessible in this crankshaft position to specified
torque ⇒ Rep. gr. 30 ; Clutch; Exploded view - flywheel and
dual clutch .
– Turn crankshaft by 60° each time and tighten remaining 5 bolts
to specified torque ⇒ Rep. gr. 30 ; Clutch; Exploded view -
flywheel and dual clutch .
– Secure drive shafts to gearbox flange shafts ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Exploded view - drive
shaft .
– Install catalytic converters ⇒ page 312 .
– Install ATF lines ⇒ Rep. gr. 34 ; ATF circuit; Removing and
installing ATF lines .

– Raise engine/gearbox assembly using scissor-type assembly

platform - VAS 6131 B- only until distance between subframe
and body is -a-.
• Dimension -a- = min. 100 mm.
– Install selector lever cable and adjust it if necessary ⇒ Rep.
gr. 34 ; Selector mechanism; Removing and installing selector
lever cable .
– Raise engine/gearbox assembly further using scissor-type as‐
sembly platform - VAS 6131 B- .
– Align subframe and tunnel cross member on longitudinal
members according to markings made before removal.
– Tighten subframe bolts only to specified torque (do not turn
further); the bolts should only be fully tightened after perform‐
ing the wheel alignment check ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Subframe; Exploded view - subframe .
WARNING
Risk of accident because of loose bolted connections.

♦ Do NOT drive the vehicle unless the subframe bolts have
been tightened to their final torque.
– Tighten bolts for tunnel cross-piece ⇒ Rep. gr. 34 ; Assembly

mountings; Exploded view - assembly mountings .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Secure intermediate steering shaft to steering rack ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering column; Removing
and installing intermediate steering shaft .
– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
– Install front silencers ⇒ page 315 .
– Install upper suspension links and suspension strut ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Suspension strut,
upper links; Exploded view - suspension strut, upper links .
– Install subframe cross brace and anti-roll bar ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Exploded view - sub‐
frame .
– Install heat shield on subframe along with diagonal struts ⇒
Running gear, axles, steering; Rep. gr. 42 ; Subframe; Ex‐
ploded view - subframe .
– Install brake calipers ⇒ Brake system; Rep. gr. 46 ; Front
brakes; Removing and installing brake caliper .
– Install air pipes ⇒ page 269 .
– Install electrical wiring, fuse holder and cover for electronics
box in engine compartment ⇒ Electrical system; Rep. gr. 97 ;
Relay carriers, fuse carriers, electronics boxes; Overview of
fitting locations - relay carriers, fuse carriers, electronics box‐
es , and ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
– Install poly V-belt ⇒ page 52 .

– Install poly V-belt tensioner for supercharger ⇒ page 54 .

– Install lock carrier cover ⇒ General body repairs, exterior;
ments .
– Observe steps required after re-connecting battery ⇒ Electri‐
cal system; Rep. gr. 27 ; Battery; Disconnecting and connect‐
ing battery .
– Install body brace ⇒ Running gear, axles, steering; Rep. gr.
40 ; Suspension strut, upper links; Exploded view - suspension
strut, upper links .
– Install filler neck for washer fluid reservoir ⇒ Electrical system;
Rep. gr. 92 ; Windscreen washer system; Exploded view -
windscreen washer system .
– Install air cleaner housing ⇒ page 270 .
– Install lock carrier braces ⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier; Exploded view - lock carrier .
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Install engine cover panel ⇒ page 47 .
Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– Fill up with engine oil and check oil level ⇒ Maintenance ;

Booklet 811 , ⇒ Maintenance ; Booklet 812 or ⇒ Maintenance ;
Booklet 818 .
– Secure coolant pipes ⇒ page 194 .
– Connect coolant hoses and connection with plug-in connector
⇒ page 206 .
Note
Do not reuse coolant.
– Fill up with coolant ⇒ page 178 .

– Align subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ;
Subframe; Removing and installing subframe with steering
rack .
– Install wheel housing liners ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
– Check wheel alignment ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheel alignment check; Wheel alignment procedure .

WARNING
Risk of accident because of loose bolted connections.

♦ Tighten subframe bolts to final setting after performing
wheel alignment check.
– Top up ATF ⇒ Rep. gr. 34 ; ATF; Checking ATF level .

– Install noise insulation panels ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .

2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 40
⇒ “2.2 Supporting engine in installation position”, page 41
⇒ “2.3 Removing and installing engine mountings”, page 42
⇒ “2.4 Removing and installing gearbox mounting”, page 45
2.1 Exploded view - assembly mountings

Engine mounting
1 - Bolt
❑ 20 Nm
2 - Bracket
❑ For engine mounting
❑ Renew bracket if engine
mounting is defective
3 - Bolt
❑ 40 Nm
4 - Engine support
5 - Bolt
❑ 10 Nm
6 - Heat shield
7 - Bolt
❑ Renew after removing
❑ 90 Nm + 90°
8 - Engine mounting
❑ Removing and installing
⇒ page 42
9 - Subframe
10 - Bolt
❑ 55 Nm
Gearbox mounting

1 - Nut
❑ Tightening torque ⇒
Rep. gr. 34 ; Assembly
mountings; Exploded
view - assembly mount‐
ings
2 - Bolt
mountings; Exploded
ings
3 - Bolt
mountings; Exploded
ings
4 - Nut
mountings; Exploded
ings
5 - Gearbox support
⇒ page 45
6 - Gearbox mounting
⇒ page 45
7 - Stop (bottom)
❑ For gearbox mounting
8 - Bolt
❑ Tightening torque ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
9 - Tunnel cross-member
❑ Removing and installing ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
2.2 Supporting engine in installation posi‐

tion
♦ Support bracket - 10 - 222 A-
2. Assembly mountings 41
Procedure
WARNING
Risk of accident when weight of engine is shifted.

♦ In order to support the engine as described below, the
gearbox and tunnel cross members must be installed.
– Remove engine cover panel ⇒ page 47 .

– Set up support bracket - 10 - 222 A- on suspension turrets (left
and right) as illustrated.
– Attach spindles -10 - 222 A/11- to engine lifting eyes.
– Partly take up weight of engine with spindles.
Assembling
Assemble in reverse order.
2.3 Removing and installing engine mount‐

ings
⇒ “2.3.1 Removing and installing engine mounting (left-side)”,
page 42
⇒ “2.3.2 Removing and installing engine mounting (right-side)”,
page 43
2.3.1 Removing and installing engine mount‐

ing (left-side)
Note
♦ To avoid repeat repairs, proceed as follows if an engine

mounting is defective:
♦ Renew engine mounting and corresponding bracket.
Removing
– Support engine in installation position ⇒ page 41 .
noise insulation .
– Remove front wheel housing liner (left-side) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing front wheel housing liner .
front ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner
compressor; Detaching and attaching air conditioner com‐
pressor at bracket .

– Remove bolt -2- for subframe (left-side).
Note
Bolts -1- and -3- on left side and all bolts for subframe on right
side remain fitted.
– Unplug electrical connector -3- on left electrohydraulic engine

mounting solenoid valve - N144- .
– Remove bolts -1, 4, 5- for engine mounting (left-side).
– Move retaining plate -2- for engine mounting (left-side) clear
to the side.
– Detach engine mounting (left-side).
Installing
Installation is carried out in the reverse order; note the following:
Note
Renew bolts tightened with specified tightening angle.

Tightening torques
♦ ⇒ “2.1 Exploded view - assembly mountings”, page 40
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
2.3.2 Removing and installing engine mount‐

ing (right-side)
Note
♦ To avoid repeat repairs, proceed as follows if an engine

mounting is defective:
♦ Renew engine mounting and corresponding bracket.
Removing
– Support engine in installation position ⇒ page 41 .
noise insulation .
– Remove front wheel housing liner (right-side) ⇒ General body

and installing wheel housing liner (front) .
– Detach electrical connector -2- on solenoid valve (right-side)
for electro-hydraulic engine mounting - N145- from bracket
and unplug connector.
– Unscrew nut -1- and detach bracket with electrical wiring from
subframe.
– Remove bolts -1, 2, 4- and move clear retaining plate -3- for
engine mounting (right-side).
– Remove bolt -arrow- on bracket for ATF lines.
Note

– Using spindle - 10 - 222 A /11- -item 1-, raise engine through

distance -a- on right side.
• Distance -a- = approx. 20 mm.
– Detach engine mounting (right-side).
Installing
Note
Tightening torques
♦ ⇒ Rep. gr. 34 ; ATF circuit; Exploded view - ATF circuit
2.4 Removing and installing gearbox

mounting
⇒ “2.4.1 Removing and installing gearbox support with gearbox
mounting”, page 45
⇒ “2.4.2 Removing and installing gearbox mounting”, page 46
2.4.1 Removing and installing gearbox sup‐

port with gearbox mounting
Removing
– Remove tunnel cross-piece ⇒ Rep. gr. 34 ; Assembly mount‐
ings; Exploded view - assembly mountings .
– Remove bolts -arrows- and detach gearbox support and gear‐
box mounting from gearbox.
Installing
Install in reverse order.
Tightening torques
♦ ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - as‐
sembly mountings
2.4.2 Removing and installing gearbox

mounting
Removing
– Remove gearbox support with gearbox mounting ⇒ page 45 .
– Unscrew bolt -1- and detach stop -2- for gearbox mounting.
– Remove nut -4- and bolt -5- and detach gearbox mounting
-6- from gearbox support -3-.
Installing
– Position gearbox support -3- on gearbox mounting -6-.
– Hand-tighten nut -4- and bolt -5-.
– Tighten bolt -1- for stop -2-.
– Tighten nut -4- and bolt -5-.
– Install gearbox support with gearbox mounting ⇒ page 45 .
Tightening torques
♦ ⇒ Rep. gr. 34 ; Assembly mountings; Exploded view - as‐
sembly mountings

3 Engine cover panel

⇒ “3.1 Removing and installing engine cover panel”, page 47
3.1 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– Position engine cover panel on engine and press it into re‐
taining clips with both hands.
3. Engine cover panel 47

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - poly V-belt drive”, page 48
⇒ “1.2 Removing and installing poly V-belts”, page 51
⇒ “1.3 Removing and installing tensioner for poly V-belt”,
page 54
⇒ “1.4 Removing and installing vibration damper”, page 56
⇒ “1.5 Removing and installing sealing flange (pulley end)”, page
57
1.1 Exploded view - poly V-belt drive

⇒ “1.1.1 Exploded view - poly V-belt drive, poly V-belt for super‐
charger”, page 48
⇒ “1.1.2 Exploded view - poly V-belt drive, poly V-belt for ancilla‐
ries”, page 49
1.1.1 Exploded view - poly V-belt drive, poly V-belt for supercharger
1 - Poly V-belt
❑ For supercharger
❑ Check for wear
⇒ page 51
❑ When installing, make
sure it is properly seated
on pulleys
2 - Bolt
❑ Not available separate‐
ly; combined as a unit
with -item 5-
❑ 40 Nm
❑ 37 Nm if using door
alignment tool - 3320-
3 - Washer
❑ Not available separate‐
ly; combined as a unit
with -item 5-
4 - Supercharger
❑ Exploded view
⇒ page 220
5 - Idler roller
❑ For poly V-belt
❑ Combined as a unit with
-items 2 and 3-
6 - Vibration damper
❑ With poly V-belt pulley
❑ Can only be installed in
one position (holes are
off-set).
48 Rep. gr.13 - Crankshaft group


⇒ page 56
7 - Bolt
❑ Tightening torque ⇒ Item 16 (page 50)
8 - Tensioner
❑ For poly V-belt
❑ Removing and installing ⇒ page 54
9 - Bolt
❑ 40 Nm
1.1.2 Exploded view - poly V-belt drive, poly V-belt for ancillaries
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
⇒ page 52
❑ Do not kink
❑ When installing, make
sure it is properly seated
on pulleys
2 - Alternator
⇒ Electrical system;
Rep. gr. 27 ; Alternator;
Removing and installing
alternator
3 - Bolt
Electrical system; Rep.
gr. 27 ; Alternator; Ex‐
ploded view - alternator
4 - Idler roller
❑ For poly V-belt
❑ Tightening torque
⇒ Item 2 (page 48)
5 - Bolt
6 - Poly V-belt pulley
❑ For coolant pump
⇒ “2.5 Removing and in‐
stalling coolant pump”, page 188
7 - Bolt
8 - Coolant pump
1. Cylinder block (pulley end) 49

9 - Tensioner
❑ For poly V-belt
10 - Vibration damper
❑ With double-sided poly V-belt pulley
11 - Bracket
❑ For air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded
view - air conditioner compressor drive unit
12 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
13 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
14 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
15 - Dowel sleeves
16 - Bolt
❑ 20 Nm +90°
Sealing flange (pulley end) - tightening torque and sequence

– Tighten bolts -arrows- in stages and in diagonal sequence; fi‐
nal torque 9 Nm.

1.2 Removing and installing poly V-belts

⇒ “1.2.1 Removing and installing poly V-belt for supercharger”,
page 51
⇒ “1.2.2 Removing and installing poly V-belt for ancillaries”, page
52
1.2.1 Removing and installing poly V-belt for

supercharger
♦ Locking pin - T10060 A-
Removing
WARNING
Risk of injury as the radiator fans may start up automatically.

♦ Even when the ignition is switched off, the radiator fans
can start up without warning due to accumulated heat in
the engine compartment, etc.
– Remove noise insulation (front) ⇒ General body repairs, ex‐

noise insulation .
Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
with chalk or felt-tip pen for re-installation.
– To slacken poly V-belt, turn tensioner in clockwise direction

-arrow-.
– Detach poly V-belt and lock tensioner with locking pin - T10060
A- .

Installing
– Fit poly V-belt on pulleys as shown in illustration.
1- Tensioner
2- Supercharger
3- Idler roller
4- Vibration damper
– Fit poly V-belt onto idler roller -3- last.
Note
When installing poly V-belt, make sure it is properly seated on

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

Tightening torques
1.2.2 Removing and installing poly V-belt for

ancillaries
♦ Special wrench, long reach -3320/2- (included with door align‐
ment tool - 3320- )
♦ Locking pin - T10060 A-

Removing
– Remove poly V-belt for supercharger ⇒ page 51 .
– Remove bolt -arrow- using special wrench, long reach
-3320/2- .
– Push guide roller towards radiator cowl.
Note
The guide roller cannot be detached.
– Remove bolt -2- for coolant pipes (front left).
Note
♦ For illustration purposes, the installation position is shown with

the engine removed.
♦ Disregard -item 1-.
Note
Disregard -item 2-.
Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
with chalk or felt-tip pen for re-installation.
– To slacken poly V-belt, turn tensioner clockwise -arrow- and

lock with locking pin - T10060 A- .
– Take off poly V-belt.

Installing
– Fit poly V-belt on pulleys as shown in illustration.
1- Alternator
2- Idler roller
3- Coolant pump
4- Air conditioner compressor
5- Tensioner for poly V-belt
6- Vibration damper
Note
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Install poly V-belt for supercharger ⇒ page 51 .

– Start engine and check that belt runs properly.
Tightening torques
♦ ⇒ “1.1.2 Exploded view - poly V-belt drive, poly V-belt for an‐
cillaries”, page 49
♦ ⇒ “3.1 Exploded view - coolant pipes”, page 194
1.3 Removing and installing tensioner for

poly V-belt
⇒ “1.3.1 Removing and installing tensioner for poly V-belt for su‐
percharger”, page 54
⇒ “1.3.2 Removing and installing tensioner for poly V-belt for an‐
1.3.1 Removing and installing tensioner for

poly V-belt for supercharger
Removing
– Remove bolt -1- and detach poly V-belt tensioner -2-.
Note
Ignore -T10060 A- .
Installing
Tightening torques
♦ ⇒ “1.1.1 Exploded view - poly V-belt drive, poly V-belt for su‐
percharger”, page 48

1.3.2 Removing and installing tensioner for

poly V-belt for ancillaries
Removing
WARNING

Note
Disregard -item 1-.
Note
Disregard -item 2-.
– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.
– Remove poly V-belt from tensioner and release tensioner.
Note
Ignore -T10060 A- .

– Remove bolt -1- and detach poly V-belt tensioner -2- from cyl‐
inder block.
Installing
Tightening torques
1.4 Removing and installing vibration damp‐

er
♦ Counterhold tool - 3036-
Removing
– Remove poly V-belt from tensioner and release tensioner
⇒ page 55 .
– Loosen bolts -1- for vibration damper using counterhold tool -
3036- .
– Remove bolts and take off vibration damper.
Installing
Note

♦ Can only be installed in one position.
– Observe dowel sleeve when installing vibration damper.

Tightening torques

1.5 Removing and installing sealing flange

(pulley end)
♦ Pin wrench - 3212-
♦ Assembly tool - T40048 A-
♦ Electric drill with plastic brush

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Procedure
– Remove vibration damper ⇒ page 56 .
– Loosen bolts -arrows- for coolant pump pulley (counterhold
with pin wrench - 3212- ).
– Remove bolts and take off poly V-belt pulley.

– Loosen bolts -arrows- in diagonal sequence and remove.

– Release sealing flange (pulley end) from bonded joint and take
off sealing flange.
Note
Renew sealing flange (pulley end) after removing.
Caution
Protect lubrication system against contamination.

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

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

section) -1- using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5

mm).

Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.
– Apply bead of sealant -arrow- onto sealing surface of new

sealing flange (pulley end) as shown in illustration.
• The groove 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 sealing flange (pulley end) must be installed within 5 minutes

after applying the sealant.
– Fit assembly aid -T40048/1- onto assembly sleeve -T40048/2-

and slide sealing flange -1- onto assembly sleeve.
– Detach assembly aid.
– First position sealing flange -1- (with assembly sleeve -

T40048/2- inserted) on crankshaft.
– Keep sealing flange straight while pushing it onto engine seal‐
ing surface. Then bolt on ⇒ page 50 .
note the following:
– Install vibration damper ⇒ page 56 .
Tightening torques
♦ ⇒ Fig. ““Sealing flange (pulley end) - tightening torque and se‐
quence”“ , page 50
♦ ⇒ “2.1 Exploded view - coolant pump and thermostat”,
page 183

2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 60
⇒ “2.2 Removing and installing drive plate”, page 60
⇒ “2.3 Renewing crankshaft oil seal (gearbox end)”, page 61
2.1 Exploded view - cylinder block (gearbox end)
Note
When performing assembly work, secure engine to engine and gearbox support - VAS 6095- ⇒ page 30 .
1 - Bolt
❑ 60 Nm +90°
2 - Drive plate
❑ With bearing flange
❑ Check running surface
on bearing flange and
holes for clutch module
for cracks and scoring.
⇒ page 60
3 - Sender wheel
❑ For engine speed send‐
er - G28-
⇒ page 69
❑ Checking ⇒ page 69
4 - Oil seal
❑ For crankshaft (gearbox
end)
❑ Renewing ⇒ page 61
5 - Crankshaft
6 - Dowel pin
2.2 Removing and installing drive plate


♦ Counterhold tool - 10 - 201-
Removing
• Gearbox removed ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox
– Insert counterhold tool - 10 - 201- to slacken bolts.
Caution
Take care not to damage outer surface of bearing flange on

drive plate.
♦ Use a multi-point socket bit with a length of at least 40 mm
to slacken and tighten the drive plate bolts.
– Remove bolts and take off drive plate -1- and sender wheel.
Installing
Note
– Pay attention to dowel pin when installing drive plate.

– Fit counterhold tool - 10 - 201- the other way round to tighten
bolts.
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 60
2.3 Renewing crankshaft oil seal (gearbox

end)
2. Cylinder block (gearbox end) 61

♦ Fitting tool - T10122 A-
♦ Guide piece - T10122/6-

♦ Extractor tool - T20143/2-
Procedure
– Remove drive plate ⇒ page 60 .
– Pry out oil seal using extractor tool -T20143/2- .
– Clean contact surface and sealing surface.
– Fit assembly aid -T10122/1- onto guide piece - T10122/6- and

slide oil seal -A- onto guide piece.
– Detach assembly aid -T10122/1- .

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

– Bolt guide piece to crankshaft through securing points -A- us‐
ing bolts -arrows-.
Caution
Risk of leaks if installed incorrectly.

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

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

T10122/5- .
– Remove guide piece - T10122/6- .
– Check that oil seal and its sealing lip are correctly seated. If
sealing lip is partially folded over, repeat procedure with a new
oil seal.
– Install drive plate ⇒ page 60 .
2. Cylinder block (gearbox end) 63

3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 64
⇒ “3.2 Crankshaft dimensions”, page 67
⇒ “3.3 Measuring axial clearance of crankshaft”, page 67
⇒ “3.4 Measuring radial clearance of crankshaft”, page 68
⇒ “3.5 Removing and installing sender wheel”, page 69
⇒ “3.6 Checking sender wheel”, page 69
3.1 Exploded view - crankshaft
Note
When performing assembly work, secure engine to engine and gearbox support - VAS 6095- ⇒ page 30 .
1 - Sealing flange (pulley end)

2 - Bolt
❑ Tightening torque and
sequence ⇒ page 50
3 - Crankshaft
❑ Measuring axial clear‐
ance ⇒ page 67
❑ Measuring radial clear‐
ance ⇒ page 68
❑ Crankshaft dimensions
⇒ page 67
4 - Dowel sleeve
❑ 4x
❑ Inserting in retaining
frame ⇒ page 66
5 - Seal
6 - Bolt
❑ For sealing surfaces: re‐
taining frame to cylinder
block
❑ Differing bolt lengths
and bolt heads
7 - Bolt
❑ Long, large collar
❑ For retaining frame (in‐
ner row)
❑ Use old bolts when measuring radial clearance
❑ Tightening torque and sequence ⇒ page 66
8 - Bolt
❑ Short, small collar

❑ For retaining frame (outer row)

9 - Retaining frame
❑ With valve for oil pressure control - N428- ⇒ page 66
❑ To remove, detach guide rail ⇒ Item 1 (page 95) for drive chain for valve gear
❑ Applying sealant ⇒ page 66
❑ Removing and installing valve for oil pressure control - N428- ⇒ page 170
10 - Seal
11 - Thrust washer
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil groove faces outwards
❑ Make sure it engages in retaining frame
12 - Bearing shell
❑ For retaining frame (without oil groove)
❑ Renew used bearing shells
❑ Note installation position
❑ Install new bearing shells for retaining frame with correct coloured markings ⇒ page 67
13 - Thrust washer
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil groove faces outwards
❑ Make sure it engages in cylinder block
14 - Bearing shell
❑ For cylinder block (with oil groove)
❑ Renew used bearing shells
❑ Note installation position
❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ page 67
15 - Cylinder block
Plug for “TDC” marking - tightening torque
Note
Renew O-ring after removal.
– Tighten plug -arrow- to 14 Nm.
3. Crankshaft 65
Valve for oil pressure control - N428-

1- Electrical connector
2- O-ring - renew
3- Bolt, 9 Nm
4- Valve for oil pressure control - N428-
Applying sealant to retaining frame, position of dowel sleeves

– Apply beads of sealant -arrows- onto clean sealing surfaces
of retaining frame as shown in illustration.
with sealant.
• The beads of sealant must project 1.5 … 2.0 mm above the
sealing surface.
– Fit seals -1- and -2-.
– Check that dowel sleeves -3 ... 6- are inserted in retaining
frame at positions shown in illustration.
Installing retaining frame
Note
– Install long bolts in inner row on retaining frame.

– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. -1 … 16- 50 Nm
2. -1 … 16- Turn 90° further
3. -17 … 31- 15 Nm
4. -17 … 31- Turn 90° further

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.
Code letter on retaining frame Colour coding of bearing
R = Red
G = Yellow
B = Blue
S = Black
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
gearbox flange on the crankshaft. The first letter in the se‐
quence stands for bearing “1”, the second letter for bearing
“2”, etc.
Letter on crankshaft Colour coding of bearing
R = Red
G = Yellow
B = Blue
S = Black
3.2 Crankshaft dimensions

Honing dimension Crankshaft bearing journal ∅ Crankshaft conrod journal ∅
mm mm
Basic dimension 65.000 – 0.022 56.000 – 0.022
– 0.042 – 0.042
3.3 Measuring axial clearance of crankshaft

3. Crankshaft 67
♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
– Secure dial gauge - VAS 6079- with universal dial gauge
bracket - VW 387- to cylinder block as shown in illustration.
– Apply dial gauge to crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
• Axial clearance: 0.15 ... 0.25 mm
3.4 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure
Note
Use old bolts when measuring radial clearance.
– Remove retaining frame and clean bearing journals.

– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
• The Plastigage must be positioned in the centre of the bearing
shell.

– Fit retaining frame and secure with old bolts ⇒ page 66 without
rotating crankshaft.
– Remove retaining frame again.
– Compare width of Plastigage with measurement scale.
Radial clearance:
• New: 0.015 ... 0.055 mm.
• Wear limit: 0.080 mm.
– When carrying out final assembly, renew bolts.
3.5 Removing and installing sender wheel

Removing
– Detach sender wheel -arrow-.
Installing
3.6 Checking sender wheel
Caution
Risk of magnetic fields causing irreparable damage to sender

wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation ⇒ page 69 .

♦ Sensor gauge - T10473-
3. Crankshaft 69
Procedure
• Sender wheel removed
– Check entire circumference of sender wheel using sensor
gauge - T10473- , as shown in illustration.
Inspection image of sender wheel

A - Sender wheel OK
B - Sender wheel defective

4 Balance shaft
⇒ “4.1 Exploded view - balance shaft”, page 71
⇒ “4.2 Removing and installing balance shaft”, page 71
4.1 Exploded view - balance shaft
1 - Balance shaft
⇒ page 71
2 - Bolt
❑ Use locating pin -
T40116- as counterhold
when loosening and
tightening
❑ 40 Nm +90°
3 - Chain sprocket for balance
shaft
❑ With balance weight
(gearbox end)
4 - Bearing plate
5 - Bolt
❑ 15 Nm
6 - Balance weight (pulley end)
❑ Can only be fitted on
balance shaft in one po‐
sition.
7 - Bolt
❑ Use locating pin -
T40116- as counterhold
when loosening and
tightening
❑ 40 Nm +90°
4.2 Removing and installing balance shaft

4. Balance shaft 71
♦ Locating pins - T40116-
Removing
– Remove sealing flange (pulley end) ⇒ page 57 .
– Remove timing chain cover (bottom) ⇒ page 87 .
– Loosen bolt -arrow- by one turn (counterhold using locating
pin -T40116- ).
– Remove drive chain for valve gear ⇒ page 109 .
– Unscrew bolt -2- at pulley end of engine (counterhold balance

weight -1- with a suitable pin) and detach balance weight from
balance shaft.
– Unscrew bolts -arrows- and detach bearing plate for balance

shaft from engine (gearbox end).
– Pull balance shaft to rear out of cylinder block.

Installing
• Crankshaft -1- locked in “TDC” position with locking pin -
T40069- .
Note
Balance weights can only be fitted on balance shaft in one posi‐

tion.
– Install drive chain for valve gear ⇒ page 109 .

– Install timing chain cover (bottom) ⇒ page 87 .
– Install sealing flange (pulley end) ⇒ page 57 .
Tightening torques
♦ ⇒ “4.1 Exploded view - balance shaft”, page 71
4. Balance shaft 73
5 Pistons and conrods

⇒ “5.1 Exploded view - pistons and conrods”, page 74
⇒ “5.2 Removing and installing pistons”, page 76
⇒ “5.3 Checking pistons and cylinder bores”, page 77
⇒ “5.4 Checking radial clearance of conrod bearings”,
page 78
5.1 Exploded view - pistons and conrods
Note
♦ All bearing and running surfaces must be oiled before assembling.

♦ Oil spray jet for piston cooling ⇒ page 76 .
1 - Bolts
❑ Use old bolts when
measuring radial clear‐
ance
❑ Lubricate threads and
contact surface
❑ 50 Nm +90°
2 - Conrod bearing cap
❑ Mark installation posi‐
tion for re-installation
❑ Mark cylinder and con‐
rod allocation in colour
⇒ page 75
❑ Installation position of
conrod pairs
⇒ page 75
3 - Bearing shells
❑ Ensure that retaining
lugs are securely seat‐
ed.
❑ Renew used bearing
shells
❑ There are oversized
bearings available for
machined crankshaft
conrod journals ⇒ Elec‐
tronic parts catalogue
❑ Lugs on conrod bear‐
ings must be on the
same side
4 - Conrod
❑ Only renew as a com‐
plete set
❑ Mark cylinder and conrod bearing cap allocation in colour ⇒ page 75
❑ Installation position of conrod pairs ⇒ page 75
❑ Axial clearance for each conrod pair (when new): 0.20 … 0.45 mm
❑ Measuring radial clearance ⇒ page 78

5 - Circlip
6 - Piston pin
❑ Removing and installing ⇒ “5.2 Removing and installing pistons”, page 76
7 - Piston
❑ Mark installation position and cylinder number ⇒ page 75
❑ Renew piston if cracking is visible on piston crown or piston skirt
❑ Checking pistons and cylinder bores ⇒ page 77
8 - Piston rings
❑ Measuring ring gap ⇒ page 78
❑ Measuring ring-to-groove clearance ⇒ page 78
❑ Use piston ring pliers (commercially available) to remove and install
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Offset gaps by 120°
Installation position of pistons
Caution
Do not damage the coating of the piston crown.

♦ If you intend to re-install used pistons, mark the cylinder
number on the piston crown using paint. Do not attempt to
mark the piston crown with a centre punch or by making
a notch or similar.
• Arrows on piston crowns point to pulley end.
Marking conrods
Note
♦ Only renew conrods as a complete set.

♦ Do not interchange conrod bearings.
– Use a coloured pen to mark matching conrods and conrod

bearing caps with cylinder numbers -arrow- for re-installation.
Conrod installation position

• The cast lugs -arrows- on the ground surfaces of the conrod
pairs “1 and 2”, “3 and 4”, and “5 and 6” must face each other.
5. Pistons and conrods 75

Oil spray jet for piston cooling

1- Apply locking fluid to bolt and tighten to 9 Nm; for locking
fluid refer to ⇒ Electronic parts catalogue .
2- Oil spray jet with spray nozzle valve (opening pressure:
2 ... 2.4 bar)
Caution
Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Always renew bent oil spray jets.
5.2 Removing and installing pistons

♦ Drift - VW 222 A-
♦ Piston ring clamp, commercially available

Removing
• Engine secured to engine and gearbox support - VAS 6095-
⇒ page 30 .
– Remove cylinder head ⇒ page 115 .
– Remove upper section of sump ⇒ page 154 .
– Mark installation position and matching of conrod bearing caps
to cylinder and to conrods for re-installation ⇒ page 75 .
– Unbolt conrod bearing caps.
– Pull out pistons upwards with conrods.
Note
If piston pin is difficult to remove, heat piston to approx. 60 °C.
– Take circlip out of piston pin boss.

– Use drift - VW 222 A- to drive out piston pin.
Installing

Note
– Oil running surfaces of bearing shells.

– Install pistons using piston ring clamp.
Installation position:
• Pistons ⇒ page 75
• Conrods ⇒ page 75
– Install conrod bearing caps according to markings.
– Install sump (upper section) ⇒ page 154 .
– Install cylinder head ⇒ page 115 .
Tightening torques
♦ ⇒ “5.1 Exploded view - pistons and conrods”, page 74
5.3 Checking pistons and cylinder bores

Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.03 mm.
Piston ∅ mm
Nominal dimension 84.49 1)
• 1) Dimensions including coating (thickness approx. 0.02 mm).
The coating will wear down in service.
Measuring cylinder bore

– Use a cylinder gauge - VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore ∅ mm
Nominal dimension 84.51 1)
• 1) Measure at 50 mm into cylinder bore.
5. Pistons and conrods 77

Measuring piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
1st compression ring 0.20 … 0.30 0.80
2nd compression ring 0.50 … 0.70 0.80
Oil scraper ring 0.25 … 0.50 – 1)
• 1) Specification not yet available.
Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring new Wear limit
mm mm
1st compression ring 0.04 … 0.08 0.20
2nd compression ring 0.03 … 0.07 0.20
Oil scraper ring 0.02 … 0.06 0.15
5.4 Checking radial clearance of conrod

bearings
♦ Plastigage
Procedure
Note
– Remove conrod bearing cap.

– Clean bearing cap and bearing journal.
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap and secure with old bolts
⇒ Item 1 (page 74) without rotating crankshaft.
– Remove conrod bearing cap again.
Radial clearance:
• New: 0.010 ... 0.052 mm.

15 – Cylinder head, valve gear

1 Timing chain cover
⇒ “1.1 Exploded view - timing chain cover”, page 79
⇒ “1.2 Removing and installing timing chain cover”, page 82
1.1 Exploded view - timing chain cover
1 - Bolt
2 - Timing chain cover (bottom)
⇒ page 87
3 - Oil seal
❑ For crankshaft (gearbox
end)
4 - Dowel sleeve
❑ 2x
5 - Bolt
6 - Engine oil cooler
⇒ page 159
7 - Gasket
8 - Bolt
9 - Oil pressure switch - F22-
❑ Opening/closing pres‐
sure 2.5 ... 3.2 bar
❑ Grey insulation
❑ Checking in Guided
Fault Finding ⇒ Vehicle diagnostic tester
❑ 20 Nm
10 - Seal
11 - Cylinder head gasket (left-side)
12 - Bolt
1. Timing chain cover 79

13 - Bracket
14 - Timing chain cover (left-side)
15 - Bolt
16 - Bracket
17 - Bracket
❑ For electrical connectors for Lambda probes (left-side)
18 - Bolt
19 - Gasket
20 - Bracket
❑ For electrical connectors for Lambda probes (right-side)
21 - Bolt
22 - Seals
23 - Bolt
24 - Bracket
❑ For electrical connectors
25 - Timing chain cover (right-side)
26 - Bracket
27 - Bolt
28 - Dowel sleeve
❑ 2x
29 - Cylinder head gasket (right-side)
30 - Bolt
31 - Engine speed sender - G28-
32 - Bolt
80 Rep. gr.15 - Cylinder head, valve gear

Timing chain cover (left-side) - tightening torque and sequence
Note

♦ The brackets -arrows A and B- are secured together with the
timing chain cover (left-side).
♦ -Item 8- is a centre hex stud.

1. -1 … 8- 5 Nm
2. -1 … 8- Turn 90° further
Timing chain cover (right-side) - tightening torque and sequence
Note

♦ The brackets -arrows A and B- are secured together with the
timing chain cover (right-side).
♦ -Item 8- is a centre hex stud.

1. -1 … 8- 5 Nm
Timing chain cover (bottom) - tightening torque and tightening

sequence
Note
– Tighten bolts in stages as follows:

1. -arrows- 3 Nm
2. -1 … 9- 3 Nm in diagonal sequence
4. -arrows- 9 Nm
5. -6, 7, 8- 8 Nm
6. -6, 7, 8- Turn 90° further
7. -9- 20 Nm
8. -9- Turn 180° further

1.2 Removing and installing timing chain

cover
⇒ “1.2.1 Removing and installing timing chain cover (left-side)”,
page 82
⇒ “1.2.2 Removing and installing timing chain cover (right-side)”,
page 84
⇒ “1.2.3 Removing and installing timing chain cover (bottom)”,
page 87
1.2.1 Removing and installing timing chain

cover (left-side)
♦ Safety goggles
Removing
Note
Re-install all cable ties in the same locations when installing.

– Unbolt combination valve (left-side) for secondary air system
from cylinder head ⇒ page 327 and place to one side.
– Remove coolant pipe (left-side) ⇒ page 200 .
– Unplug connectors -1- for camshaft control valve 2 - N208- and
for exhaust camshaft control valve 2 - N319- .
Note
Disregard -item 2-.
– Release retainers -arrow-, detach wiring duct -1- towards rear

and press to one side.

– Detach electrical connectors -3, 4- from bracket and place to

one side.
Note
Disregard -items 1, 2, 5-.
– Unscrew bolts -arrows- and detach bracket -1- for electrical

connectors.
– Unscrew bolts -1 ... 8- and detach brackets -arrows A, B-.

– Carefully release timing chain cover (left-side) from bonded
joint, e.g. using a spatula, and detach.
Installing
Note

♦ Renew O-rings after removing.
– Remove old sealant from sealing surfaces.
Caution

WARNING
Risk of eye injury.

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

inder head using rotating plastic brush or similar.

Note
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2

mm).
Caution

– Apply sealant bead -arrow- onto clean sealing surfaces of tim‐

ing chain cover as illustrated.
• Width of sealant bead: 2.5 mm.
Note
The timing chain cover must be installed within 5 minutes after

applying the sealant.
– Fit timing chain cover (left-side) together with brackets

-arrows A and B- and tighten bolts ⇒ page 81 .
note the following:
Note
– Install coolant pipe (left-side) ⇒ page 200 .

– Install combination valve for secondary air ⇒ page 327 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (left-side) - tightening torque and
sequence”“ , page 81

cover (right-side)
♦ Safety goggles

Removing
Note

– Remove Lambda probe - G39- ⇒ page 303 .
air hoses -arrows-.
– Remove nuts -1, 3- and bolt -2-, move secondary air pipe to
side.
– Unbolt combination valve (right-side) for secondary air system
from cylinder head ⇒ page 329 and place to one side.
– Unplug connectors -1- for camshaft control valve - N205- and

exhaust camshaft control valve 1 - N318- .
Note
Disregard -item 2-.
– Detach electrical connectors -1 ... 5- from bracket and place

to one side.

– Move wiring harness clear at timing chain cover (right-side).

– Unscrew bolts -1 ... 8- and detach brackets -arrows A, B-.
– Carefully release timing chain cover (right-side) from bonded
joint, e.g. using a spatula, and detach.
Installing
Note

– Remove old sealant from sealing surfaces.
Caution

WARNING
Risk of eye injury.

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

inder head using rotating plastic brush or similar.
Note

mm).

Caution

– Apply sealant bead -arrow- onto clean sealing surfaces of tim‐

ing chain cover as illustrated.
• Width of sealant bead: 2.5 mm.
Note

– Fit timing chain cover (right-side) together with brackets

-arrows A and B- and tighten bolts ⇒ page 81 .
note the following:
Note
– Install combination valve for secondary air ⇒ page 329 .

– Install Lambda probe - G39- ⇒ page 303
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (right-side) - tightening torque and
♦ ⇒ “4.1 Exploded view - valve gear”, page 126
♦ ⇒ “3.1 Exploded view - secondary air system”, page 323

cover (bottom)
♦ Electric drill with plastic brush attachment
♦ Safety goggles
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 811 , ⇒ Mainte‐
nance ; Booklet 812 or ⇒ Maintenance ; Booklet 818 .
Note


– Remove timing chain covers (left and right) ⇒ page 82 .
– Remove oil filter element ⇒ Maintenance ; Booklet 811 ,
⇒ Maintenance ; Booklet 812 or ⇒ Maintenance ; Booklet
818 .
– Remove engine oil cooler ⇒ page 159 .
– Unplug electrical connector -arrow- at oil pressure switch -
F22- and move wiring clear.
– Unscrew bolts -arrows- and detach bracket -1-.

– Perform the same work steps on the right side of the vehicle.

– Detach connection with crankcase breather hose, move clear
and swivel to side.
Note
Disregard -item 2-.
– Unplug electrical connector -3- at starter (push retainer to the

rear and press down release catch).
– Remove nut -2- for electrical wiring and detach starter.
Note

– Remove bolts -arrows-.

– Slacken bolts -1 ... 9- in diagonal sequence and remove.
– Carefully release timing chain cover (bottom) from bonded
joint and remove cover.
– Press crankshaft oil seal (gearbox end) out of timing chain
cover (bottom).
Installing
Note

♦ Renew seals after removing.
– Pull dowel sleeve at 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.
Caution


WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover (bottom)

-1-, cylinder block and cylinder head using rotating plastic
brush or similar.
– Before installing gearbox, remove residue from threaded holes
for engine/gearbox bolts in cylinder block using a thread tap.
– Clean old sealant from holes -arrow- in cylinder head gaskets.
Note
With the cylinder head installed the holes in the cylinder head
gasket are only half visible.
Caution
Avoid damage to cylinder head gasket.

♦ Only bend the ends of the cylinder head gaskets slightly
and do not kink.
Note
If the cylinder head gasket has been bent and kinked it must be
renewed.
– 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 cylinder head gasket and cylinder
head.
– Clean cylinder head gaskets (top and bottom); they must be
free of oil and grease.

Note

mm).
– 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 -arrows-.
– Use a flat object (e.g. a feeler gauge) to apply sealant to the
area between cylinder head and gasket.
– Clean holes -arrow- in cylinder head gaskets and fill them with
sealant.

Caution

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

of the timing chain cover (bottom) as illustrated.
with sealant.
• The beads of sealant must project 1.5 … 2.0 mm above the
sealing surface.
• Apply sealant -3- in a continuous bead as shown in illustration
(although groove is not continuous).
Note

– Insert seals -arrows- in grooves on timing chain cover (bot‐

tom).
– Fit timing chain cover (bottom), guiding it towards sealing sur‐

face 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.
– Tighten bolts ⇒ page 81 .
note the following:
– Install crankshaft oil seal (gearbox end) ⇒ page 61 .
– Install engine oil cooler ⇒ page 159 .
– Install oil filter element ⇒ Maintenance ; Booklet 811 , ⇒ Main‐
tenance ; Booklet 812 or ⇒ Maintenance ; Booklet 818 .
– Install timing chain covers (left and right) ⇒ page 82 .
Booklet 818 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (bottom) - tightening torque and
tightening sequence”“ , page 81
♦ ⇒ “3.1 Exploded view - crankcase breather system”,
page 162

2 Chain drive
⇒ “2.1 Exploded view - camshaft timing chains”, page 93
⇒ “2.2 Exploded view - drive chain for valve gear”, page 95
⇒ “2.3 Exploded view - drive chain for oil pump”, page 97
⇒ “2.4 Removing camshaft timing chain from camshafts”,
page 97
⇒ “2.5 Removing and installing camshaft timing chain”,
page 107
⇒ “2.6 Removing and installing drive chain for valve gear”,
page 109
⇒ “2.7 Removing and installing drive chain for oil pump”,
page 112
2.1 Exploded view - camshaft timing chains

Camshaft timing chain (left-side)
1 - Bolts
2 - Bearing mounting
❑ For drive chain sprocket
for camshaft timing
chain (left-side)
3 - Bolt
❑ 80 Nm +90°
4 - Camshaft adjuster
❑ For exhaust camshaft
❑ Identification: “EX”
⇒ “2.4 Removing cam‐
shaft timing chain from
camshafts”, page 97
5 - Bolt
❑ 80 Nm +90°
❑ For inlet camshaft
❑ Identification: “IN”
7 - Camshaft timing chain (left-
side)
❑ Mark direction of rota‐
with a paint marker
❑ Removing from camshafts ⇒ page 97
2. Chain drive 93
8 - Bolt
❑ 9 Nm
9 - Slide
10 - Chain tensioner
❑ For camshaft timing chain (left-side)
❑ Removing and installing ⇒ “2.5 Removing and installing camshaft timing chain”, page 107
11 - Bearing plate
12 - Bolt
13 - Drive chain sprocket
❑ For camshaft timing chain (left-side)
Camshaft timing chain (right-side)
1 - Bolt
❑ 80 Nm +90°
❑ For exhaust camshaft
❑ Identification: “EX”
3 - Bolt
for camshaft timing
chain (right-side)
❑ Asymmetric version
❑ Installation position
⇒ page 96
❑ For camshaft timing
chain (right-side)
⇒ page 96
6 - Bolt
❑ 80 Nm +90°
❑ For inlet camshaft
❑ Identification: “IN”
❑ Removing and installing ⇒ “2.4 Removing camshaft timing chain from camshafts”, page 97
8 - Camshaft timing chain (right-side)
❑ Mark direction of rotation for re-installation with a paint marker

❑ Removing from camshafts ⇒ page 97

9 - Thrust washer
❑ For drive chain sprocket for camshaft timing chain (right-side)
❑ Installation position ⇒ page 96
❑ For camshaft timing chain (right-side)
❑ Removing and installing ⇒ “2.5 Removing and installing camshaft timing chain”, page 107
11 - Slide
12 - Bolt
❑ 9 Nm
2.2 Exploded view - drive chain for valve gear
1 - Guide rail
2 - Bolt
❑ 16 Nm
3 - Bolt
❑ 16 Nm
4 - Bolts
❑ 5 Nm +90°
for camshaft timing
chain (left-side)
❑ For camshaft timing
chain (left-side)
7 - Drive chain
❑ For timing drive
with a paint marker
⇒ page 109
8 - Bolt
❑ 8 Nm +45°
9 - Bearing plate
for camshaft timing
chain (left-side)
10 - Chain sprocket for balance
shaft
❑ With balance weight (gearbox end)
2. Chain drive 95
11 - Bolt
❑ 30 Nm +90°
❑ For camshaft timing chain (right-side)
14 - Thrust washer
15 - Seal
❑ Removing and installing ⇒ “2.6 Removing and installing drive chain for valve gear”, page 109
17 - Bolt
❑ 9 Nm
18 - Crankshaft
19 - Bolt
Installation position: bearing mounting for drive sprocket for cam‐

shaft timing chain (right-side)
• Dowel pins in bearing mounting -3- for drive sprocket for cam‐
shaft timing chain (right-side) must engage in drillings in thrust
washer -1- and in cylinder block drillings.
2 - Drive sprocket for camshaft timing chain (right-side)
4 - Bolt

2.3 Exploded view - drive chain for oil pump
1 - Bolt
❑ 30 Nm +90°
❑ For oil pump
❑ Installation position:
Side with lettering faces
gearbox
❑ Can only be installed in
one position
3 - Chain tensioner
❑ With guide rail
4 - Bolt
❑ 20 Nm
5 - Drive chain
❑ For oil pump
with a paint marker
⇒ page 112
2.4 Removing camshaft timing chain from

camshafts
2. Chain drive 97
♦ Locking pin - T40069-
♦ 2x Locking pin - T40071-
♦ 2x Camshaft clamp - T40133-
♦ Socket -T40297-
Removing
Note
♦ In the following procedure the camshaft timing chains remain

on the engine.
♦ Even when working on one cylinder head only, the procedure
must still be carried out on both cylinder banks.
– Remove timing chain covers (left and right) ⇒ page 82 .

– Remove cylinder head cover (left and right) ⇒ page 122 .
noise insulation .


gine.

shaft in direction of engine rotation -arrow- to “TDC”.
Note
♦ Turn the engine until the small notch -1- on the vibration damp‐
er is in line with the joint -2- between the cylinder block and
the retaining frame on the left side (as seen in direction of
travel). This makes it easier to screw in locking pin - T40069-
in a later step.
♦ The marking on the vibration damper is only a visual aid. The
exact “TDC” position can only be obtained by screwing in the
locking pin - T40069- .
• Threaded holes -arrows- in all camshafts must face upwards.
Note
If camshafts are not positioned as described, turn crankshaft one

rotation further and return to TDC position.
2. Chain drive 99
Cylinder bank 1 (right-side):

– Fit camshaft clamp - T40133/1- onto cylinder head -arrows-
and tighten to 25 Nm.
Cylinder bank 2 (left-side):

Continued for both cylinder banks:

– Remove plug -arrow- for crankshaft “TDC” marking from cyl‐
inder block.
– Screw locking pin - T40069- into hole (20 Nm); if necessary,

turn crankshaft -1- backwards and forwards slightly to fully
centralise locking pin.


– Press guide rail of chain tensioner for camshaft timing chain
(right-side) inwards as far as the stop using a screwdriver
-1-. Then lock chain tensioner by inserting locking pin -
T40071- .
Note
The chain tensioner is oil-damped and can therefore only be

compressed slowly by applying constant pressure.
Caution
Risk of damage to camshafts.

♦ Do NOT use camshaft clamp - T40133- to counterhold
when loosening bolt for camshaft adjuster or camshaft
chain sprocket.
– Apply socket -T40297- with ring spanner -2- to counterhold at

corresponding camshaft adjuster.
– Loosen bolt -1- for camshaft adjuster (inlet side).
– Loosen bolt -3- for camshaft adjuster (exhaust side) by coun‐
terholding with socket -T40297- as well.
Caution
Risk of irreparable damage to engine.

♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine.
– Mark position of camshaft adjusters with paint for re-installa‐

tion.
– Unscrew bolts -1 and 2- and detach both camshaft adjusters.
2. Chain drive 101


– Press guide rail of chain tensioner for camshaft timing chain
(left-side) inwards as far as the stop using a screwdriver -1-.
Then lock chain tensioner by inserting locking pin - T40071- .
Note
The chain tensioner is oil-damped and can therefore only be

compressed slowly by applying constant pressure.
Caution
Risk of damage to camshafts.

♦ Do NOT use camshaft clamp - T40133- to counterhold
when loosening bolt for camshaft adjuster or camshaft
chain sprocket.
– Apply socket -T40297- with ring spanner -2- to counterhold at

corresponding camshaft adjuster.
– Loosen bolt -1- for camshaft adjuster (exhaust side).
– Loosen bolt -3- for camshaft adjuster (inlet side) by counter‐
holding with socket -T40297- as well.
Caution

♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine.
– Mark position of camshaft adjusters with paint for re-installa‐

tion.
– Unscrew bolts -1 and 2- and detach both camshaft adjusters.
Installing
Note
Caution
Risk of damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshafts are turned.

• Drive chain for valve gear installed ⇒ page 109

T40069- .
• Camshaft clamp -T40133/1- installed on cylinder bank 1 (right-

side) and tightened to 25 Nm -arrows-.
• Camshaft clamp -T40133/2- installed on cylinder bank 2 (left-
side) and tightened to 25 Nm -arrows-.
Caution
Risk of damage to engine.

♦ The camshaft adjusters MUST be installed as described
in the following work steps:
• Fit camshaft adjusters according to marks applied during re‐

moval.
• Groove -1- or -4- on camshaft adjuster should align with cor‐
responding adjustment window -2- or -3-.
2. Chain drive 103

– Fit camshaft adjusters according to marks applied during re‐

moval.
– Fit timing chain onto drive chain sprocket and camshaft ad‐
justers and fit bolts -1 and 2- without tightening.
• It should just be possible to turn both camshaft adjusters on
the camshaft without axial movement.
– Remove locking pin - T40071- .
Caution
Risk of damage to engine.

♦ The camshaft adjusters MUST be installed as described
in the following work steps:
• Fit camshaft adjusters according to marks applied during re‐

moval.
• Groove -1- or -4- on camshaft adjuster should align with cor‐
responding adjustment window -2- or -3-.
– Fit camshaft adjusters according to marks applied during re‐

moval.
– Fit timing chain onto drive chain sprocket and camshaft ad‐
justers and fit bolts -1 and 2- without tightening.
• It should just be possible to turn both camshaft adjusters on
the camshaft without axial movement.


– Fit socket -T40297- onto camshaft adjuster of exhaust cam‐
shaft.
– Apply torque wrench - V.A.G 1332- with open ring spanner
insert - V.A.G 1332/9- to socket -T40297- .
– Have a second mechanic apply a torque of 40 Nm to camshaft
adjuster in direction of -arrow-.
– Tighten bolts as follows while keeping camshaft adjuster un‐
der tension:
Stage Bolt Tightening torque
1. -1- Tighten on camshaft to 60 Nm
– Remove socket -T40297- .
– Remove camshaft clamp -T40133/1- -arrows-.

– Fit socket -T40297- onto camshaft adjuster of inlet camshaft.
– Apply torque wrench - V.A.G 1332- with open ring spanner
insert - V.A.G 1332/9- to socket -T40297- .
– Have a second mechanic apply a torque of 40 Nm to camshaft
adjuster in direction of -arrow-.
– Tighten bolts as follows while keeping camshaft adjuster un‐
der tension:
– Remove socket -T40297- .
– Remove camshaft clamp -T40133/2- -arrows-.
2. Chain drive 105


– Tighten camshaft adjuster bolts on cylinder head (right-side)
as follows:
2. -1- Tighten on camshaft to final tightening
torque ⇒ page 93
torque ⇒ page 93

– Tighten camshaft adjuster bolts on cylinder head (left-side) as
follows:
torque ⇒ page 93
torque ⇒ page 93
– Using adapter - T40058- and angled ring spanner, turn crank‐

shaft 2 revolutions in normal direction of rotation -arrow- until
crankshaft is at “TDC” again.
Note
If you turn the crankshaft beyond “TDC” by mistake, turn it back

approx. 30° and set to “TDC” again.


– Fit camshaft clamp -T40133/1- on cylinder head and tighten
-arrows-.
• Tightening torque: 25 Nm

– Fit camshaft clamp -T40133/2- on cylinder head and tighten
-arrows-.
• Tightening torque: 25 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.
– Remove camshaft clamps from both cylinder heads.
– Remove locking pin.
note the following:
– Install cylinder head cover ⇒ page 122 .
– Install timing chain covers (left and right) ⇒ page 82 .
Tightening torques
♦ ⇒ “2.1 Exploded view - camshaft timing chains”, page 93
♦ ⇒ Fig. ““Plug for TDC marking - tightening torque”“ , page 65
2.5 Removing and installing camshaft tim‐

ing chain
Removing
– Remove timing chains from camshafts ⇒ page 97 .
2. Chain drive 107

Caution
If a used timing chain rotates in the opposite direction when it

is refitted, this can cause breakage.
♦ Mark running direction of timing chains (left and right) with
paint for re-installation. Do not attempt to mark the timing
chain with a centre punch or by making a notch or similar.
– Remove locking pin - T40071- and detach camshaft timing

chain (left-side).
– Remove bolts -1, 2- and take off chain tensioner (right-side).
– Press guide rail of chain tensioner for drive chain for valve gear
in direction of -arrow- and lock chain tensioner by inserting
locking pin - T40071- .
– Remove bolt -1- securing bearing mounting for drive chain
sprocket.
– Pull off drive sprocket with bearing mounting and lift off cam‐
shaft timing chain (right-side).
Installing
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.
♦ Renew the bolts tightened with specified tightening angle.
Caution
Risk of damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshafts are turned.

– Fit camshaft timing chain (left-side) on drive chain sprocket

according to marks made upon removal and guide chain up‐
wards to cylinder head.
– Press down guide rail of chain tensioner for timing chain (left-
side) and lock chain tensioner by inserting locking pin -
T40071- .
– Fit camshaft timing chain (right-side) on drive chain sprocket

according to marks made upon removal and guide chain up‐
wards to cylinder head.
– Install drive sprocket ⇒ page 96 .
– Tighten bolt -1- securing bearing mounting for drive chain
sprocket.
Note
Disregard -arrow-.
– Fit chain tensioner on cylinder head (right-side).

– Tighten bolts -1- and -2-.
note the following:
– Fit timing chains on camshafts ⇒ page 102 .
Tightening torques
♦ ⇒ “2.1 Exploded view - camshaft timing chains”, page 93
2.6 Removing and installing drive chain for

valve gear
2. Chain drive 109

Removing
– Remove timing chains ⇒ page 107 .
– Remove bolts -1, 2- and take off chain tensioner (left-side).
– Remove drive chain for oil pump ⇒ page 112 .
Caution
If a used drive chain rotates in the opposite direction when it is

refitted, this can cause breakage.
♦ Mark running direction of drive chain with coloured arrows
for re-installation.
– Unscrew bolts -1- and remove guide rail.

– Remove bolts -2- and take off chain tensioner.
– Detach drive chain for valve gear.
Installing
Note


T40069- .
– Lock balance shaft sprocket in “TDC” position by inserting lo‐

cating pin -T40116- in adjustment window -arrow- of sprocket.
– Position drive chain for valve gear onto drive chain sprockets
(according to marks applied during removal).
– Install guide rail and tighten bolts -1-.

– Install chain tensioner and tighten bolts -2-.
• Locating pin -T40116- must be positioned in approximate cen‐

tre of adjustment window -arrow- in balance shaft sprocket.
• Locating pin must NOT make contact on left or right side. If
necessary, adjust drive chain by one tooth.
– Install drive chain for auxiliary drives ⇒ page 112 .
– Install camshaft timing chains ⇒ page 107 .
Tightening torques
♦ ⇒ “2.2 Exploded view - drive chain for valve gear”, page 95
2. Chain drive 111

2.7 Removing and installing drive chain for

oil pump
♦ Locking pin - T40071-
Removing
– Use pliers to press down chain tensioner spring -arrows- and
lock in place by inserting locking pin - T40071- .
Caution
If a used drive chain rotates in the opposite direction when it is

refitted, this can cause breakage.
♦ Mark running direction of drive chain with paint for re-in‐
stallation. Do not attempt to mark the drive chain with a
centre punch or by making a notch or similar.
– Remove bolt -1- and take off chain tensioner.
– Counterhold chain sprocket with a screwdriver -2- and remove

bolt -1-.
– Detach drive chain with chain sprocket.
Installing
Tightening torques
♦ ⇒ “2.3 Exploded view - drive chain for oil pump”, page 97

3 Cylinder head
⇒ “3.1 Exploded view - cylinder head”, page 113
⇒ “3.2 Removing and installing cylinder head”, page 115
⇒ “3.3 Removing and installing cylinder head cover”, page 122
⇒ “3.4 Checking compression”, page 124
3.1 Exploded view - cylinder head
Note
Illustration shows the cylinder head for cylinder bank 2 (left-side) as an example.
1 - Cylinder head gasket

❑ Renewing
stalling cylinder head”,
page 115
❑ Installation position:
part number must face
cylinder head
❑ If renewed, change
coolant and engine oil
2 - Cylinder head
⇒ page 115
❑ Checking for distortion
⇒ page 115
❑ Machining limit
⇒ page 115
❑ If renewed, change
coolant and engine oil
3 - Bolt
❑ Note correct sequence
when loosening
⇒ page 117
4 - Gasket
❑ For cylinder head cover
❑ Renew if damaged or
leaking
5 - Cylinder head cover
⇒ page 122
6 - Filler cap
7 - Seal
❑ Renew if damaged or leaking
8 - Bolt
❑ Renew if seal is damaged
❑ Tightening torque and sequence:
3. Cylinder head 113

♦ ⇒ Fig. ““Cylinder head cover (left-side) - tightening torque and sequence”“ , page 114
♦ ⇒ Fig. ““Cylinder head cover (right-side) - tightening torque and sequence”“ , page 114
9 - Bolt
Cylinder head cover (left-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 12- to 9 Nm.
Cylinder head cover (right-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 12- to 9 Nm.
Cylinder head - tightening torque and sequence
Note

1. -1 … 8- Screw in by hand until contact is made
2. -1 … 8- 40 Nm

Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Maximum distortion: 0.05 mm
Cylinder head machining limit

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

⇒ “3.2.1 Removing and installing cylinder head, bank 1 (right-
side)”, page 115
⇒ “3.2.2 Removing cylinder head, bank 2 (left-side)”, page 117
⇒ “3.2.3 Installing cylinder head”, page 120
3.2.1 Removing and installing cylinder head,

bank 1 (right-side)
♦ Socket XZN M12 (at least 75 mm), commercially available
♦ Engine bung set - VAS 6122-
Procedure
• Engine in vehicle.
Note

– Remove coolant pipe (front right) ⇒ page 198 .

– Remove coolant pipe (top) ⇒ page 201 .
WARNING


– Remove camshafts (right-side) ⇒ page 131 .
– Unplug electrical connectors -arrows- at injectors.

– Unplug electrical connector -1- at temperature sender for en‐
gine temperature regulation - G694- .
– Remove bolts -1, 2- and take chain tensioner off cylinder head.
Note
Locking pin - T40071- remains in place.

– Unscrew bolts -arrows- and detach bracket -1-.
– Remove bolts -arrows- at rear of cylinder head.
– Slacken cylinder head bolts in the sequence -1 ... 8-.

– Unscrew bolts, detach cylinder head and set it down on a soft
surface (foam plastic).
3.2.2 Removing cylinder head, bank 2 (left-

side)
♦ Socket XZN M12 (at least 75 mm), commercially available

Procedure
• Engine in vehicle.
Note
– Remove fuel line for MPI injection system ⇒ page 280 .

– Remove camshafts (left-side) ⇒ page 131 .
– Remove coolant pipe (front left) ⇒ page 195 .
– Unplug electrical connectors -1, 3- at injectors.
– Unplug electrical connector -4- at fuel pressure sender -
G247- .
WARNING

– Remove union nut -2-.
Note
Electrical connector -5- is unplugged in a later step.
• If connection -arrow- has been unfastened or unbolted, it must

be renewed.

– Remove bolts -1, 2- and take chain tensioner off cylinder head.
Note
Locking pin - T40071- remains in place.
– Move electrical wiring clear.

– Remove bolt -arrow- and pull out guide tube for oil dipstick.
– Remove bolts -arrows- at rear of cylinder head.
– Slacken cylinder head bolts in the sequence -1 ... 8-.

– Remove bolts, detach cylinder head and unplug electrical con‐
nector for injector for cylinder 4.
– Place cylinder head onto soft surface (foam plastic).

3.2.3 Installing cylinder head

Procedure
Caution
Risk of damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Risk of damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Risk of leaks at cylinder head gasket.
♦ Carefully remove any sealant residue 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 ma‐
terial.
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Risk of damage to open valves.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Risk of damage to valves and piston crowns after working on
valve gear.
♦ Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐
erated.
Note

♦ Renew self-locking nuts, seals, gaskets and O-rings after re‐
moval.
♦ When installing an exchange cylinder head, the contact sur‐
faces between the hydraulic compensation elements, roller
rocker fingers and cams must be oiled before installing the
cylinder head cover.
♦ After renewing the cylinder head or cylinder head gasket,
change the coolant and engine oil.


be renewed.
• Camshafts on cylinder head (right-side) locked in “TDC” posi‐

tion -arrows- with camshaft clamp - T40133/1- (25 Nm)
• The camshaft clamp - T40133/1- is positioned correctly if the
holes for the cylinder head bolts remain free.
• Camshafts on cylinder head (left-side) locked in “TDC” posi‐

tion -arrows- with camshaft clamp - T40133/2- (25 Nm)
• The camshaft clamp - T40133/2- is positioned correctly if the
holes for the cylinder head bolts remain free.

T40069- .

– Fit new seals for coolant pipe (front).

– Place cylinder head gasket in position.
• Installation position: the word “oben” (top) or the Part No.
should be visible.
• Pay attention to dowel sleeves -arrows- in cylinder block.
– Fit cylinder head.
– Tighten cylinder head bolts ⇒ page 114 .
– Tighten bolts -arrows-.
Note
Cylinder head bolts do not have to be torqued down again later

after repair work.

note the following:
– Install camshafts ⇒ page 131 .
– Install coolant pipe (front left) ⇒ page 195 .
– Install fuel line for MPI injection system ⇒ page 280 .
– Install coolant pipe (front right) ⇒ page 198 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Change engine oil ⇒ Maintenance ; Booklet 811 , ⇒ Mainte‐
– Fill cooling system with fresh coolant ⇒ page 176 .
Tightening torques
♦ ⇒ Fig. ““Cylinder head - tightening torque and sequence”“ ,
page 114
♦ ⇒ Fig. ““Guide tube for oil dipstick - tightening torque”“ ,
page 152
3.3 Removing and installing cylinder head

cover
Removing
– Remove ignition coils ⇒ page 338 .


– Move fuel hose clear at cylinder head cover.
– Unscrew bolts in the sequence -12 ... 1- and remove cylinder
head cover.
Note
The crankcase breather hose -arrow- cannot be disconnected

from the cylinder head cover without being damaged irreparably.
– Remove bolts in the sequence -12 ... 1-.

– Move cylinder head cover to one side with crankcase breather
hose -arrow- connected.
If cylinder head cover is being removed:

– Remove throttle valve module - J338- ⇒ page 278 .
– Remove bolt -1-, detach connection with crankcase breather
hose and move clear.
– Detach cylinder head cover.
Note
Disregard -item 2-.
Installing
Note
♦ Renew O-ring after removal.

♦ Renew gasket for cylinder head cover if damaged.
♦ Renew cylinder head cover bolts if gasket is damaged.

– Install throttle valve module - J338- ⇒ page 278 .
– Install ignition coils ⇒ page 338 .
Tightening torques
♦ ⇒ Fig. ““Cylinder head cover (left-side) - tightening torque and
♦ ⇒ Fig. ““Cylinder head cover (right-side) - tightening torque
and sequence”“ , page 114

3.4 Checking compression

♦ Vehicle diagnostic tester
♦ Spark plug socket and extension - 3122 B-
♦ Compression tester - V.A.G 1763-
Procedure
• Engine oil temperature at least 30 ℃
• Battery voltage at least 12.5 V
– Remove ignition coils ⇒ page 338 .

– Unplug electrical connectors -4, 5- for injectors at rear of cyl‐

inder head (left and right).
Note
Disregard -items 1, 2, 3-.
– Remove spark plugs with spark plug socket and extension -

3122 B- .
– Check compression pressure with 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 at the same time operate the starter until the
pressure on the tester display no longer increases.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 11.0 … 14.0
Wear limit 10.0
Maximum difference between cylinders 3.0
– Install spark plugs ⇒ Maintenance ; Booklet 811 , ⇒ Mainte‐
– Install ignition coils ⇒ page 338 .
– Erase any entries in event memory resulting from testing:
• Vehicle diagnostic tester must be connected.
– Selecting operating mode.
– Using Go To button and “Function/component selection” func‐
tion, select the following in succession from tree:
♦ Power train
♦ 01 - Self-diagnosis compatible systems
♦ Simos injection and ignition system
♦ Functions
♦ Readiness code

4 Valve gear
⇒ “4.1 Exploded view - valve gear”, page 126
⇒ “4.2 Measuring axial clearance of camshaft”, page 129
⇒ “4.3 Measuring radial clearance of camshaft”, page 130
⇒ “4.4 Removing and installing camshaft”, page 131
⇒ “4.5 Removing and installing camshaft control valves”,
page 137
⇒ “4.6 Checking hydraulic valve compensation elements”,
page 138
⇒ “4.7 Removing and installing valve stem oil seals”, page 140
4.1 Exploded view - 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.
♦ Illustration shows the cylinder head for cylinder bank 2 (left-side) as an example.

1 - Exhaust valve
❑ Must not be machined;
only grinding-in is per‐
missible
❑ Valve dimensions
⇒ page 148
❑ Checking valve guides
⇒ page 147
2 - Sealing plug
❑ Apply sealant when in‐
stalling; refer to ⇒ Elec‐
tronic parts catalogue
3 - Cylinder head
❑ Checking valve guides
⇒ page 147
4 - Valve stem oil seal
⇒ page 140
5 - Valve spring
⇒ page 128
6 - Valve spring plate
7 - Valve cotters
8 - Hydraulic valve compensa‐
tion element
❑ Clipped into roller rocker
finger -item 8-
❑ Lubricate contact surface before installing
9 - Securing clip
❑ Not supplied separately
❑ Check for firm attachment
10 - Roller rocker finger
❑ Mark installation position for re-installation
❑ Check roller bearings for ease of movement
❑ Lubricate contact surface before installing
❑ Assembly: attach to hydraulic compensation element -item 5- using securing clip -item 9-
11 - Bolt
12 - Retaining frame
❑ With integrated camshaft bearings
❑ Removing and installing ⇒ “4.4 Removing and installing camshaft”, page 131
13 - Bolt
❑ 5 Nm
4. Valve gear 127

14 - Camshaft control valve 2 - N208-

❑ Cylinder bank 1 (right-side): camshaft control valve 1 - N205-
15 - O-ring
16 - Bolt
❑ 5 Nm
17 - Exhaust camshaft control valve 2 - N319-
❑ Cylinder bank 1 (right-side): exhaust camshaft control valve 1 - N318-
18 - O-ring
19 - Compression ring
20 - Inlet camshaft
❑ Measuring axial clearance ⇒ page 129
❑ Runout: max. 0.04 mm
21 - Rectangular section seals
❑ One or two installed (depending on version); for allocation refer to ⇒ Electronic parts catalogue
22 - Exhaust camshaft
❑ Measuring axial clearance ⇒ page 129
❑ Runout: max. 0.04 mm
23 - Banjo bolt
❑ With valve
❑ 25 Nm
24 - Oil pipe
25 - Inlet valve
❑ Must not be machined; only grinding-in is permissible
❑ Mark installation position for re-installation
❑ Valve dimensions ⇒ page 148
❑ Checking valve guides ⇒ page 147
Installation position of valve spring

• Closely spaced spring coils -arrow- face towards cylinder
head.

Retaining frame for camshafts of cylinder head, bank 1 (right-

side) - tightening torque and sequence
Note

1. -1 … 19- Screw in by hand until they make con‐
tact.
• The retaining frame should make
contact with the cylinder head over
the full surface
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further
Retaining frame for camshafts of cylinder head, bank 2 (left-side)

- tightening torque and sequence
Note

1. -1 … 21- Screw in by hand until they make con‐
tact.
• The retaining frame should make
contact with the cylinder head over
the full surface
2. -1 … 21- 8 Nm
3. -1 … 21- Turn 90° further
4.2 Measuring axial clearance of camshaft

4. Valve gear 129

Procedure
– Remove camshafts ⇒ page 131 .
– Mark allocation of roller rocker fingers for re-installation.
– Carefully remove roller rocker fingers and place them on a
clean surface.
– Re-insert camshafts, install retaining frame ⇒ page 129 or
⇒ page 129 and tighten with old bolts to 8 Nm (do not turn
further).
– Secure universal dial gauge bracket - VW 387- with dial gauge
- VAS 6079- to cylinder head as shown in illustration.
– 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
4.3 Measuring radial clearance of camshaft

♦ Plastigage
Procedure
Note

– Mark allocation of roller rocker fingers for re-installation.
– Carefully remove roller rocker fingers and place them on a
clean surface.
– Clean bearings and bearing journals.
bearing on the bearing journal or bearing shell to be measured.
• The Plastigage must be positioned in the centre of the bearing.
– Re-insert camshafts, fit retaining frame and secure with old
bolts without rotating camshafts ⇒ page 129 or ⇒ page 129 .
– Remove retaining frame and camshafts again.
Radial clearance:

• 24 mm bearing diameter: 0.024 ... 0.066 mm

• 36 mm bearing diameter: 0.032 ... 0.078 mm
4.4 Removing and installing camshaft

♦ Impact extractor attachment -T10133/3- from tool set for FSI
engines - T10133 C-

♦ Safety goggles
Removing
– Remove timing chains from camshafts ⇒ page 97 .
– Remove high-pressure pump ⇒ page 296 .
– Unplug electrical connector -2- at Hall sender - G40- .
– Remove bolts -arrows- and detach housing -1- for high-pres‐
sure pump.
4. Valve gear 131

– Remove bolt -4- for earth connection.

– Unplug electrical connectors on cylinder head:
1 - For camshaft control valve 1 - N205- / exhaust camshaft con‐
trol valve 1 - N318-
5 - For Hall sender 3 - G300-
– Move electrical wiring harness clear to side.
Note

– Remove vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vac‐
uum system; Removing and installing vacuum pump .
– Remove bolt -5- for earth connection.
– Unplug electrical connectors on cylinder head:
3 - For camshaft control valve 2 - N208- / exhaust camshaft con‐
trol valve 2 - N319-
– Move electrical wiring harness clear to side.
Note
Disregard -item 2-.
Both sides (continued):

– Remove corresponding intake manifold (bottom section)
⇒ page 274 .
– Remove bolts -arrows- and detach corresponding camshaft
control valves.

Note
For better access, loosen high-pressure pipe at fuel rail and

bracket (leave high-pressure pipe in installation position).
– Slacken retaining frame bolts in the sequence -19 ... 1-.

– Remove bolts, carefully release retaining frame from bonded
joint and set it down with camshafts on a soft surface on work‐
bench.
– Remove camshaft clamp - T40133/1- -arrows-.

– Mark camshafts, remove and place on a clean surface.

– Slacken retaining frame bolts in the sequence -21 ... 1-.
– Remove bolts, carefully release retaining frame from bonded
joint and set it down with camshafts on a soft surface on work‐
bench.
4. Valve gear 133

– Remove camshaft clamp - T40133/2- -arrows-.
Installing
Note
Renew seals and sealing plugs after removing.

T40069- .
• Hydraulic compensation elements and roller rocker fingers in‐
stalled.
Caution
Protect lubrication system and bearings against contamina‐

tion.
WARNING
Risk of eye injury.

– Remove remaining sealant from cylinder head and retaining

frame -1- using rotating plastic brush or similar.
– Oil running surfaces of both camshafts.

– Fit camshafts in retaining frame.

• Camshafts must be in correct position in axial bearings
-arrows- in retaining frame.
• The ends of the rectangular section seals -1, 2, 3- must point
up or down. The ends of the rectangular section seals must
never point to the side.
Note
One or two rectangular section seals are installed on the exhaust

camshaft -2 and/or 3- (depending on version); for allocation refer
to ⇒ Electronic parts catalogue .
– Turn retaining frame over with camshafts fitted, holding cam‐

shafts firmly in position.
– Turn camshafts until threaded holes -arrows- point upwards.

– Check that camshafts are still in correct position in axial bear‐
ings in retaining frame.


4. Valve gear 135

Note

mm).
– Turn retaining frame upside down again.
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
♦ The beads of sealant must not be thicker than specified.
– Apply beads of sealant -4 ... 8- onto clean sealing surfaces of

retaining frame as shown in illustration.
• Width of sealant beads: 2.0 mm.
– Apply beads of sealant -1 ... 3- onto clean sealing surfaces of
retaining frame as shown in illustration.
• Width of sealant beads: 2.5 mm.
Note
The retaining frame must be installed within 5 minutes after ap‐

plying the sealant.
– Fit retaining frame onto cylinder head.

– Insert locating pins -T40116- in retaining frame and cylinder
head.
– Tighten bolts securing retaining frame for camshafts.
Note
After installing the retaining frame, wait about 30 minutes for the
sealant to dry.

– Clean bore for outer sealing plug in cylinder head (left and
right); 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.
– Use impact extractor attachment -T40116- to pull out locating

pins -T10133/3- .
note the following:
– Install intake manifold (bottom section) ⇒ page 274 .
– Install housing for high-pressure pump drive and high-pres‐
sure pump ⇒ page 296 .
– Install vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vacuum
system; Removing and installing vacuum pump .
– Fit timing chains on camshafts ⇒ page 102 .
Caution

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
erated.
Tightening torques
♦ ⇒ Fig. ““Retaining frame for camshafts of cylinder head, bank
1 (right-side) - tightening torque and sequence”“ , page 129
♦ ⇒ Fig. ““Retaining frame for camshafts of cylinder head, bank
2 (left-side) - tightening torque and sequence”“ , page 129
4.5 Removing and installing camshaft con‐

trol valves
Removing
4. Valve gear 137


clear at air pipe.
-arrows-.

– Unplug relevant electrical connector -1-.
– Unscrew bolt -2- and detach valve.
Installing
Note


Tightening torques
♦ ⇒ “2.2 Exploded view - hose connections for charge air sys‐
tem”, page 253
4.6 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 run until radiator fan has started up once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
– If the compensation elements are still noisy, locate the defec‐
tive compensation element as follows:
– Remove cylinder head cover ⇒ page 122 .
noise insulation .
gine.

shaft in direction of engine rotation -arrow-.
– Press roller rocker finger down -arrow- to determine clearance

between cam and roller rocker finger.
– If it is possible to insert a feeler gauge of 0.20 mm between
cam and roller rocker finger, renew hydraulic compensation
element
⇒ “4.4 Removing and installing camshaft”, page 131 .
Additional steps required
– Install cylinder head cover ⇒ page 122 .
Tightening torques
4. Valve gear 139

4.7 Removing and installing valve stem oil

seals
⇒ “4.7.1 Removing and installing valve stem oil seals (cylinder
head installed)”, page 140
⇒ “4.7.2 Removing and installing valve stem oil seals (cylinder
head removed)”, page 143
4.7.1 Removing and installing valve stem oil seals (cylinder head installed)

equipment required
♦ Spark plug socket and ex‐
tension - 3122 B-
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Removal and installation
device for valve cotters -
VAS 5161 A- with guide
plate -VAS 5161/19C- , or
substitute -VAS 5161/19B-
♦ Adapters - T40012-
Procedure
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Remove spark plugs with spark plug socket and extension -
3122 B- .
– Set piston of appropriate cylinder to “bottom dead centre”.

– Apply drift -VAS 5161/3A- to valve spring plate and use plastic-
headed hammer to release sticking valve cotters.
– Fit guide plate -VAS 5161/19C- from removal and installation

device for valve cotters - VAS 5161 A- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw adapter - T40012/1- with seal hand-tight into the cor‐
responding spark plug thread.
– Connect adapter to compressed air line using a commercially
available connection piece, and apply constant air pressure.
• Minimum pressure: 6 bar
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw 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 pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
• The compressed air hose remains connected.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
4. Valve gear 141

If the valve stem seal puller - 3364- cannot be used on some of

the valve stem oil seals due to the confined space, proceed as
follows:
– Knock out pin -arrow- of puller using a drift and remove impact
extractor attachment.
– Apply bottom section of puller -3364- to valve stem oil seal.

– Secure puller with a punch or roll-pin drift -1-, as shown in il‐
lustration.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.

– Insert valve spring and valve spring plate.

• The closely spaced spring coils -arrow- face the cylinder head.
– Secure guide plate -VAS 5161/19C- back onto cylinder head.

– Insert assembly cartridge in guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install spark plugs ⇒ Maintenance ; Booklet 811 , ⇒ Mainte‐
Caution

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
erated.
4.7.2 Removing and installing valve stem oil seals (cylinder head removed)
4. Valve gear 143


equipment required
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Removal and installation
device for valve cotters -
VAS 5161 A- with guide
plate -VAS 5161/19C- , or
substitute -VAS 5161/19B-
♦ Engine and gearbox sup‐
port - VAS 6095-
♦ Cylinder head tensioning
device - VAS 6419-
Procedure
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
shown in illustration.
– 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.

– Apply drift -VAS 5161/3A- to valve spring plate and use plastic-
headed hammer to release sticking valve cotters.
– Fit guide plate -VAS 5161/19C- onto cylinder head.

– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw 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 pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
4. Valve gear 145

Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert valve spring and valve spring plate.

• The closely spaced spring coils -arrow- face the cylinder head.
– Secure guide plate -VAS 5161/19C- back onto cylinder head.

– Insert assembly cartridge in guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.

5 Inlet and exhaust valves

⇒ “5.1 Checking valve guides”, page 147
⇒ “5.2 Checking valves”, page 148
⇒ “5.3 Valve dimensions”, page 148
5.1 Checking valve guides

Procedure
Note
♦ If the valve has to be renewed as part of a repair, use a new

valve for the measurement.
♦ Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.
5. Inlet and exhaust valves 147

– Secure dial gauge - VAS 6079- to cylinder head with universal

dial gauge bracket - VW 387- as shown in illustration.
– Insert valve into guide.
• End of valve stem must be flush with valve guide.
– Measure the amount of sideways play.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be renewed.
5.2 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.
– Renew valve if scoring is clearly visible.
5.3 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 ± 0.10
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.00 ± 0.20 101.9 ± 0.20
α ∠° 45 45
WARNING
Care must be taken when disposing of old sodium-cooled ex‐

haust valves - risk of injury.
♦ 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.
♦ Then throw a maximum of ten valves into a bucket of water
and step away immediately.
♦ A sudden chemical reaction will occur upon contact with
water in which the sodium filling burns.
♦ After performing these steps the valves can be disposed
of in the normal way.

17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 149
⇒ “1.2 Engine oil”, page 152
⇒ “1.3 Removing and installing sump (bottom section)”,
page 152
⇒ “1.4 Removing and installing sump (top section)”, page 154
⇒ “1.5 Removing and installing oil pump”, page 157
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 158
1.1 Exploded view - sump/oil pump
Note
♦ If large quantities of metal shavings or abrasion are found when performing engine repairs, this may be an
indication of damage to the crankshaft or conrod bearings. To prevent further damage, the following steps
are required after completion of repair work: clean the oil passages carefully and renew the oil spray jets,
engine oil cooler and oil filter.
♦ Refer to ⇒ Maintenance tables for engine oil capacity, oil specifications and viscosity grades.
♦ Oil spray jet for piston cooling ⇒ page 76 .
1. Sump/oil pump 149

1 - Oil level and oil temperature

sender - G266-
⇒ page 158
2 - Seal
3 - Bolt
4 - Sump (bottom section)
⇒ page 152
5 - Bolt
❑ 9 Nm
6 - Baffle plate (bottom)
7 - Bolt
8 - Sump (top section)
⇒ page 154
9 - Dowel sleeve
❑ 2x
10 - Baffle plate (top)
11 - Bolt
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts catalogue
❑ 3 Nm +90°
12 - Seal
❑ Insert in retaining frame
13 - Oil pump drive shaft
14 - O-ring
15 - Sleeve
❑ 2x
16 - Bearing bracket
17 - Bolt
❑ 9 Nm
18 - Chain sprocket for oil pump
❑ Can only be fitted in one position on drive shaft
19 - Bolt
❑ 3 Nm +90°
150 Rep. gr.17 - Lubrication

20 - O-ring
21 - Seal
22 - Oil pump
❑ Do not dismantle
23 - Bolt
❑ 20 Nm
24 - O-ring
25 - Bolt
❑ 9 Nm
26 - Intake connecting pipe
❑ For oil pump
27 - Seal
28 - Oil drain plug
❑ 30 Nm
29 - Nut
❑ 9 Nm
Sump (bottom section) - tightening torque and sequence
Note
Renew the bolts tightened with specified tightening angle.

Stage Tightening torque/angle specification
1. 8 Nm in diagonal sequence
2. Turn 90° further in diagonal sequence

Sump (top section) - tightening torque and sequence

– Tighten bolts -1 ... 6- in diagonal sequence and in stages to
20 Nm:
Guide tube for oil dipstick - tightening torque

– Tighten bolt -arrow- to 9 Nm.
1.2 Engine oil

Refer to ⇒ Maintenance tables for engine oil capacity, oil speci‐
fications and viscosity grades.
Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the “MAX” mark on the
dipstick.
1.3 Removing and installing sump (bottom

section)
♦ Safety goggles
Removing

– Unplug electrical connector -1- at oil level and oil temperature

sender - G266- and move electrical wiring clear.
Caution
Take care to keep components clean.

♦ There will still be some oil in the sump (bottom section).
– Loosen bolts for sump (bottom section) -2- in diagonal se‐

quence and remove bolts.
– Release sump (bottom section) from bonded joint e.g. with a
spatula, taking care not to bend sump.
Installing
Note

♦ The sump (bottom section) must be renewed if its coating is
damaged or if it is bent.
Caution

tion.
WARNING
Risk of eye injury.

– Remove sealant residue from sump (top and bottom sections)

-1- using rotating plastic brush or similar.
Note

mm).

Caution

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

sump (bottom section) as shown in illustration.
• Width of sealant bead: approx. 1.5 mm.
Note
The sump (bottom section) must be installed within 5 minutes af‐

ter applying the sealant.
– Fit sump (bottom section) -2-, tighten bolts ⇒ page 151 and
attach electrical connector -1-.
note the following:
Booklet 818 .
Tightening torques
♦ ⇒ Fig. ““Sump (bottom section) - tightening torque and se‐
1.4 Removing and installing sump (top sec‐

tion)
♦ Safety goggles
Removing
• Engine secured to engine and gearbox support ⇒ page 30 .
– Remove oil pump ⇒ page 157 .

– Unplug electrical connector -2-.
– Slacken bolts -1 ... 6- for sump (top section) in diagonal se‐

quence and remove.
– Carefully release sump (top section) from bonded joint and pry
sump off dowel pins on cylinder block.
Installing
Note
Renew seal and O-ring after removal.

Caution

tion.
– Remove old sealant from grooves on sump (top section) and

from sealing surface.
WARNING
Risk of eye injury.

– Remove remaining sealant from sump (top section) -1- and

cylinder block using rotating plastic brush or similar.
Note
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5

mm).
Caution

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

sump (top section) as shown in illustration.
• The grooves on the sealing surfaces must be completely filled
with sealant.
• The bead of sealant must project 1.5 … 2.0 mm above the
sealing surface.
Note
The sump (top section) must be installed within 5 minutes after


– Fit seal -1- into retaining frame.
Note
Disregard -item 2-.
– Check that dowel sleeves are fitted, fit sump (top section) and
tighten bolts ⇒ page 152 .
note the following:
– Install oil pump ⇒ page 157 .
Tightening torques
♦ ⇒ “1.1 Exploded view - sump/oil pump”, page 149
♦ ⇒ Fig. ““Sump (top section) - tightening torque and se‐
1.5 Removing and installing oil pump

Removing
– Remove sump (bottom section) ⇒ page 152 .
– Remove bolts -arrows- and detach baffle plate.

– Using pliers -2-, press drive shaft -1- back against spring pres‐
sure and detach oil pump -3-.
Note
Oil pump drive shaft remains in position.
Installing
Note
Renew O-rings.
– Install sump (bottom section) ⇒ page 152 .

Booklet 818 .
Tightening torques
1.6 Removing and installing oil level and oil

temperature sender - G266-
Removing
– Remove nuts -1- and detach oil level and oil temperature
sender - G266- -item 3-.
Installing
Note
Renew seal -4- after removing.

Booklet 818 .
Tightening torques

2 Engine oil cooler

⇒ “2.1 Exploded view - engine oil cooler”, page 159
⇒ “2.2 Removing and installing engine oil cooler”, page 159
2.1 Exploded view - engine oil cooler

❑ With oil cooler bypass
valve
❑ See note ⇒ page 149
⇒ page 159
2 - Bracket
3 - Bolt
❑ 3 Nm +90°
4 - Coolant hose
5 - Timing chain cover (bottom)
6 - Gasket
7 - Coolant pipe (top)
⇒ page 201
8 - Bolt
9 - Bolt
❑ 3 Nm +90°
2.2 Removing and installing engine oil cool‐

er
2. Engine oil cooler 159

♦ Hose clip pliers - VAS 6362-
Removing
– Drain coolant ⇒ page 176 .
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum
chamber partition panel .
– Unplug electrical connector -2- and move wiring harness clear.
– Release fastener -arrow-, detach coolant circulation pump -
V50- and move it to one side.
Note
Disregard -item 1-.
– Release retainers -arrow-, detach wiring duct -1- towards rear

and push it upwards.
– Move electrical wiring and hoses to side.
– Loosen secondary air pipe and press to one side.

– Release hose clip -2- and detach coolant hose.

– Unscrew bolts -3- and -arrows- and detach engine oil cooler
-1- to left side.
Installing
Note

♦ Renew gasket after removing.
♦ Do not reuse coolant.

Tightening torques
♦ ⇒ “2.1 Exploded view - engine oil cooler”, page 159
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead;
Exploded view - plenum chamber partition panel
2. Engine oil cooler 161

3 Crankcase breather
⇒ “3.1 Exploded view - crankcase breather system”, page 162
⇒ “3.2 Removing and installing oil separator”, page 163
⇒ “3.3 Removing and installing hose for crankcase breather sys‐
tem”, page 164
3.1 Exploded view - crankcase breather system
1 - Gasket
2 - Oil separator with cover
❑ With connection for
crankcase breather
⇒ page 163
3 - Bolt
❑ 9 Nm
4 - O-ring
❑ 2x on USA versions
5 - Connection
❑ For crankcase breather
⇒ page 163
6 - O-ring
❑ 2x on USA versions
7 - Bolt
❑ 9 Nm
8 - O-ring
9 - Crankcase breather hoses
❑ To cylinder head covers
⇒ page 164
10 - Bolt
❑ 2.5 Nm
11 - O-ring
12 - Crankcase breather hose
❑ To air pipe
13 - Hose clip
14 - Bolt
❑ 2.5 Nm
15 - Bracket

Installing connection for crankcase breather

– Insert connection -1- for crankcase breather with new O-rings
in cover for oil separator.
• Installation position: lug -2- must engage in guide -arrow-.
3.2 Removing and installing oil separator

Removing
– Remove coolant pipe (top) ⇒ page 201 .
– Remove fuel pressure sender - G247- ⇒ page 292 .
– Unscrew connection -arrow- (left and right).

– Detach connection with crankcase breather hose.
Note
♦ The illustration shows the installation position with the super‐

charger installed.
♦ Disregard -item 2-.
3. Crankcase breather 163

– Remove bolts -2- and -arrows-.

– Detach bracket -3-.
– Push electrical wiring and vacuum hoses to one side and de‐
tach oil separator with cover -1-.
Installing
Note
Renew gasket after removing.
• Renew connection -arrow-.

– Install fuel pressure sender - G247- ⇒ page 292 .
– Install coolant pipe (top) ⇒ page 201 .
Tightening torques
page 162
3.3 Removing and installing hose for crank‐

case breather system
Removing
Note

♦ Crankcase breather hose cannot be detached from cylinder
head cover (left-side) without being irreparably damaged. Al‐
ways renew hose after removal.

– Release fasteners -arrow- and detach wiring duct -1- towards
rear.

– Detach crankcase breather hose -2- from cylinder head cov‐

ers.
– Move crankcase breather hose clear.
– Remove bolt -1- and detach connection with crankcase
breather hose.
Installing
Note
Renew O-rings after removing.

Tightening torques
page 162
3. Crankcase breather 165

4 Oil filter/oil pressure switches

⇒ “4.1 Exploded view - oil filter”, page 166
⇒ “4.2 Exploded view - oil pressure switches/oil pressure control”,
page 167
⇒ “4.3 Removing and installing oil pressure switch F22 ”,
page 167
⇒ “4.4 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 168
⇒ “4.5 Checking oil pressure”, page 169
⇒ “4.6 Removing and installing valve for oil pressure control N428
”, page 170
4.1 Exploded view - oil filter
1 - Oil filter housing

❑ With filter bypass valve
❑ With oil drain valve
❑ Combined as one unit
with timing chain cover
(bottom)
2 - Oil filter element
⇒ Maintenance ; Book‐
let 811 , ⇒ Mainte‐
nance ; Booklet 812 or
let 818
3 - Seal
4 - Sealing cap
❑ 25 Nm

4.2 Exploded view - oil pressure switches/oil pressure control
1 - Seal
sure 2.5 ... 3.2 bar (high
pressure stage oil
pump)
❑ Black insulation
Fault Finding ⇒ Vehi‐
cle diagnostic tester
⇒ page 167
❑ 20 Nm
3 - Oil pressure switch for re‐
duced oil pressure - F378-
sure 0.75 ... 1.05 bar
(low pressure stage oil
pump)
❑ Light grey insulation
⇒ page 168
❑ 20 Nm
4 - Seal
5 - Bolt
❑ 9 Nm
6 - Valve for oil pressure con‐
trol - N428-
❑ Checking in Guided Fault Finding ⇒ Vehicle diagnostic tester
7 - O-ring
4.3 Removing and installing oil pressure

switch - F22-
4. Oil filter/oil pressure switches 167

♦ Articulated wrench, 24 mm - T40175-
Removing
– Release fasteners -arrow- and press wiring duct -1- upwards.
– Move electrical wiring and hoses clear and press to one side.
Note
Place a cloth beneath the oil filter housing to catch escaping oil.
– Unplug electrical connector -arrow-.

– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐
sure switch - F22- .
Installing
Note
♦ Renew seal after removing.

♦ Fit the new oil pressure switch - F22- into the connection im‐
mediately to avoid loss of engine oil.

– Check oil level ⇒ Maintenance ; Booklet 811 , ⇒ Maintenance ;
Booklet 812 or ⇒ Maintenance ; Booklet 818 .
Tightening torques
♦ ⇒ “4.2 Exploded view - oil pressure switches/oil pressure con‐
trol”, page 167
4.4 Removing and installing oil pressure

switch for reduced oil pressure - F378-

♦ Assembly tool - T10118-
♦ Articulated wrench, 24 mm - T40175-
Removing
– Remove supercharger ⇒ page 224 .
– Use assembly tool - T10118- to unplug electrical connector
-2-.
– Use articulated wrench (24 mm) - T40175- to unscrew oil
pressure switch for reduced oil pressure - F378- -item 1-.
Installing
Note
Renew seal after removing.
– Install supercharger ⇒ page 224 .

Tightening torques
trol”, page 167
4.5 Checking oil pressure


♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch - F22- ⇒ page 167 .
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw oil pressure switch - F22- into oil pressure tester.
– Start engine.
• Minimum oil pressure at idling speed: 1.2 bar.
• Minimum oil pressure at 2000 rpm: 1.5 bar.
Assembling
– Install oil pressure switch - F22- ⇒ page 167 .
4.6 Removing and installing valve for oil

pressure control - N428-
Removing
noise insulation .

Note
Place a cloth underneath to catch escaping engine oil.
– Remove bolt -1- and detach valve for oil pressure control -
N428- .
Installing
Note
Tightening torques
trol”, page 167

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 172
⇒ “1.2 Checking cooling system for leaks”, page 175
⇒ “1.3 Draining and filling cooling system”, page 176
1.1 Connection diagram - coolant hoses

⇒ “1.1.1 Connection diagram - coolant hoses, vehicles without
auxiliary heater”, page 172
⇒ “1.1.2 Connection diagram - coolant hoses, vehicles with aux‐
iliary heater”, page 174
1.1.1 Connection diagram - coolant hoses, vehicles without auxiliary heater
Note
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Orange = Coolant circuit for charge air cooler.
♦ Brown = Heating circuit.
♦ Arrows show direction of coolant flow.
172 Rep. gr.19 - Cooling

1 - Water radiator for charge air

cooling circuit
2 - Radiator
3 - Coolant temperature send‐
er - G62-
4 - Thermostat
5 - Coolant pump
6 - Charge air cooler (right-
side)
❑ In supercharger hous‐
ing
7 - Bleeder screw
8 - Cylinder head
❑ Cylinder bank 1 (right-
side)
9 - Temperature sender for en‐
gine temperature regulation -
G694-
10 - Coolant circulation pump -
V50-
11 - Bleeder screw
12 - Heat exchanger for heater
⇒ Heating, air condi‐
tioning; Rep. gr. 87 ;
Front air conditioning
unit; Removing and in‐
stalling heat exchanger
14 - Cylinder head
❑ Cylinder bank 2 (left-
side)
15 - Bleeder screw
16 - Filler cap
❑ Checking pressure relief valve ⇒ page 176
17 - Coolant expansion tank
18 - Charge air cooler (left-side)
❑ In supercharger housing
19 - Coolant shut-off valve
❑ Vacuum-controlled by solenoid for coolant circuit - N492-
20 - Non-return valve
❑ Located in coolant line
❑ Located in coolant hose
23 - Charge air cooling pump - V188-
1. Cooling system/coolant 173

1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater
Note
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Orange = Coolant circuit for charge air cooler.
♦ Brown = Heating circuit.
♦ Arrows show direction of coolant flow.
1 - Water radiator for charge air

cooling circuit
2 - Radiator
er - G62-
4 - Auxiliary heater
❑ With circulation pump -
V55-
⇒ Auxiliary heater, sup‐
plementary heater; Rep.
gr. 82 ; Auxiliary/sup‐
plementary heater; Re‐
moving and installing
auxiliary/supplementary
heater
5 - Thermostat
6 - Coolant pump
side)
❑ In supercharger hous‐
ing
8 - Bleeder screw
9 - Cylinder head
side)
10 - Temperature sender for
engine temperature regulation
- G694-
11 - Heater coolant shut-off
valve - N279-
⇒ Auxiliary heater, supplementary heater; Rep. gr. 82 ; Coolant circuit with auxiliary/supplementary
heater; Removing and installing heater coolant shut-off valve
12 - Bleeder screw
13 - Heat exchanger for heater
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Front air conditioning unit; Removing
and installing heat exchanger


15 - Cylinder head
❑ Cylinder bank 2 (left-side)
16 - Bleeder screw
17 - Filler cap
❑ Checking pressure relief valve ⇒ page 176
18 - Coolant expansion tank
❑ In supercharger housing
❑ Vacuum-controlled by solenoid for coolant circuit - N492-
❑ Located in coolant line
1.2 Checking cooling system for leaks

♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-

Procedure
• Engine must be warm.
WARNING
The cooling system is under pressure when the engine is hot.

Danger of scalding skin and other parts of the body.
♦ Wear protective gloves.
♦ Release pressure (cover filler cap on coolant expansion
tank with a cloth and open carefully).
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.5 bar.
• The pressure should not drop more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops more than 0.2 bar, locate leak and elim‐
inate fault.
Note
The drop in pressure of 0.2 bar within 10 minutes is caused by

the decrease in coolant temperature. The colder then engine is,
the less the pressure will fall. If necessary, check again when the
engine is cold.
Checking pressure relief valve in filler cap

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- onto filler cap.
– Build up pressure with hand pump on cooling system tester.
• The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
– Renew filler cap if pressure relief valve does not open as de‐
scribed.
1.3 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-
♦ Drip tray for workshop hoist
- VAS 6208-
6362-
♦ Refractometer - T10007 A-
Draining
WARNING


WARNING

hot.

noise insulation .

Note
Disregard -item 2-.
– Release hose clips -2-, disconnect coolant hoses from coolant

pipes (front left) and drain off coolant.
Note
Disregard -item 1-.
Filling
• Ignition off.
Caution
Always use distilled water for mixing coolant additives as this

ensures optimum corrosion protection.

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

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . Other coolant additives could seriously
impair in particular the anti-corrosion properties. The resulting
damage could lead to loss of coolant and consequently to se‐
rious engine damage.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- MUST be used to determine the
current level of frost protection.
♦ The mixture must guarantee frost protection down to at least
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ Read off the level of frost protection on the scale for the rele‐
vant coolant additive.
♦ The temperature indicated on the refractometer - T10007A-
corresponds to the temperature at which the first ice crystals
can form in the coolant.
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
Recommended mixture ratio for coolant

• Coolant (40 %) and water (60 %) for frost protection to -25 ℃
• Coolant (50 %) and water (50 %) for frost protection to -36 ℃
• Coolant: ⇒ Electronic parts catalogue (ETKA)

Procedure
– Close drain plug -1-.
– Fit coolant hoses with hose clips -2- onto coolant pipes (front
left).
– Fill reservoir of -VAS 6096- with at least 15 litres of premixed

coolant (according to recommended ratio).
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-.
Note
The vented air draws along a small amount of coolant, which

should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar.

– 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 of -VAS 6096- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump continues to generate a partial 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.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
– Detach cooling system charge unit - VAS 6096- from adapter
-V.A.G 1274/8- on coolant expansion tank.
– Attach pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .

– Fill up with coolant until pipe for cooling system tester is filled.
If required, add further coolant when performing bleeding pro‐
cedure.

Note
Place a cloth underneath to catch escaping coolant.
– Open bleeder screws -1- and -2- on charge air coolers one
after the other until coolant comes out.
– Close bleeder screws.
chamber cover .
– Release coolant hose going to heat exchanger and pull back

hose until coolant flows out at bleeder hole -arrow- in coolant
hose.
– Push coolant hose back onto connection and secure with
spring-type hose clip.
– Close bleeder screw.
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Close filler cap on coolant expansion tank (make sure it en‐
gages).
– Start engine.
– Set temperature to “HI” for all zones and select lowest blower
speed (= 0).
– Switch off air conditioner compressor (press AC button).
• LED in button should not light up.
– Run engine for 3 minutes at 2000 rpm.
– Allow engine to run at idling speed until both large coolant ho‐
ses at radiator become warm.
– Run engine for 2 minutes at 2000 rpm.
– Switch off ignition and allow engine to cool down.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .
– 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.
Tightening torques
♦ ⇒ “4.1 Exploded view - radiator/radiator fans”, page 205
♦ ⇒ “1.1 Exploded view - supercharger”, page 220
♦ Plenum chamber cover ⇒ General body repairs, exterior; Rep.
gr. 50 ; Bulkhead; Exploded view - plenum chamber partition
panel

2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump and thermostat”,
page 183
⇒ “2.2 Exploded view - electric coolant pump”, page 184
⇒ “2.3 Exploded view - coolant temperature senders”,
page 185
⇒ “2.4 Removing and installing electric coolant pump”,
page 185
⇒ “2.5 Removing and installing coolant pump”, page 188
⇒ “2.6 Removing and installing thermostat”, page 190
⇒ “2.7 Removing and installing coolant temperature sender G62
”, page 191
⇒ “2.8 Removing and installing temperature sender for engine
temperature regulation G694 ”, page 192
2.1 Exploded view - coolant pump and thermostat
1 - Bolt
2 - Washer
3 - Idler roller
❑ For poly V-belt
4 - Connection
❑ For coolant hose
5 - Gasket
6 - Gasket
7 - Thermostat
⇒ page 190
❑ Starts to open at approx.
87 ℃
❑ Fully open at approx.
102°C
❑ Opening travel at least 8
mm
Note
When removing and installing the

thermostat, make sure that the nee‐
dle is fitted correctly (conical end
fitted in wax expansion element of
thermostat). If necessary, push ther‐
mostat needle as far as possible into
wax expansion element.
8 - Seal
2. Coolant pump/thermostat assembly 183

9 - Bolt
❑ 9 Nm
10 - Coolant valve for cylinder head - N489-
11 - Coolant pump
❑ With seal
12 - Bolt
❑ 9 Nm
13 - Poly V-belt pulley
❑ For coolant pump
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ 9 Nm
2.2 Exploded view - electric coolant pump
1 - Bracket
❑ For charge air cooling
pump - V188-
2 - Longitudinal member (left-
side)
3 - Bolt
❑ 9 Nm
4 - Coolant hoses
V50-
⇒ page 185
6 - Heat shield
7 - Bracket
❑ For coolant circulation
pump - V50-
8 - Gearbox
9 - Coolant hose
10 - Nut
❑ 9 Nm
11 - Retaining clip
❑ For charge air cooling
pump - V188-
12 - Coolant hose
13 - Charge air cooling pump -
V188-
⇒ page 187

14 - Nut
❑ 9 Nm
2.3 Exploded view - coolant temperature senders
1 - O-ring
2 - Retaining clip
er - G62-
⇒ page 191
4 - O-ring
5 - Temperature sender for en‐
gine temperature regulation -
G694-
⇒ page 192
❑ 3 Nm
2.4 Removing and installing electric coolant

pump
⇒ “2.4.1 Removing and installing coolant circulation pump V50 ”,
page 185
⇒ “2.4.2 Removing and installing charge air cooling pump V188
”, page 187
2.4.1 Removing and installing coolant circula‐

tion pump - V50-

♦ Hose clamps, up to 25 mm - 3094-
Removing
Note
– Release fastener -arrow- and lift coolant circulation pump -

V50- upwards out of bracket.
– Clamp off coolant hoses using hose clamps up to 25 mm -
3094- , release hose clips -1- and disconnect hoses.
Installing
Note
Secure all hose connections with correct type of hose clips (as
– Check coolant level ⇒ page 178 .

Tightening torques
♦ ⇒ “2.2 Exploded view - electric coolant pump”, page 184

2.4.2 Removing and installing charge air cool‐

ing pump - V188-
Removing
– Remove front wheel (left-side) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 44 ; Wheels, tyres .
– Remove front wheel housing liner (left-side) ⇒ General body
and installing front wheel housing liner .


– Remove nut -2- and detach bracket.
Note
– Use hose clamps up to 25 mm - 3094- to clamp off coolant

hoses at charge air cooling pump - V188- .
– Detach charge air cooling pump, then release hose clips -1-
and disconnect coolant hoses.
Installing
Note

Tightening torques
♦ ⇒ “2.2 Exploded view - electric coolant pump”, page 184
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
2.5 Removing and installing coolant pump

♦ Pin wrench - 3212-
Removing
– Remove coolant pipes (front left) ⇒ page 196 .

– Remove bolts -1- and -2- and take off coolant pipes.
– Detach poly V-belt from air conditioner compressor, but do not
remove completely
⇒ “1.2.2 Removing and installing poly V-belt for ancillaries”,
page 52 .
– Lift retaining clip -arrow- and detach coolant hose from coolant
pipe (front left).
– Lift retaining clip -2- and detach connection (top left) from ra‐
diator.
– Detach coolant hose.
Note
Disregard -item 1-.
– Remove bolts for coolant pump pulley -arrows- (counterhold

with pin wrench - 3212- ).

– Disconnect vacuum hose -1-.
Note
– Remove bolts -arrows- and detach coolant pump.

Installing
– Install coolant pipes (front left) ⇒ page 196 .
⇒ page 206 .
Note

Tightening torques
page 183
2.6 Removing and installing thermostat

Removing
– Remove coolant pipe (front right) ⇒ page 198 .

Note

– Detach coolant thermostat with hose connection.
Installing
Note
When removing and installing the thermostat, make sure that the
needle is fitted correctly (conical end fitted in wax expansion el‐
ement of thermostat). If necessary, push thermostat needle as far
as possible into wax expansion element.
Note
Renew seal after removing.
– Install coolant pipe (front right) ⇒ page 198 .

Tightening torques
page 183
2.7 Removing and installing coolant temper‐

ature sender - G62-
Removing
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
on coolant expansion tank briefly and then close cap again (it
should click into place).

Note
– Pull off retaining clip -1- and detach coolant temperature send‐
er - G62- .
Installing
Note

♦ To avoid loss of coolant, insert new coolant temperature send‐
er - G62- immediately in coolant pipe (front).

2.8 Removing and installing temperature

sender for engine temperature regula‐
tion - G694-
♦ Twelve-point socket with jointed extension (15 mm, commer‐
cially available)
Note
To avoid having to remove the fuel rail, use a twelve-point socket

(15 mm) -item 1- with jointed extension -2- to unscrew the sender.

Removing
– Unscrew temperature sender for engine temperature regula‐
tion - G694- -item 1-
Installing
Tightening torques
♦ ⇒ “2.3 Exploded view - coolant temperature senders”,
page 185

3 Coolant pipes
⇒ “3.1 Exploded view - coolant pipes”, page 194
⇒ “3.2 Removing and installing coolant pipes”, page 195
3.1 Exploded view - coolant pipes
Note
The arrow markings on coolant pipes and on ends of hoses must align.
1 - Bolt
❑ 9 Nm
2 - Coolant pipes (front left)
⇒ page 196
3 - Bolt
❑ 9 Nm
4 - Bracket
5 - Bolt
❑ 22 Nm
6 - Seal
7 - Bolt
❑ 9 Nm
8 - Coolant pipe (front right)
⇒ page 198
9 - Seal
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 5 Nm
13 - Bolt
❑ 5 Nm
14 - Seals
15 - Coolant pipes on supercharger
16 - Seals
17 - Seal

18 - Coolant pipe (top)

19 - Bolt
❑ 9 Nm
20 - Bolt
❑ 9 Nm
21 - Coolant pipe (left-side)
22 - Bolt
❑ 9 Nm
23 - Seal
24 - Coolant pipe (front left)
25 - Bolt
❑ 9 Nm
3.2 Removing and installing coolant pipes

⇒ “3.2.1 Removing and installing coolant pipe (front left)”,
page 195
⇒ “3.2.2 Removing and installing coolant pipes (front left)”,
page 196
⇒ “3.2.3 Removing and installing coolant pipe (front right)”, page
198
⇒ “3.2.4 Removing and installing coolant pipe (left-side)”,
page 200
⇒ “3.2.5 Removing and installing coolant pipe (top)”, page 201
⇒ “3.2.6 Removing and installing coolant pipes on supercharger”,
page 202
3.2.1 Removing and installing coolant pipe

(front left)
3. Coolant pipes 195

Removing
WARNING


– Remove coolant pipes (front left) ⇒ page 196 .
– Lift retaining clip -2- and detach connection (top left) from ra‐
diator.
Note
Disregard -item 1-.
– Move clear vacuum hose -2-.

– Lift retaining clip -3- and remove coolant hose.
– Remove bolts -arrows-, release hose clips -1, 4- and detach
coolant pipe (front left).
Installing
Note
♦ Renew seal after removing.


⇒ page 206 .
Note

Tightening torques
3.2.2 Removing and installing coolant pipes

(front left)

♦ Drip tray for workshop hoist - VAS 6208-
Removing
WARNING


noise insulation .

WARNING

hot.
Note
For illustration purposes, the installation position is shown in the

following illustrations with the engine removed.
– Clamp off coolant hoses using hose clamps, up to 25 mm -

3094- , release hose clips -2- and disconnect coolant hoses
from coolant pipes (front left).
– Release hose clips -1- and detach coolant hoses from coolant
pipes at supercharger.
– Detach coolant pipes (front left) from below.
Installing
Note

Tightening torques

(front right)
Removing
– Remove coolant pipe (front left) ⇒ page 195 .


ments .
– Detach air duct -1- with intermediate flange -2- from air cleaner
housing.
– Lift retaining clip -1- and disconnect coolant line.

– Release fasteners -arrows- and detach intake manifold flap
potentiometer - G336- .


– Lift retaining clip -1- and disconnect coolant hose.
– Unscrew bolts -arrows- and remove coolant pipe (front right).
Installing
Note

– Connect coolant line and coolant hose with plug-in connector

⇒ page 206 .
ments .
– Install coolant pipe (front left) ⇒ page 195 .
Note

Tightening torques
♦ ⇒ “3.1 Exploded view - air cleaner housing”, page 269

(left-side)
Removing

– Take electrical connector -1- for Lambda probe 2 - G108- out

of bracket, unplug and move wiring clear.
Note
Disregard -item 2-.

– Release hose clips -arrows- and detach coolant hoses.
– Remove bolt -1- and nut -2- and detach coolant pipe (left-side)
towards rear.
Installing
Note

Tightening torques

(top)
Removing
Note

– Remove high-pressure pipe ⇒ page 299 .

Note
– Lift retaining clip -2- and disconnect coolant hose from coolant
pipe.
– Remove bolt -1- and pull coolant pipe rearwards out of cylinder
block -arrow-.
Installing
Note
– Clean and smoothen sealing surface for O-ring.

– Lubricate O-ring with coolant and slide onto coolant pipe.
– Connect coolant hose with plug-in connector ⇒ page 206 .
– Install high-pressure pipe ⇒ page 299 .
Note

Tightening torques
3.2.6 Removing and installing coolant pipes

on supercharger

Removing
WARNING

hot.

noise insulation .

– Clamp off coolant hoses using hose clamps, up to 25 mm -
3094- , release hose clips -1- and disconnect coolant hoses
from coolant pipes at supercharger.
Note
Disregard -item 2-.


– Remove bolts -1 and 2- and detach coolant pipes from super‐
charger.
Installing
Note


Tightening torques

4 Radiator/radiator fans
⇒ “4.1 Exploded view - radiator/radiator fans”, page 205
⇒ “4.2 Removing and installing radiator”, page 207
⇒ “4.3 Removing and installing water radiator for charge air cool‐
ing circuit”, page 211
⇒ “4.4 Removing and installing radiator cowl”, page 213
⇒ “4.5 Removing and installing radiator fan V7 ”, page 218
4.1 Exploded view - radiator/radiator fans

Radiator
1 - Coolant hose
❑ Lift retaining clip to de‐
tach
❑ Connecting
⇒ page 206
2 - O-ring
3 - Air duct
4 - Coolant hose
❑ Lift retaining clip to de‐
tach
❑ Connecting
⇒ page 206
5 - O-ring
6 - Radiator
❑ Remove and install to‐
gether with radiator cowl
⇒ page 207
❑ If renewed, refill system
with fresh coolant
7 - O-ring
8 - Coolant hose
❑ To coolant expansion
tank
❑ Press release ring to de‐
tach
❑ Connecting
⇒ page 206
9 - Coolant hose
❑ To coolant expansion tank
❑ Press release ring to detach
❑ Connecting ⇒ page 206
10 - O-ring
4. Radiator/radiator fans 205

11 - Air duct
12 - Coolant hoses
13 - Bolt
❑ 4.5 Nm
14 - Water radiator for charge air cooling circuit
15 - Retaining pin
❑ Use screwdriver to release and pull off
16 - Rubber mounting
❑ For radiator
17 - Bolt
❑ 5.5 Nm
18 - Radiator bracket
19 - Bolt
❑ 5 Nm
20 - Washer
21 - Bolt
❑ 4.5 Nm
Connecting coolant hose with plug-in connector

– Remove old O-ring -2- from coolant hose -3-.
– Lightly lubricate new O-ring with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto connection -1- until it engages audi‐
bly.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
Radiator cowl and radiator fans

1 - Radiator fan 2 - V177-

❑ With radiator fan control
unit 2 - J671-
⇒ page 218
2 - Radiator fan - V7-
❑ With radiator fan control
unit - J293-
⇒ page 218
3 - Radiator cowl
⇒ page 213
4 - Bolt
❑ 3.5 Nm
5 - Fan wheel
❑ Pin must engage in hole
6 - Bolt
❑ 5 Nm
7 - Fan wheel
❑ Pin must engage in hole
8 - Bolt
❑ 5 Nm
9 - Bolt
❑ 3.5 Nm
4.2 Removing and installing radiator
Note
Radiator can only be removed and installed together with radiator

cowl.


Removing
WARNING


noise insulation .
– Remove impact absorber ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Removing and installing impact
absorber .
– Remove water radiator for charge air cooling circuit
⇒ page 211 .
– Remove condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; Removing and installing condenser .
– Audi A4: Remove bracket for mounting for headlight housing
⇒ Electrical system; Rep. gr. 94 ; Headlights; Exploded view
- headlights .


tor.
– Detach connection from radiator (lift retaining clip -arrow-).
– Unplug electrical connectors -1- and -2- for radiator fan (push
retainer to the rear -arrow- and press down release catch).

Note
Observe rules for cleanliness when working on gearbox ⇒ Rep.

gr. 00 ; Repair instructions; Rules for cleanliness .
– Unscrew bolts -arrows- and detach ATF lines from radiator.
Note
Tie ATF lines up onto longitudinal member to prevent fluid es‐

caping.

– Lift retaining clips -1- and -2- and detach connection from ra‐
diator.

– Detach air duct -1- from intermediate flange -2- for air cleaner
housing.
– Release retaining pins for radiator on both sides -arrow A- and

pull out upwards -arrow B-.
– Remove bolts -1- on both sides and detach radiator bracket

with radiator from lock carrier -arrow-.
– Slightly lower radiator and detach.

– Press locking tabs on left and right sides of radiator cowl

-arrow- and at the same time lift radiator cowl off radiator.
Installing
Note
If there are slight impressions on the fins, refer to ⇒ page 6 .

– Install water radiator for charge air cooling circuit
⇒ page 211 .
⇒ page 206 .
Note

– Check ATF level ⇒ Rep. gr. 34 ; ATF; Checking ATF level .
Tightening torques
♦ Bracket for mounting for headlight housing ⇒ Electrical sys‐
tem; Rep. gr. 94 ; Headlights; Exploded view - headlights
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
Exploded view - condenser
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - impact bar
4.3 Removing and installing water radiator

for charge air cooling circuit

Removing
ments .
housing.
– Remove closure plate for bumper cover (front) ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing
and installing attachments .
– Remove air intake grille (left and right) ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Removing and
installing attachments .
Note
For illustration purposes, the installation position is shown in the

following illustrations with the bumper removed.
– Release catches -arrows A- and swivel air duct -1- on left and
right to centre of vehicle -arrow B-.
– Place drip tray for workshop hoist - VAS 6208- beneath water
radiator (front) for charge air cooling circuit.

– Clamp off coolant hoses using hose clamps up to 25 mm -

3094- , release hose clips -arrows- and disconnect hoses.
– Push catch down -arrow A- and move water radiator (front) for
charge air cooling circuit slightly in direction of -arrow B-.
Note
Disregard -item 1-.
– Lift water radiator (front) for charge air cooling circuit off radi‐
ator -arrows A- and swivel in direction of -arrow B-.
– Detach water radiator for charge air cooling circuit from right
side downwards -arrow C-.
Installing
– Install closure plate for bumper cover, air intake grille and lock
carrier cover ⇒ General body repairs, exterior; Rep. gr. 63 ;
Bumper (front); Removing and installing attachments .
Note

Tightening torques
4.4 Removing and installing radiator cowl


Removing
WARNING


noise insulation .


tor.
– Detach connection from radiator (lift retaining clip -arrow-).
– Unplug electrical connector -1- and, if fitted, -2- for radiator fan
(push retainer to the rear -arrow- and press down release
catch).


Note
Observe rules for cleanliness when working on gearbox ⇒ Rep.

gr. 00 ; Repair instructions; Rules for cleanliness .
– Unscrew bolts -arrows- and detach ATF lines from radiator.
Note
Tie ATF lines up onto longitudinal member to prevent fluid es‐

caping.
ments .

housing.
– Remove air intake grille (left and right) ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Removing and
installing attachments .
– Release catches -arrows A- and swivel air duct -1- on left and
right to centre of vehicle -arrow B-.

– Lift retaining clip -2- and detach connection from radiator.
Note
Disregard -item 1-.
– Move coolant hoses -arrows- clear at lock carrier.
Note
Disregard -item 1-.
– Remove bolts -1- on both sides.

– Pivot bottom of radiator forwards -arrow-.

– Press locking tabs on left and right sides of radiator cowl si‐
multaneously -arrow- and detach radiator cowl downwards
from radiator.
Installing
Note
– Install closure plate for bumper cover, air intake grille and lock
carrier cover ⇒ General body repairs, exterior; Rep. gr. 63 ;
Bumper (front); Removing and installing attachments .
– Attach connection with plug-in connector ⇒ page 206 .
Note

– Check ATF level ⇒ Rep. gr. 34 ; ATF; Checking ATF level .
Tightening torques
4.5 Removing and installing radiator fan -

V7-
Removing
Note
– Remove radiator cowl ⇒ page 213 .

– Remove bolts -1- or -2- and detach corresponding fan wheel.
– Remove bolts -arrows- on radiator fan.
– Move electrical wiring harness clear and detach radiator fan.

Installing
– Note installation position of fan wheel.
• Pin -2- must engage in hole -1-.
– Install radiator cowl ⇒ page 213 .
Tightening torques

21 – Turbocharging/supercharging
1 Supercharger
⇒ “1.1 Exploded view - supercharger”, page 220
⇒ “1.2 Exploded view - magnetic clutch”, page 223
⇒ “1.3 Exploded view - rotor assembly”, page 224
⇒ “1.4 Removing and installing supercharger”, page 224
⇒ “1.5 Checking supercharger for leaks”, page 229
⇒ “1.6 Removing and installing magnetic clutch”, page 231
⇒ “1.7 Removing and installing pulley for supercharger”,
page 238
⇒ “1.8 Removing and installing drive unit”, page 239
⇒ “1.9 Removing and installing rotor assembly”, page 241
⇒ “1.10 Renewing drive shaft oil seal”, page 245
⇒ “1.11 Securing supercharger to engine and gearbox support”,
page 247
⇒ “1.12 Removing and installing sender 1 for turbocharger speed
G688 ”, page 251
1.1 Exploded view - supercharger
220 Rep. gr.21 - Turbocharging/supercharging

1 - Supercharger
❑ With charge air coolers
supercharger
⇒ page 224
❑ Exploded view - charge
air coolers ⇒ page 252
❑ Secure to engine and
gearbox support - VAS
6095- when performing
assembly work
⇒ page 247
❑ Secure to engine and
gearbox support - VAS
6095- when checking
for leaks ⇒ page 249
2 - Ball stud
❑ For engine cover panel
❑ 5 Nm
3 - Insulating plate
4 - Bolt
❑ 5 Nm
5 - O-rings
6 - Bolt
⇒ page 274
7 - Throttle valve module -
J338-
⇒ page 278
8 - Intermediate flange
9 - O-rings
10 - Bolt
11 - Intermediate flange
12 - Regulating flap control unit - J808-
13 - Bolt
❑ 9 Nm
14 - Bracket
❑ For change-over valves
15 - Connection
16 - Bolt
17 - O-ring
18 - Bolt
❑ 10 Nm
1. Supercharger 221
19 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
20 - O-ring
21 - Bleeder screw
❑ For charge air cooler
❑ 1.5 … 3.0 Nm
22 - Seal
23 - Nut
❑ 20 Nm
24 - Charge pressure sender
❑ Cylinder bank 1 (right-side): charge pressure sender - G31-
❑ Cylinder bank 2 (left-side): charge pressure sender 2 - G447-
25 - Bolt
❑ 10 Nm
26 - O-ring
27 - Stud
❑ 17 Nm
28 - Connection
❑ For crankcase breather
29 - Seals
30 - O-rings
❑ 2x on NAR versions
31 - Engine lifting eye
32 - Bolt
❑ 27 Nm
33 - O-ring
34 - Sender 1 for turbocharger speed - G688-
❑ Do not use opening to check oil level
35 - Bolt
❑ 10 Nm

1.2 Exploded view - magnetic clutch
1 - Pulley
❑ For supercharger
⇒ page 238
2 - Bolt
❑ 20 Nm +90°
3 - Magnetic clutch
⇒ page 231
4 - Bolt
❑ 20 Nm
5 - Armature
❑ Only renew together
with -item 3-
❑ Do not loosen bolts on
armature
❑ Renew armature if nuts
are loose
stalling magnetic
clutch”, page 231
❑ Clean friction lining and
friction surface with
brake cleaner before in‐
stalling
❑ Tightening torque for
clamping bolt
⇒ page 223
6 - Bolt
❑ 3.6 Nm
7 - Woodruff key
8 - Supercharger
9 - O-ring
10 - Trim
Tightening torque for clamping bolt

– Tighten clamping bolt -arrow- to 20 Nm.
1. Supercharger 223
1.3 Exploded view - rotor assembly
1 - Bolt
❑ 27 Nm
❑ Remove old sealant/
locking fluid from
threads (using a thread
tap or similar)
❑ Before installing, lubri‐
cate a few threads of the
cleaned bolts with seal‐
ant ⇒ Electronic parts
catalogue
2 - Drive unit
❑ Always renew oil seal
-item 3- after removing
⇒ page 239
3 - Oil seal
❑ For drive shaft
❑ Renewing
⇒ “1.10 Renewing drive
shaft oil seal”,
page 245
4 - Dowel sleeve
5 - Rotor assembly
⇒ page 241
❑ After every removal and
installation
⇒ “1.5 Checking super‐
charger for leaks”,
page 229
❑ Remove old sealant/
locking fluid from
threads (using a thread
tap or similar)
6 - Needle bearing
❑ For rotor assembly
❑ Renew together with rotor assembly ⇒ page 241
7 - Supercharger housing
8 - Needle bearing
❑ For rotor assembly
❑ Renew together with rotor assembly ⇒ page 241
9 - Dowel sleeve
1.4 Removing and installing supercharger


1. Supercharger 225
Removing
Note
♦ Observe rules for cleanliness ⇒ page 5 .

♦ Check that all air pipes and hoses and vacuum lines are cor‐
rectly fitted and that there are no leaks before carrying out tests
or repairs.

chamber cover .
– Clamp off coolant hoses -2- with hose clamps, up to 25 mm -
3094- .
– Release hose clips -1- and detach coolant hoses from coolant
pipes at supercharger.
– Remove bolt -2- and press coolant pipes to the side.
– Unplug electrical connectors -1, 2-.
Note
Disregard -item 3-.

clear at air pipe.
-arrows-.
– Disconnect vacuum hose -1- on rear side of plenum chamber

partition panel and detach vacuum connection -2- from ple‐
num chamber partition panel.
– Unplug electrical connector -3- at activated charcoal filter sol‐
enoid valve 1 - N80- and detach vacuum hose -4-.
– Detach activated charcoal filter solenoid valve 1 - N80- from
bracket and move it clear to the side with hoses still attached.
– Unplug electrical connector -arrow- at throttle valve module -

J338- .
– Unplug electrical connector -arrow- at regulating flap control

unit - J808- .
1. Supercharger 227
– Unplug electrical connectors -1-.
Note
Mark installation position of vacuum hoses for re-installation.
– Disconnect vacuum hoses -4- and vacuum line -3-.

– Move vacuum hose -2- clear and place to left side.
– Release fasteners -arrow- and press wiring duct -1- towards

rear.

– Detach valve -3- for crankcase breather system from bracket.
– Unplug electrical connector -2- at intake air temperature send‐
er - G42- / intake manifold pressure sender - G71- .

– Unplug electrical connectors -1, 2-.

– Remove nuts -arrows- and lift off supercharger with charge air
coolers.
– Seal openings on supercharger and all relevant ducts and ho‐
ses of the charge air system using plugs from engine bung set
- VAS 6122- or clean cloths.
– Detach noise insulation panels.
Installing
Note
♦ Renew seals and O-rings after removal.

♦ Do not remove plugs or protective caps until you are ready to
fit the relevant line.
– Fit noise insulation panels.
– Ensure that crankcase breather connection is positioned cor‐

rectly when fitting supercharger ⇒ page 163 .
chamber cover .
Note

Tightening torques
tem”, page 253
1.5 Checking supercharger for leaks

1. Supercharger 229
♦ Charge air system tester - V.A.G 1687- with adapters -V.A.G

1687/4- , -V.A.G 1687/10- , -V.A.G 1687/13-1- and -V.A.G
1687/13-2-
Procedure
• Supercharger secured to engine and gearbox support - VAS
6095- for leak test ⇒ page 247 .
• Regulating flap control unit - J808- installed ⇒ page 280 .
– Secure adapter -V.A.G 1687/13-1- to bottom of supercharger
housing.
– Secure hose connections with hose clips.
Note
For illustration purposes the supercharger is shown without the

gearbox support.
– Secure adapter -V.A.G 1687/4- to top of supercharger hous‐

ing.
– Secure adapter -V.A.G 1687/13-2- to supercharger housing

with adapter - V.A.G 1687/10- .

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

– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
• Make sure knob is pulled out before turning pressure control
valve.
– Connect charge air system tester - V.A.G 1687- as shown in

illustration, and connect to compressed air line using a com‐
mercially available connection piece -1-.
– If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high.

♦ The pressure must not exceed 0.5 bar.
– Adjust pressure to 0.5 bar via pressure control valve -2-.

– Open valve -4- and wait until test system is pressurised. If
necessary, adjust pressure to 0.5 bar again.
– Close valve -3-.
• Pressure must not drop by more than 0.1 bar for 30 seconds.
– Check charge air system for audible leaks or leaks that can be
felt with the hand; apply commercially available leak detecting
spray or use ultrasonic tester - V.A.G 1842- .
Note
♦ For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒

Operating instructions .
♦ Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
1.6 Removing and installing magnetic clutch

1. Supercharger 231
♦ Puller -T40301-
♦ Centring pin -T40302-
♦ External power supply unit for clutch for supercharger - VAS

6909-
Removing
• Supercharger secured to engine and gearbox support for as‐
sembly work ⇒ page 247 .
– Detach coolant pipes from supercharger ⇒ page 202 .
– Lift magnetic clutch -1- slightly and turn it until one of the three
bolts for trim is accessible.
– Remove first bolt -arrow-.
– Remove remaining bolts; to do so, turn magnetic clutch 1/3 of
a rotation each time.

– Detach magnetic clutch -1- -arrow-.
– Loosen clamping bolt -arrow- for armature by two turns (turn

armature to corresponding position).
– Apply puller -T40301- to armature.

• Claws -arrows- of puller must engage on armature as shown
in illustration.
1. Supercharger 233
– Detach armature -2- and remove.

– Detach trim -1-.
– Remove O-ring -arrow-.

Checking for wear on inner and outer friction linings
Note
Before re-installing a used magnetic clutch, the degree of wear

on the inner and outer friction linings must be checked. This step
is not necessary when fitting a new magnetic clutch.
– Position caliper gauge -1- on highest point of inner friction lin‐

ing -2- (as shown in illustration) and measure distance -X- to
friction surface -3-.
• Specification -X-: at least 0.2 mm.
– Perform measurement in at least three different positions
around circumference.
– If specification is not met, renew magnetic clutch.
– Fit armature -2- onto magnetic clutch -1- and tighten centring
pin -T40302- hand-tight.
– Use feeler gauge -3- to check distance between outer friction
lining and outer friction surface.
• Specification: minimum 0.2 mm.
– Perform measurement in at least three different positions
around circumference.
– If specification is not met, renew magnetic clutch.

• Armature -2- must still be on magnetic clutch -1- and centring

pin -T40302- must be tightened hand-tight.
– Connect external power supply unit for clutch for supercharger
- VAS 6909- to a 12 Volt battery or to jump-start terminal of
another vehicle.
– Connect electrical connector of adapter cable -VAS 6909- to
magnetic clutch and switch on power supply to magnetic
clutch.
Caution
Risk of irreparable damage to magnetic clutch

♦ The magnetic clutch must not be connected to the power
supply for longer than 15 minutes.
♦ The magnetic clutch heats up when current is applied.
– With current applied, use feeler gauge -3- to check distance

between clamping hub (shown in -blue-) and outer friction sur‐
face at point shown in illustration.
– Perform this measurement in all three positions of clamping
hub.
• Specification: maximum 1.3 mm.
– If specification is exceeded, renew magnetic clutch.
– Switch off external power supply unit for clutch for supercharg‐
er - VAS 6909- .
Installing
Note
– Insert O-ring -arrow- into groove on supercharger housing.
1. Supercharger 235
– Fit armature -2- onto magnetic clutch -1-.

– Fit trim -3- onto magnetic clutch and secure with three bolts
-4-.
– Fit centring pin -T40302- into armature and magnetic clutch.

• Armature will be centred relative to magnetic clutch.
– Connect external power supply unit for clutch for supercharger
- VAS 6909- to a 12 Volt battery or to jump-start terminal of
another vehicle.
– Connect electrical connector of adapter cable -VAS 6909- to
magnetic clutch and switch on power supply to magnetic
clutch.
• Armature is fixed to magnetic clutch when power supply is
switched on.
Note
♦ It is important to ensure that the current to the magnetic clutch

generated by the external power supply unit for clutch for su‐
percharger - VAS 6909- is not interrupted during installation.
♦ The current to the magnetic clutch generated by the external
power supply unit for clutch for supercharger - VAS 6909- may
be disconnected only after the clamping bolt of the clamping
hub is tightened on the shaft.
Caution
Risk of irreparable damage to magnetic clutch

♦ The magnetic clutch must not be connected to the power
supply for longer than 15 minutes.
♦ The magnetic clutch heats up when current is applied.
– Remove centring pin -T40302- with power supply switched on.

– Check that Woodruff key -1- is seated correctly in drive shaft

-2--
• Drive shaft must be free of oil and grease
The following markings assist in aligning the armature of the mag‐

netic clutch with the shaft of the supercharger:
• Position armature of magnetic clutch so that groove -4- for
Woodruff key is opposite arrow marking -3- on trim.
• Position shaft of supercharger so that Woodruff key -2- faces
“KEY” marking -1-.
– Fit armature -1- of magnetic clutch onto shaft -2- of super‐

charger -arrow-.
– Fit magnetic clutch onto supercharger and tighten bolts

-arrows- (keep power supply switched on).
1. Supercharger 237
– Press pulley downwards by hand towards supercharger

-arrow A- and at the same time tighten clamping bolt
-arrow B- (keep power supply switched on).
– Switch off power supply and disconnect external power supply
unit for clutch for supercharger - VAS 6909- from magnetic
clutch and from power source.
– Install coolant pipes on supercharger ⇒ page 202 .
– Perform adaption for magnetic clutch after removing and in‐
stalling/renewing:
♦ 01 - Engine, self-diagnosis compatible systems
♦ Functions
♦ 01 - Compressor clutch adaption
Tightening torques
♦ ⇒ “1.2 Exploded view - magnetic clutch”, page 223
1.7 Removing and installing pulley for su‐

percharger
♦ Counterhold tool - T10172 A- with adapter -T10172/5-
Removing
– Loosen two bolts for pulley by one turn; when doing so, coun‐
terhold the other two bolts with counterhold tool - T10172 A-
and adapters -T10172/5- .
– Apply counterhold tool to loosened bolts and remove both oth‐
er bolts.
– Remove remaining bolts and remove pulley.
Installing
Tightening torques
♦ ⇒ “1.2 Exploded view - magnetic clutch”, page 223

1.8 Removing and installing drive unit


♦ Oil for supercharger drive ⇒ Electronic parts catalogue
♦ Spreader tool (commercially available)
Removing
– Remove magnetic clutch ⇒ page 231 .
– Position supercharger vertically in engine and gearbox sup‐
port.
• Drive unit faces upwards.
– Detach Woodruff key -1- from drive shaft -2-.
1. Supercharger 239
Caution
♦ To make sure bearing cover -1- for rotor assembly does

not come loose and remains properly sealed, always use
spreader tool -arrows- to press off drive unit -2- as shown
in illustration (do not use a hammer).
– Using a spreader tool, carefully press off drive unit from bear‐
ing cover and detach.
– With the aid of used oil collection and extraction unit - VAS
6622A- , extract all oil for supercharger drive from bearing
cover (including oil chambers -arrows- between ribs).
Installing
Note
♦ Renew seal for drive unit after removal.

♦ Fit self-locking bolts or bolts with sealant ⇒ Electronic parts
catalogue .

– Before assembly, always remove residues from threaded
holes using a thread tap.
– Fill bearing cover with oil for supercharger drive.
Note
The container is filled with the required amount of oil. It is not

possible to check the oil level at a later stage.
– Apply a thin layer of sealant to sealing surface -arrow- for drive

unit on rotor assembly and fit assembly sleeve - T40318- onto
drive shaft, as shown in illustration.
– Fit drive unit with new seal onto rotor assembly (note position
of dowel sleeves -1, 2-).

– Tighten bolts -arrows-.
– Fit Woodruff key -1- into drive shaft -2-.

– Install magnetic clutch ⇒ page 231 .
note the following:
– Check supercharger for leaks ⇒ page 229 .
Tightening torques
♦ ⇒ “1.3 Exploded view - rotor assembly”, page 224
1.9 Removing and installing rotor assembly

♦ Internal puller - VAS 501 001- (not illustrated)
♦ Assembly tool -T40303-
Removing
– Remove magnetic clutch ⇒ page 231 .
– Remove drive unit ⇒ page 239 .
– Position supercharger vertically in engine and gearbox sup‐
port.
• Spur gears of rotor assembly face upwards.
1. Supercharger 241
– Carefully detach rotor assembly upwards -arrow-, ensuring

that rotors do not damage inner surfaces of supercharger
housing.
– Set rotor module down carefully and ensure that it is kept free
of dust.
– Block off air ducts with clean cloths to prevent dirt or small
objects from dropping into supercharger housing.
Caution
Risk of damage to surfaces of supercharger housing.

♦ If necessary, use cloths to protect the surfaces of the su‐
percharger housing during the following steps.
– Using a screwdriver, bend seals -arrows- of both rotor needle

bearings inwards.
– Remove seals -arrows- of both rotor needle bearings with

long-nose pliers.
– Break open needle bearing cages -arrows- of both bearings

with a screwdriver.

– Use long-nose pliers to remove needle bearing cages

-arrows- of both bearings.
– Remove loose roller bearings completely using a magnet.
Caution
Make sure that no loose parts of the needle bearing remain

inside the supercharger housing.
– Insert threaded bush -VAS 501 001/4- into sleeve of needle

bearing; ensure that collar -1- faces upwards.
– Place thrust washer -VAS 501 001/5- on threaded bush -VAS
501 001/4- with writing on tool facing upwards.
– Screw spindle -VAS 501 001/1- hand-tight into threaded bush

-VAS 501 001/4- -item 1- as far as it will go.
– Attach support sleeve -VAS 501 001/3- ; end with flat face
must point downwards.
1. Supercharger 243
– Screw forcing nut -VAS 501 001/2- onto spindle.

– Position socket -VAS 501 002/6- on forcing nut.
– Pull out sleeve of needle bearing by turning socket -VAS 501

002/6- ; counterhold with suitable tool at spindle -VAS 501
001/1- .
– Pull out sleeve of second needle bearing in the same way.
Installing
– Thoroughly clean bearing seats and contact surfaces for rotor
assembly.
– Fit new needle bearing onto tool -T40303- .
• Groove -arrow- faces supercharger housing.
• Seal in needle bearing faces tool.
Caution
Risk of diluting grease filling in needle bearing if too much en‐

gine oil is applied.
♦ Apply only a very thin layer of engine oil.
– Lightly lubricate outer circumference (sleeve) of needle bear‐

ing with engine oil.

– Using assembly tool -T40303- , position needle bearing at hole

in supercharger housing (ensure it is straight) and drive it in
as far as stop with a large plastic hammer.
– Check seating of needle bearing -1- in supercharger housing

-2- after driving needle bearing in:
• Dimension -a- = 1.5 mm
– If necessary, drive needle bearing in further.
– Apply a thin layer of sealant -arrow- to sealing surface for rotor

module on supercharger housing.
– Carefully fit rotor assembly in supercharger housing.
– Ensure that rotors do not damage inner surfaces of super‐
charger housing, and that rotor shafts are inserted into needle
bearings.
– Install drive unit ⇒ page 239 .
– Install magnetic clutch ⇒ page 231 .
1.10 Renewing drive shaft oil seal

♦ Drift - VW 295-
1. Supercharger 245
♦ Sleeve - 3144-
♦ Tube - VW 421-
♦ Plate - T40285-
Procedure
– Remove drive unit ⇒ page 239 .
– Place drive unit on plate - T40285- with front side facing up‐
wards, as shown in illustration.
– Use drift - VW 295- to drive oil seal out of drive unit.

– Place drive unit on sleeve - 3144- with front side facing down‐
wards.
– Drive in oil seal with tube - VW 421- .
• Installation position: Open side of oil seal faces tool.
– Install drive unit ⇒ page 239 .
1.11 Securing supercharger to engine and

gearbox support
⇒ “1.11.1 Securing supercharger to engine and gearbox support
for assembly work”, page 247
⇒ “1.11.2 Securing supercharger to engine and gearbox support
for leak test”, page 249
1.11.1 Securing supercharger to engine and

gearbox support for assembly work
Note
When performing assembly work, the openings in the bottom of

the supercharger housing make it possible for you to see and ac‐
cess the charge air coolers.

♦ Engine and gearbox support - VAS 6095-
1. Supercharger 247
♦ Gearbox support - T40206- with -T40206/1-
♦ Mounting -T40304-
Procedure
• Supercharger removed ⇒ page 224 .
– Insert gearbox support - T40206- with -T40206/1- into engine
– Secure mounting -T40304- to -T40206/1- (only screw in bolts
lightly at first), observing alignment of holes -1, 3, 10, 12- on
mountings and gearbox support - T40206- .

– Place supercharger onto mounting -T40304- , as shown in il‐

lustration.
• Bottom openings in supercharger housing make it possible for
you to see and access charge air coolers.
– Hand-tighten bolts -1- evenly in a diagonal sequence on both
sides.
– Tighten bolts securing mounting -T40304- to -T40206/1- to 21
Nm.
– Tighten bolts -1- on both sides in diagonal sequence to 21 Nm.
1.11.2 Securing supercharger to engine and

gearbox support for leak test
Note
When checking for leaks, the seals on the mountings -T40304-

should seal off the openings in the supercharger housing.

♦ Engine and gearbox support - VAS 6095-
♦ Gearbox support - T40206- with -T40206/1-
1. Supercharger 249
♦ Mounting -T40304-
Procedure
• Supercharger removed ⇒ page 224 .
– Insert gearbox support - T40206- with -T40206/1- into engine
– Secure mounting -T40304- to -T40206/1- (only screw in bolts
lightly at first), observing alignment of holes -2, 5, 8, 14- on
mountings and gearbox support - T40206- .
– Place supercharger onto mounting -T40304- , as shown in il‐

lustration.
• Seals of mountings should seal off openings in supercharger
housing.
– Lightly hand-tighten bolts -1- evenly in a diagonal sequence
on both sides.
– Tighten bolts securing mounting -T40304- to -T40206/1- to 21
Nm.

– Use a feeler gauge -2- to check that bolts are tightened evenly
and adjust if necessary.
• There must be an even gap all around between supercharger
-1- and mounting -T40304- .
• Maximum permissible deviation in gap dimension: 0.2 mm.
1.12 Removing and installing sender 1 for tur‐

bocharger speed - G688-
Removing
– Remove bolt -3- and detach sender 1 for turbocharger speed
- G688- .
Note
Disregard -item 1-.
Installing
Note
Renew seals.

Tightening torques
1. Supercharger 251
2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 252
⇒ “2.2 Exploded view - hose connections for charge air system”,
page 253
⇒ “2.3 Removing and installing charge air cooler”, page 253
⇒ “2.4 Removing and installing charge pressure sender G31 /
G447 ”, page 257
2.1 Exploded view - charge air system
1 - Gasket
2 - O-ring
❑ Coat with engine oil
when installing charge
air cooler
3 - O-ring
air cooler
4 - Gasket
side)
⇒ page 253
6 - Bolt
❑ Self-locking
❑ 10 Nm
7 - Gasket
❑ Must not be detached
from charge air cooler
air cooler
8 - Supercharger housing
9 - Bolt
❑ Self-locking
❑ 10 Nm
10 - Gasket
❑ Must not be detached from charge air cooler
❑ Coat with engine oil when installing charge air cooler


2.2 Exploded view - hose connections for

charge air system
Note
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.
Tightening torque for

1- Hose clip -a- = 13 mm wide: 5.5 Nm
2- Hose clip -b- = 9 mm wide: 3.4 Nm
2.3 Removing and installing charge air cool‐

er
♦ Fitting sleeve - 2033-
2. Charge air system 253

♦ Assembly device for valves - 2036-
♦ Tyre lever for aluminium rims - V.A.G 1942-

Removing
• Supercharger secured to engine and gearbox support - VAS
6095- for assembly work ⇒ page 247 .
– Unscrew bolts -arrows- and detach bracket -1- with change‐
over valves.
Charge air cooler (left-side):
– Remove charge pressure sender 2 - G447- ⇒ page 257 .
Charge air cooler (right-side):
– Remove charge pressure sender - G31- ⇒ page 257 .

– Remove bolts -1- and -2- and detach coolant pipes from su‐
percharger.
– Remove bolts -1, 2- for charge air cooler (left-side) and bolts
-3, 4- for charge air cooler (right-side).

– Attach valve assembly device - 2036- with -2036/1- to super‐

charger, as shown in illustration.
– Apply fitting sleeve - 2033- at front of charge air cooler.
– Using tyre lever - V.A.G 1942- , apply moderate pressure and
slowly press charge air cooler out of supercharger housing.
Installing
Note
♦ Renew gaskets, O-rings and self-locking bolts after removal.

♦ Before assembly, always remove residues from threaded
holes in supercharger housing using a thread tap.
– Check gasket -5- on charge air cooler -4-.

• The gasket must not be cracked or damaged.
– Slide gasket -1- onto charge air cooler.
– Insert O-ring -2- into opening in supercharger housing -3-.
– Coat sealing surface -arrow A- and gasket -arrow B- of charge

air cooler -1- with engine oil.
– Also coat sealing surface inside supercharger housing with
engine oil.

– When fitting charge air cooler, make sure that seals align with
recesses in supercharger housing -arrows-.
Note
To make it easier to insert and press in the charge air cooler,

position the supercharger housing vertically in engine and gear‐
box support - VAS 6095- .
Caution
Risk of damage to charge air cooler.

♦ Only insert charge air cooler by hand.
– Insert charge air cooler in supercharger housing -arrow A- by

hand as far as stop, letting charge air cooler slide into hole
-arrow B- in front of supercharger housing.
– If necessary, guide charge air cooler by hand via openings

-arrows- in supercharger housing when inserting cooler.
– As soon as possible (due to length of bolts), screw in 2 bolts
loosely by hand to guide charge air cooler additionally.
Caution
Risk of damage to charge air cooler.

♦ The charge air cooler must not be pulled in by screwing in
the securing bolts.
♦ Insert charge air cooler by hand (without using tools) until
sealing flange with gasket makes contact with super‐
charger housing (maximum: 1 mm distance). Only then
tighten bolts, as described in the following.

– Tighten bolts -1, 2- for charge air cooler (left-side) and bolts
-3, 4- for charge air cooler (right-side) in diagonal sequence
and in small steps.
note the following:
– Install charge pressure sender ⇒ page 257 .
Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 252
2.4 Removing and installing charge pres‐

sure sender -G31- / -G447-
Removing
– Unscrew bolt -2- and detach charge pressure sender -G31- or
-G447- -item 1-.
Installing
Note
♦ Renew self-locking bolts and O-ring after removal.

♦ Before assembly, always remove residues from threaded
holes for charge pressure senders in supercharger housing
using a thread tap.

Tightening torques

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 258
⇒ “1.2 Checking fuel system for leaks”, page 265
1.1 Overview of fitting locations - injection system

Fitting locations in engine compartment
1 - Intake manifold flap poten‐

tiometer - G336-
❑ Fitting location
⇒ page 260
2 - Secondary air pump motor
- V101-
❑ Exploded view
⇒ page 323
3 - Activated charcoal filter sol‐
enoid valve 1 - N80-
4 - Crankcase breather shut-
off valve - N548-
V50-
⇒ page 259
❑ Exploded view
⇒ page 184
6 - Brake servo pressure sen‐
sor - G294-
⇒ page 260
7 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
⇒ page 259
8 - Brake light switch - F-
⇒ page 259
9 - Engine control unit - J623-
⇒ page 307
❑ Fitting location ⇒ page 260
❑ Exploded view ⇒ page 184
11 - Intake manifold flap potentiometer 2 - G512-
258 Rep. gr.24 - Mixture preparation - injection

Fitting location of accelerator position sender - G79- / accelerator

position sender 2 - G185-
♦ In accelerator pedal module
Note
The accelerator position sender - G79- and accelerator position

sender 2 - G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Removing and installing ⇒ Fuel supply system, petrol engines;

Rep. gr. 20 ; Accelerator mechanism; Removing and installing
accelerator pedal module with accelerator position sender -G79- /
-G185-
Fitting location of brake light switch - F-

♦ On mounting bracket for pedal cluster
1- Brake light switch - F-
Removing and installing ⇒ Brake system; Rep. gr. 45 ; Sensors;
Removing and installing brake light switch
Fitting location of temperature sender for engine temperature

regulation - G694-
♦ -Item 1- below intake manifold (bottom section) on cylinder
bank 1 (right-side)
Removing and installing ⇒ page 192
Fitting location of coolant circulation pump - V50-

♦ On top of gearbox housing
2 - Electrical connector for coolant circulation pump - V50-
1. Injection system 259

Fitting location of charge air cooling pump - V188-

♦ Beneath longitudinal member (front left)
Fitting location of brake servo pressure sensor - G294-

♦ In vacuum hose to brake servo
Removing and installing ⇒ Brake system; Rep. gr. 47 ; Vacuum
system; Removing and installing brake servo pressure sensor
Fitting location of intake manifold flap potentiometer - G336-

♦ Located in intake manifold (bottom section)
2 - Electrical connector for intake manifold flap potentiometer -
G336- .
Note
The fitting location of the intake manifold flap potentiometer 2 -

G512- is symmetrically reversed.
Fitting locations on engine (from above)

1 - Ignition coils with output

stages for cylinder bank 1
♦ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
❑ Exploded view
⇒ page 337
2 - Exhaust camshaft control
valve 1 - N318-
❑ Exploded view
⇒ page 126
3 - Camshaft control valve 1 -
N205-
❑ Exploded view
⇒ page 126
4 - FSI injectors
♦ Injector, cylinder 1 - N30-
❑ Exploded view
⇒ page 282
5 - Knock sensor 1 - G61-
❑ Exploded view
⇒ page 337
6 - Knock sensor 2 - G66-
❑ Exploded view
⇒ page 337
8 - Oil pressure switch for reduced oil pressure - F378-
9 - FSI injectors
10 - Camshaft control valve 2 - N208-
11 - Exhaust camshaft control valve 2 - N319-
12 - Ignition coils with output stages for cylinder bank 2
♦ Ignition coil 4 with output stage - N292-

13 - MPI injectors
♦ Injector 2, cylinder 4 - N535-
♦ Exploded view ⇒ page 272
14 - Hall sender 2 - G163-
15 - Fuel pressure sender - G247-
16 - Fuel pressure sender for low pressure - G410-
17 - Temperature sender for engine temperature regulation - G694-
❑ Fitting location ⇒ page 259
18 - Coolant temperature sender - G62-
19 - Hall sender - G40-
20 - MPI injectors
♦ Exploded view ⇒ page 272
Fitting locations on engine (from left side)


❑ Exploded view
⇒ page 337
2 - Lambda probe 2 after cata‐
lytic converter - G131-
❑ With Lambda probe 2
heater after catalytic
converter - Z30-
❑ Exploded view
⇒ page 302
3 - Lambda probe 2 - G108-
❑ With Lambda probe
heater 2 - Z28-
❑ Exploded view
⇒ page 302
4 - Left electrohydraulic engine
mounting solenoid valve -
N144-
5 - Valve for oil pressure con‐
trol - N428-
❑ Exploded view
⇒ page 167
Fitting locations on engine (from right side)

1 - Engine speed sender -

G28-
❑ Exploded view
⇒ page 337
2 - Lambda probe after catalyt‐
ic converter - G130-
converter - Z29-
❑ Exploded view
⇒ page 302
3 - Lambda probe - G39-
heater - Z19-
❑ Exploded view
⇒ page 302
❑ Exploded view
⇒ page 337
5 - Fuel metering valve - N290-
❑ Exploded view
⇒ page 295
6 - Oil level and oil temperature
sender - G266-
❑ Exploded view
⇒ page 149
7 - Right electrohydraulic en‐
gine mounting solenoid valve -
N145-
Fitting locations on supercharger

1 - Magnetic clutch for super‐

charger - N421-
⇒ page 220
2 - Charge pressure sender -

G31-
⇒ page 220
3 - Throttle valve module -

J338-
❑ Including throttle valve
drive for electric throttle
- G186- , throttle valve
drive angle sender 1 for
electric throttle - G187-
and throttle valve drive
angle sender 2 for elec‐
tric throttle - G188-
❑ Exploded view
⇒ page 220
4 - Engine oil cooler valve -
N554-
5 - Solenoid for coolant circuit
- N492-
6 - Intake manifold flap valve -
N316-
7 - Secondary air inlet valve -
N112-
8 - Intake air temperature
sender - G42- / intake manifold
pressure sender - G71-
❑ Exploded view
⇒ page 220
9 - Regulating flap control unit
- J808-
❑ With regulating flap position control motor - V380- and regulating flap potentiometer - G584-
10 - Charge pressure sender 2 - G447-
11 - Sender 1 for turbocharger speed - G688-
1.2 Checking fuel system for leaks

– Allow engine to run for several minutes at moderate rpm.
– 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 again for leaks.

2 Vacuum system
⇒ “2.1 Connection diagram - vacuum system”, page 266
⇒ “2.2 Checking vacuum system”, page 267
2.1 Connection diagram - vacuum system
Caution
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.
Note
♦ Dark grey = Vacuum supply line

♦ Red = Control pipe to vacuum units for actuating intake mani‐
fold flaps
♦ Pink = Control pipe to the secondary air combination valves
♦ Green = Control pipe to coolant shut-off valve
♦ Light grey = Control pipe to coolant pump

1 - Coolant pump
2 - Vacuum unit
❑ For intake manifold flap
on cylinder bank 1
(right-side)
3 - Secondary air inlet valve -
N112-
4 - Intake manifold flap valve -
N316-
5 - Solenoid for coolant circuit
- N492-
6 - Engine oil cooler valve -
N554-
7 - Combination valve for sec‐
ondary air system (right-side)
ondary air system (left-side)
9 - Vacuum unit
❑ For intake manifold flap
on cylinder bank 2 (left-
side)
11 - Vacuum pump
2.2 Checking vacuum system

♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
2. Vacuum system 267

♦ 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 event memory, check the vacuum lines
leading to the corresponding component and also check the
remaining vacuum lines in the system.
– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

3 Air cleaner
⇒ “3.1 Exploded view - air cleaner housing”, page 269
⇒ “3.2 Removing and installing air cleaner housing”, page 270
3.1 Exploded view - air cleaner housing
1 - Water drain valve

2 - Water drain hose
❑ Clean
3 - Air cleaner housing
❑ Clean out dirt, leaves
and salt deposits
⇒ page 270
4 - Hose
❑ Leading to secondary
air pump motor - V101-
5 - O-ring
❑ Renew
6 - Mounting
❑ For air cleaner housing
7 - Air filter element
❑ Use genuine air filter el‐
ement ⇒ Electronic
parts catalogue
❑ Change intervals ⇒
Maintenance tables
let 811 , ⇒ Mainte‐
nance ; Booklet 812 or
let 818
8 - Air cleaner (top section)
❑ Clean out dirt, leaves
and salt deposits
9 - Bolt
❑ 1.5 Nm
10 - Bolt
❑ 1.5 Nm
11 - Connection
12 - Air pipe
❑ With resonator
13 - Air duct
14 - Air duct
15 - Bolt
❑ 2 Nm
16 - Air duct
❑ On lock carrier
3. Air cleaner 269

17 - Rubber buffer
3.2 Removing and installing air cleaner

housing
Removing
ments .
clear at air pipe.
-arrows-.
– Remove bolts -arrows- at air duct -1-.
Note
Disregard -item 2-.
– Detach air cleaner housing and, if fitted, unplug electrical con‐

nector -arrow- at on reverse side of air cleaner.
Installing
Note
♦ The air cleaner housing MUST be clean.

♦ To prevent malfunctions, cover critical parts of the engine air
intake (such as air pipes, etc.) with a clean cloth when blowing
out the air cleaner housing with compressed air.
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.

– Blow out water drain -1- with compressed air.

– Vehicles with hot air intake: Make sure it is engaged correctly
-arrows-.
note the following:
ments .
Tightening torques
tem”, page 253
3. Air cleaner 271

4 Intake manifold
⇒ “4.1 Exploded view - intake manifold (bottom section) with fuel
rail”, page 272
⇒ “4.2 Removing and installing intake manifold (bottom section)
with fuel rail”, page 274
⇒ “4.3 Removing and installing throttle valve module J338 ”, page
278
⇒ “4.4 Removing and installing regulating flap control unit J808 ”,
page 280
4.1 Exploded view - intake manifold (bottom section) with fuel rail
MPI low-pressure injection system
Note
Illustration shows components for cylinder bank 2 (left-side).
1 - Vacuum hose
❑ To intake manifold flap
valve - N316-
2 - O-ring
3 - Intake manifold flap poten‐
tiometer 2 - G512-
side): intake manifold
flap potentiometer -
G336-
4 - O-ring
5 - Retaining clip
6 - Injector
❑ For MPI low-pressure
injection system
Removing and installing
⇒ page 286
7 - O-ring
8 - Fuel rail
❑ For MPI low-pressure
injection system
stalling intake manifold
(bottom section) with
fuel rail”, page 274
9 - Fuel pressure sender for
low pressure - G410-
❑ 15 Nm

10 - Bolt
❑ 9 Nm
11 - Fuel supply line
❑ For MPI low-pressure injection system
12 - Bolt
❑ 9 Nm
13 - Fuel hose
14 - Bolt
❑ 5 Nm
15 - Gaskets
16 - Bolt
❑ Tightening torque ⇒ page 273 , ⇒ page 273
17 - Intake manifold (bottom section)
18 - Gaskets
Intake manifold (bottom section) for cylinder bank 1 (right-side) -

tightening torque
– Tighten bolts and nuts -arrows- in stages (final torque 9 Nm).
Intake manifold (bottom section) for cylinder bank 2 (left-side) -

tightening torque
– Tighten bolts and nuts -arrows- in stages (final torque 9 Nm).
4. Intake manifold 273

Throttle valve module - J338- - tightening torque

– Tighten bolts -arrows- in diagonal sequence to 10 Nm.
Regulating flap control unit - J808- - tightening torque and se‐

quence
Stage Bolts Tightening torque
1. -5, 6- Screw in by hand until contact is made
2. -6- 10 Nm
3. -5- 10 Nm
4.2 Removing and installing intake manifold

(bottom section) with fuel rail
♦ Tool inserts - V.A.G 1331/2-
Removing

Intake manifold (bottom section) for cylinder bank 1 (right-side):

– Move fuel hose -1- clear at MPI fuel rail.
– Unplug electrical connectors -4- and move electrical wiring
clear.
Note
Place a cloth underneath to catch escaping fuel.
WARNING

– Release hose clip -2- and detach fuel hose.

– Remove bolts -3- and -arrow-.
– Disconnect vacuum hose -2-.

– Unscrew bolts -arrows- and detach bottom section of intake
manifold (right-side), paying attention to MPI fuel line -3-.

Intake manifold (bottom section) for cylinder bank 2 (left-side):
Note
Place a cloth underneath to catch escaping fuel.
WARNING


– Unplug electrical connectors -3- and move electrical wiring
clear.
– Remove bolts -1- and -arrows-.
– Unplug electrical connector -2- and disconnect vacuum hose

-1-.
– Unscrew bolts -arrows- and detach bottom section of intake
manifold (left-side), paying attention to MPI fuel line.
Caution

♦ Block off the intake ports with clean cloths to prevent small
objects from dropping into the engine through the intake
ports in the cylinder heads.
Installing
Note


Caution
Risk of damage to intake manifold flaps.

♦ To prevent the intake manifold flaps from catching on the
guide plates in the cylinder head, the flaps must be in the
power mode position -arrows- (intake passage fully open)
when the intake manifold (bottom section) is installed.
Intake manifold (bottom section) for cylinder bank 1 (right-side):

– Connect hand vacuum pump - VAS 6213- to vacuum unit
(right-side), as shown in illustration.
– Use vacuum pump to generate a vacuum.
• This will cause the intake manifold flaps to open.
Intake manifold (bottom section) for cylinder bank 2 (left-side):

– Connect hand vacuum pump - VAS 6213- to vacuum hose
-1- for vacuum unit (left-side), as shown in illustration.
– Use vacuum pump to generate a vacuum.
• This will cause the intake manifold flaps to open.
– Tighten bolts and nuts for intake manifold (bottom section).
– Press intake manifold (bottom section) with fuel rail evenly on‐
to injectors.
– Disconnect hand vacuum pump from vacuum unit/vacuum
hose.
Tightening torques
♦ ⇒ “4.1 Exploded view - intake manifold (bottom section) with
♦ ⇒ Fig. ““Intake manifold (bottom section) for cylinder bank 2
(left-side) - tightening torque”“ , page 273
♦ ⇒ Fig. ““Intake manifold (bottom section) for cylinder bank 1
(right-side) - tightening torque”“ , page 273

4.3 Removing and installing throttle valve

module - J338-
Removing
clear at air pipe.
-arrows-.

– Remove bolts -arrows- and detach throttle valve module -
J338- .
– Disconnect intermediate flange from crankcase breather shut-
off valve - N548- and detach.
Caution

♦ Block off the intake port with a clean cloth to prevent small
items from dropping into the supercharger.
Installing
Note


– Insert intermediate flange -2- with O-rings into supercharger

-1- -left arrows-.
– Fit throttle valve module - J338- -item 3- on intermediate flange
-right arrows-.
– Tighten bolts -4-.
– Engage crankcase breather shut-off valve - N548- .
– Adapt throttle valve module after renewal:
♦ Power train
♦ Functions
♦ Adapt throttle valve control module
Tightening torques
♦ ⇒ Fig. ““ Throttle valve module -J338- - tightening torque”“ ,
page 274
tem”, page 253

4.4 Removing and installing regulating flap

control unit - J808-
Removing
– Remove bolts -5- and -6-.
– Detach bypass elbow -1- with intermediate flange -2- and reg‐
ulating flap control unit - J808- -item 4-.
Installing
Note

– Adapt regulating flap control unit after renewal:
♦ Power train
♦ Functions
♦ Adapt regulating flap control unit
Tightening torques
♦ ⇒ Fig. ““ Regulating flap control unit -J808- - tightening torque
and sequence”“ , page 274
4.5 Removing and installing fuel line

Removing
– Remove intake manifold (bottom section) for cylinder bank 1
(right-side) ⇒ page 274 .
ments .


– Detach air duct -1- with intermediate flange -2- from air cleaner
housing.
– Unscrew bolts -2, 3- and detach connection -1-.

– Remove bolts -arrows-, detach fuel line and unplug electrical
connector -1-.
Installing
ments .
– Install intake manifold (bottom section) for cylinder bank 1
(right-side) ⇒ page 274 .
Tightening torques

5 Injectors
⇒ “5.1 Exploded view - fuel rail with injectors”, page 282
⇒ “5.2 Removing and installing fuel rail”, page 284
⇒ “5.3 Removing and installing injectors”, page 285
⇒ “5.4 Cleaning injectors”, page 290
5.1 Exploded view - fuel rail with injectors

⇒ “5.1.1 Exploded view - fuel rail with injectors, vehicles up to
03.2015”, page 282
⇒ “5.1.2 Exploded view - fuel rail with injectors, vehicles from
04.2015 onwards”, page 283
5.1.1 Exploded view - fuel rail with injectors, vehicles up to 03.2015

FSI high-pressure injection system
1 - Injector
⇒ page 286
❑ Cleaning ⇒ page 290
2 - Spacer ring
❑ Renew if damaged
3 - O-ring
❑ Lubricate lightly with
clean engine oil
4 - Support ring
❑ Make sure it is correctly
seated
❑ Via this support ring, the
fuel rail exerts the force
which holds the injector
in the cylinder head
5 - Fuel pressure sender -
G247-
⇒ page 292
❑ Lubricate threads lightly
with clean engine oil
❑ 25 Nm
6 - Bolt
❑ 9 Nm
7 - High-pressure pipe
⇒ page 299
❑ Do not alter shape
❑ Check for damage before re-installing
❑ To loosen and tighten high-pressure pipe, counterhold at pipe connection
❑ Lubricate threads of union nuts with fuel
❑ 25 Nm

8 - Connection
❑ 40 Nm
9 - Fuel rail
10 - Bolt
❑ Tighten alternately in stages; final torque 9 Nm
11 - Washer
❑ Installation position: conical side faces injector
12 - Retaining ring
❑ Fitting location: side with collar faces injector
13 - Circlip
14 - Combustion chamber ring seal
❑ Renew after removing ⇒ “5.3.2 Removing and installing injectors, FSI engines”, page 286
❑ Do not apply grease or use any other lubricants
5.1.2 Exploded view - fuel rail with injectors, vehicles from 04.2015 onwards
FSI high-pressure injection system
1 - Bolt
❑ 9 Nm
⇒ page 299
❑ Check for damage be‐
fore re-installing
❑ To loosen and tighten
high-pressure pipe,
counterhold at pipe con‐
nection
❑ Lubricate threads of un‐
ion nuts with fuel
❑ 25 Nm
3 - Connection
❑ 40 Nm
4 - Fuel rail
5 - Bolt
❑ Tighten alternately in
stages; final torque 9
Nm
6 - Support ring
❑ Make sure it is correctly
seated
❑ Via this support ring, the
fuel rail exerts the force
which holds the injector
in the cylinder head
5. Injectors 283
7 - O-ring
❑ Lubricate lightly with clean engine oil
8 - Spacer ring
9 - Injector
❑ Cleaning ⇒ page 290
10 - Combustion chamber ring seal
❑ Renew after removing ⇒ “5.3.2 Removing and installing injectors, FSI engines”, page 286
❑ Do not apply grease or use any other lubricants
11 - Fuel pressure sender - G247-
❑ Lubricate threads lightly with clean engine oil
❑ 25 Nm
5.2 Removing and installing fuel rail
Note
The removal and installation procedures are described for cylin‐

der bank 2 (left-side).
Removing

WARNING

– Remove union nut -1- and bolts -arrows- and detach fuel rail
-3- from injectors.
Note
Unplug electrical connectors of any injectors that remained

lodged in fuel rail.
Installing
Note
Renew O-rings.

be renewed.
Tightening torques
♦ ⇒ “5.1 Exploded view - fuel rail with injectors”, page 282
5.3 Removing and installing injectors

⇒ “5.3.1 Removing and installing injectors, MPI engines”,
page 285
⇒ “5.3.2 Removing and installing injectors, FSI engines”,
page 286
5.3.1 Removing and installing injectors, MPI

engines
Note
The removal and installation procedures are described for cylin‐

der bank 1 (right-side).
5. Injectors 285
Removing
– Move fuel hose -1- clear.
– Unplug electrical connectors -4-.
WARNING


– Remove bolts -arrow- and detach fuel rail with injectors from
intake manifold (bottom section).
Note
Disregard -item 3-.
– Remove retaining clip -2- and detach injector -3- from fuel rail
-1-.
Installing
Note
♦ Renew O-rings.

Tightening torques
5.3.2 Removing and installing injectors, FSI

engines

♦ Tool set for FSI engines - T10133 C-
Removing
– Remove relevant fuel rail ⇒ page 284 .
Removing any injectors lodged in fuel rail:
– Carefully pull injectors out of fuel rail.
Removing any injectors lodged in cylinder head:
– Cover open inlet ports with a clean cloth.
– Unplug electrical connector on injector that is to be removed.
– Slide sleeve -T10133/18A- over injector.
– Carefully knock against stop sleeve several times to loosen
injector.
Note
♦ Use a torque wrench to pull out injector.

♦ Adjust torque wrench to 5 Nm.
– Apply puller -T10133/20- to groove on injector.

– Attach puller -T10133/16A- .
– Pull out injector by turning bolt with torque wrench.
– If injector does not come loose after limit torque of 5 Nm is
reached, remove puller and repeat procedure using sleeve to
loosen injector.
Note
♦ Observe correct torque to avoid irreparable damage to injec‐

tor.
♦ Renew combustion chamber ring seal before re-installing in‐
jector.
5. Injectors 287
Dismantling injector - vehicles up to 03.2015

– Pull support ring -4-, O-ring -3- and spacer ring -2- off injector
-1-.
Note
Renew retaining ring -6-, washer -5- and circlip -7- only if they are
damaged or when installing a new injector.
– Carefully remove old combustion chamber ring seal -8-. To do

so, cut open combustion chamber ring seal using knife or prise
open with small screwdriver and then pull off forwards.
Note
Take care not to damage groove on injector. The injector must be

renewed if the groove is damaged.
Dismantling injector - vehicles from 04.2015 onwards

– Pull support ring -5- and spacer ring -3- off injector -2-.
– Carefully remove old combustion chamber ring seal -1-. To do
so, cut open seal using knife or prise open with small screw‐
driver and then pull off forwards.
Note
Take care not to damage groove on injector. The injector must be

renewed if the groove is damaged.
Installing
Note
♦ Renew combustion chamber ring seal, spacer ring, O-ring and

support ring after removing.
♦ Lubricate O-rings of injectors lightly with clean engine oil.
– Clean bore in cylinder head with nylon cylinder brush -

T10133/4- .

– Fit assembly cone -T10133/5- with new combustion chamber

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

ber ring seal onto assembly cone -T10133/5- as far as it will
go.
– Turn round assembly sleeve -T10133/6- and slide combustion
chamber ring seal into groove.
Note
The combustion chamber ring seal is widened when it is pushed

onto the injector. After pushing it on, it therefore has to be com‐
pressed again. This is done in two stages, as described below.
– Push calibration sleeve -T10133/7- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again by turning it in the
opposite direction.
– Push calibration sleeve -T10133/8- onto injector as far as it will

go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/8- off again by turning it in the
opposite direction.
5. Injectors 289
Fully assembling injector - vehicles up to 03.2015

– Fit parts from repair kit onto injector -1-:
2 - Spacer ring
3 - O-ring
4 - Support ring
5 - Washer
6 - Retaining ring
7 - Circlip
– To make it easier to install injector in fuel rail, lubricate new O-
ring lightly with clean engine oil before installing it.
Note
The combustion chamber ring seal -8- must not be lubricated.
Fully assembling injector - vehicles from 04.2015 onwards

– Fit parts from repair kit onto injector -2-:
3 - Spacer ring
4 - O-ring
5 - Support ring
– To make it easier to install injector in fuel rail, lubricate new O-
ring lightly with clean engine oil before installing it.
Note
The combustion chamber ring seal -1- must not be lubricated.
All vehicles (continued)

– Use assembly tool -T10133/9- to insert injector as far as it will
go into hole in cylinder head; note correct installation position.
• Electrical connector of injector must engage in recess in cyl‐
inder head.
Note
It should be possible to insert the injector easily. If necessary wait

until the combustion chamber ring seal has contracted sufficient‐
ly.
Perform further installation in reverse order, paying attention to

the following:
– Install fuel rail ⇒ page 284 .
5.4 Cleaning injectors


♦ Ultrasonic cleaning unit - VAS 6418-

♦ Mounting plate for injection modules - VAS 6418/1-
♦ Cleaning fluid - VAS 6418/2-
Cleaning
– Remove injectors ⇒ page 286 .
– Close drain tap -arrow- on ultrasonic cleaning unit - VAS 6418-
(located on right side of housing).
– Fill ultrasonic unit with 2,120 ml of water which has been al‐
lowed to settle for a few minutes and cleaning fluid - VAS
6418/2- .
Mixture ratio for cleaning fluid
• 2,100 ml of tap water which has been allowed to settle for a
few minutes and 20 ml of cleaning fluid - VAS 6418/2-
– Place mounting plate for injection modules - VAS 6418/1- on

top of cleaning unit.
WARNING
It is important to read the safety notes in the operating instruc‐

tions before switching on the ultrasonic cleaning unit - VAS
6418- .
The ideal fluid level is approx. 1-4 mm above the base of the
mounting plate. The ultrasonic cleaning unit - VAS 6418- can
be damaged if the fluid level is too low.
– Insert FSI injectors all the way into guides of mounting plate
for injection modules - VAS 6418/1- .
– Switch on cleaning unit by pressing on/off button -C-.

– Select a cleaning time of 30 minutes with rotary control -A-.
– Set rotary control -B- to a temperature of 50°C.
– Press ► button -D- to start cleaning procedure.
Note
♦ The temperature-controlled cleaning process is now started.

While the fluid is being heated, the ultrasound is activated at
intervals in order to circulate the cleaning solution. The ultra‐
sound is activated continuously when the preselected tem‐
perature is reached.
♦ The actual cleaning process commences when the tempera‐
ture reaches at least 50 ℃ and must last for at least 30
minutes.
– Install injectors with new combustion chamber seal

⇒ page 286 .
5. Injectors 291
6 Senders and sensors

⇒ “6.1 Removing and installing intake air temperature sender
G42 / intake manifold pressure sender G71 ”, page 292
⇒ “6.2 Removing and installing fuel pressure sender G247 ”, page
292
⇒ “6.3 Removing and installing fuel pressure sender for low pres‐
sure G410 ”, page 293
6.1 Removing and installing intake air tem‐

perature sender - G42- / intake manifold
pressure sender - G71-
Removing
– Unscrew bolts -arrows- and detach intake air temperature
sender - G42- / intake manifold pressure sender - G71- .
Note
Disregard -item 2-.
Installing
Note

Tightening torques
6.2 Removing and installing fuel pressure

sender - G247-
♦ Assembly tool - T10118-

♦ Socket (27 mm) - T40218- or commercially available socket

(27 mm)
Removing
WARNING

– Unscrew fuel pressure sender - G247- -item 2-.

Installing
– Check tightening torque of connection before tightening fuel
pressure sender.
Tightening torques
6.3 Removing and installing fuel pressure

sender for low pressure - G410-
Removing
6. Senders and sensors 293


– Unscrew fuel pressure sender for low-pressure - G410-
-item 1-.
Installing
Tightening torques

7 High-pressure pump
⇒ “7.1 Exploded view - high-pressure pump”, page 295
⇒ “7.2 Removing and installing high-pressure pump”, page 296
⇒ “7.3 Removing and installing high-pressure pipe”, page 299
7.1 Exploded view - high-pressure pump
1 - Bolt
2 - High-pressure pump
❑ With fuel metering valve
- N290-
❑ Do not dismantle
⇒ page 296
3 - Union nut
❑ Lubricate thread of un‐
ion nut with fuel
❑ 27 Nm
4 - O-ring
5 - Bolt
❑ 9 Nm
6 - Fuel supply hose with con‐
nection
❑ Low-pressure side lead‐
ing from fuel tank
⇒ page 299
❑ Check for damage be‐
fore re-installing
8 - Bolt
❑ 9 Nm
9 - Roller tappet
❑ Can only be installed in one position
❑ Lubricate lightly with clean engine oil before installing
10 - Gasket
11 - Housing
12 - O-ring
13 - Hall sender - G40-
14 - Bolt
7. High-pressure pump 295

15 - Threaded pin
❑ 9 Nm
16 - Protective plate
❑ For high-pressure pipe
17 - Nut
❑ 9 Nm
18 - Bolt
❑ 9 Nm
19 - Fuel supply hose with connection
❑ Low-pressure side to MPI injectors
20 - Bolt
❑ 9 Nm
21 - O-ring
22 - O-ring
High-pressure pump - tightening torque and sequence

Stage Bolts Tightening torque
1. -arrows- Screw in by hand until contact is made
2. -arrows- Tighten in stages; final torque 20 Nm
7.2 Removing and installing high-pressure

pump
♦ Ratchet - V.A.G 1331/1-
♦ Socket insert AF 14, flared ring spanner - V.A.G 1331/8-

♦ Feeler gauge
Removing
Note
♦ The high-pressure pump should only be removed and installed

when the engine is cold.
♦ When installing the high-pressure fuel pump, it is essential to
ensure that no dirt enters the fuel system.
♦ Use a cloth to catch escaping fuel.
– Remove air cleaner housing ⇒ page 270 .

– Unscrew nuts -arrows- and remove guard plate -1-.

WARNING


– Unscrew bolt -2- and detach connection -1-.
Note
Disregard -item 3-.

– Remove bolt -2- on retaining clip.
– Remove union nut -1-.
– Carefully pull out high-pressure pump. It is possible that the
roller tappet may remain lodged inside.
Note
Do not attempt to bend high-pressure pipe to a different shape.
Installing
Note

♦ The connections of the high-pressure pipe must not be dam‐
aged.
♦ Do not attempt to bend high-pressure pipe to a different shape.

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

– Lightly lubricate roller tappet with oil and insert it so that lug
-arrow A- slides into guide notch -arrow B-.

gine.
noise insulation .
– Rotate crankshaft in direction of engine rotation -arrow- using

adapter - T40058- and angled ring spanner, and at the same
time press roller tappet into housing until it reaches lowest
point.
– Only lift high-pressure pipe slightly to fit high-pressure pump.
– Press high-pressure pump down by hand as far as possible
onto stop.
– At the same time, tighten securing bolts by hand.
– Tighten bolts; for procedure refer to ⇒ page 296 .
– Install high-pressure pipe ⇒ page 299 .
– Check fuel system for leaks ⇒ page 265 .
Tightening torques
♦ ⇒ Fig. ““High-pressure pump - tightening torque and se‐
♦ ⇒ “7.1 Exploded view - high-pressure pump”, page 295
7.3 Removing and installing high-pressure

pipe

♦ Open end spanner insert, AF 17 - V.A.G 1331/6-
Removing
– Remove fuel line for MPI injection system ⇒ page 280 .
WARNING

– Remove union nuts -1, 2, 3-. If necessary, counterhold threa‐

ded connection.
Note
Do not attempt to bend high-pressure pipe to a different shape.
Installing
Note
♦ The connections of the high-pressure pipe must not be dam‐

aged.
♦ Do not attempt to bend high-pressure pipe to a different shape.

be renewed.

– First tighten union nut by hand until it makes contact, making

sure that high-pressure pipe is not under tension.
– Tighten union nut with torque wrench - V.A.G 1331- and open
end spanner insert AF 17 - V.A.G 1331/6- ; to do so, counter‐
hold at hexagon flats of threaded connection on fuel rail with
an open-end spanner.
– Do not tighten bolt for retainer until high-pressure pipe has
been tightened.
– Install fuel line for MPI injection system ⇒ page 280 .
Tightening torques
♦ ⇒ “7.1 Exploded view - high-pressure pump”, page 295

8 Lambda probe
⇒ “8.1 Exploded view - Lambda probe”, page 302
⇒ “8.2 Removing and installing Lambda probe”, page 303
8.1 Exploded view - Lambda probe
Note
♦ New Lambda probes are coated with an assembly paste.

♦ In the case of a used Lambda probe, coat only the thread with high-temperature paste; refer to ⇒ Electronic
parts catalogue for high-temperature paste.
♦ The assembly paste / high-temperature paste must not make contact with the slots on the Lambda probe
body.
1 - Lambda probe 2 after cata‐

lytic converter - G131-
converter - Z30-
⇒ page 304
❑ 55 Nm
2 - Lambda probe 2 - G108-
heater 2 - Z28-
⇒ page 304
❑ 55 Nm
3 - Lambda probe - G39-
heater - Z19-
⇒ page 303
❑ 55 Nm
4 - Lambda probe after catalyt‐
ic converter - G130-
converter - Z29-
⇒ page 303
❑ 55 Nm

8.2 Removing and installing Lambda probe

⇒ “8.2.1 Removing and installing Lambda probe G39 / G130 ”,
page 303
⇒ “8.2.2 Removing and installing Lambda probe G108 / G131 ”,
page 304
8.2.1 Removing and installing Lambda probe

-G39- / -G130-
♦ Lambda probe open ring spanner set - 3337-
Removing
Note

– Unplug relevant electrical connector and move electrical wir‐
ing clear:
1- For Lambda probe after catalytic converter - G130-
2- For Lambda probe - G39-
Lambda probe - G39- :

– Remove bolts -arrows- and unplug electrical connectors at ig‐
nition coils.
– Press electrical wiring harness -1- up slightly.
8. Lambda probe 303

Continuation for both Lambda probes:

– Unscrew relevant Lambda probe using ring spanner -3337/7- :
1- Lambda probe - G39-
2- Lambda probe after catalytic converter - G130-
Note
For illustration purposes, the installation position is shown with

the engine removed.
Installing
Note

♦ If re-installing the old Lambda probes, coat the threads with
high-temperature paste ⇒ Electronic parts catalogue .
♦ The assembly paste/high-temperature paste must not get into
the slots on the Lambda probe body.
♦ 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.

Tightening torques
♦ ⇒ “8.1 Exploded view - Lambda probe”, page 302
8.2.2 Removing and installing Lambda probe

-G108- / -G131-
♦ Lambda probe open ring spanner set - 3337-
Removing
Note


– Unplug relevant electrical connector and move electrical wir‐
ing clear:
1- For Lambda probe 2 - G108-
2- For Lambda probe 2 - G131- (after catalytic converter)
Lambda probe 2 - G108- :

– Disconnect coolant hose -2- from coolant expansion tank.
– Remove bolts -arrows-, unplug electrical connector at coolant
shortage indicator switch - F66- and move coolant expansion
tank to one side with coolant hose -1- attached.
8. Lambda probe 305

Continuation for both Lambda probes:

– Unscrew relevant Lambda probe using ring spanner -3337/7- :
1- Lambda probe 2 - G108-
2- Lambda probe 2 after catalytic converter - G131-
Note

the engine removed.
Installing
Note

♦ If re-installing the old Lambda probes, coat the threads with
high-temperature paste ⇒ Electronic parts catalogue .
♦ The assembly paste/high-temperature paste must not get into
the slots on the Lambda probe body.
♦ 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.

Tightening torques
♦ ⇒ “8.1 Exploded view - Lambda probe”, page 302

9 Engine control unit

⇒ “9.1 Removing and installing engine control unit J623 ”,
page 307
9.1 Removing and installing engine control

unit - J623-
⇒ “9.1.1 Removing and installing engine control unit J623 without
protective housing”, page 307
⇒ “9.1.2 Removing and installing engine control unit J623 with
protective housing”, page 308
9.1.1 Removing and installing engine control

unit - J623- without protective housing
Removing
Note
If renewing engine control unit, select “Replace and code engine

control unit” on ⇒ vehicle diagnostic tester .

chamber cover .
– Pull off rubber seal in front of nut -1- on plenum chamber cover
slightly.
– Unhook wiring harness -2- from retainers -A-.
– Remove nut -1-.
– Pull filler neck -3- with filler pipe out of washer fluid reservoir
and through opening in body.
– Remove bolts -arrows- and detach cover for electronics box.
9. Engine control unit 307

– Release retainers -arrows A- and take out engine control unit

- J623- -arrow B-.
Installing
chamber cover .
– Activate new engine control unit:
♦ Power train
♦ Functions
♦ Replace and code engine control unit
Tightening torques
♦ Filler neck for washer fluid reservoir ⇒ Electrical system; Rep.
gr. 92 ; Windscreen washer system; Exploded view - wind‐
screen washer system
♦ ⇒ Electrical system; Rep. gr. 97 ; Relay carriers, fuse carriers,
electronics boxes; Overview of fitting locations - relay carriers,
fuse carriers, electronics boxes
9.1.2 Removing and installing engine control

unit - J623- with protective housing
Note
♦ Not every engine control unit is bolted to a protective housing.

Whether a protective housing is fitted depends on the engine/
gearbox combination.
♦ The engine control unit -1- is bolted to a protective casing
-2 and 5-. To make it more difficult to unscrew the shear bolts
-4- for locking plate -2-, their threads have been coated with
locking fluid.
♦ The metal housing has to be removed before the connectors
can be unplugged from the engine control unit (e.g. to connect
the test box or renew the engine control unit).

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐

ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small grinder (commercially available)

Removing
Note
If renewing engine control unit, select “Replace and code engine

control unit” on ⇒ vehicle diagnostic tester .

chamber cover .
– Pull off rubber seal in front of nut -1- on plenum chamber cover
slightly.
– Unhook wiring harness -2- from retainers -A-.
– Remove nut -1-.
– Pull filler neck -3- with filler pipe out of washer fluid reservoir
and through opening in body.
– Remove bolts -arrows- and detach cover for electronics box.

– Release retainers -arrows A- and take out engine control unit

- J623- -arrow B-.
Caution
Wiring, connectors, insulation and control units can be burnt

and damaged.
♦ Keep exactly to the following procedure. Observe the in‐
structions for operating the hot air blower.
To help prevent unauthorised access to the connectors on the

engine control unit, the engine control unit -1- is bolted to a pro‐
tective housing -5- by means of shear bolts -3 and 4- and a locking
plate -2-.
The threads of the two shear bolts -4- which are not screwed into
the engine control unit are secured with locking fluid. To unscrew
these two bolts, the threads must therefore be heated with the hot
air blower.
The threads of the two shear bolts -3- which are screwed into the
engine control unit are not secured with locking fluid. Do not apply
heat to the threads in the control unit housing; this is not neces‐
sary and would cause overheating of the control unit.
– Select settings on hot air blower -4- as shown in illustration:

2 - Temperature potentiometer to maximum heat output
3 - Two-stage air flow switch to position “3”
WARNING
Risk of burns from hot air blower.

♦ Parts of the protective housing will become very hot as a
result of heating the threads. It is also important to ensure
that only the thread is heated and none of the surrounding
components if at all possible. These should be covered if
necessary.

– Switch on hot air blower and heat bolt for 20 ... 30 seconds.
– Unscrew shear bolts using vice-grip pliers -arrow-.

– The two shear bolts screwed into the engine control unit do
not need to be heated. They should be removed without being
heated.
– Detach protective housing from control unit connectors.
– Release and unplug electrical connectors from engine control
unit.
Installing
– It is important that protective housing is re-fitted on engine
control unit - J623- with new shear bolts.
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
chamber cover .
– Activate new engine control unit:
♦ Power train
♦ Functions
♦ Replace and code engine control unit
Tightening torques
♦ Filler neck for washer fluid reservoir ⇒ Electrical system; Rep.
gr. 92 ; Windscreen washer system; Exploded view - wind‐
screen washer system
♦ ⇒ Electrical system; Rep. gr. 97 ; Relay carriers, fuse carriers,
electronics boxes; Overview of fitting locations - relay carriers,
fuse carriers, electronics boxes

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 312
⇒ “1.2 Separating exhaust pipes/silencers”, page 314
⇒ “1.3 Removing and installing front silencers”, page 315
⇒ “1.4 Removing and installing silencers”, page 317
⇒ “1.5 Stress-free alignment of exhaust system”, page 317
⇒ “1.6 Checking exhaust system for leaks”, page 318
1.1 Exploded view - silencers
1 - Bolt
❑ 23 Nm
2 - Mounting
❑ Check preload
⇒ “1.5 Stress-free align‐
ment of exhaust sys‐
tem”, page 317
3 - Nut
❑ 23 Nm
4 - Clamp (front)
⇒ page 314
❑ Before tightening, align
exhaust system so it is
free of stress
⇒ page 317
❑ Tighten bolted connec‐
tions evenly
5 - Bolt
❑ 23 Nm
6 - Mounting
❑ Check preload
⇒ “1.5 Stress-free align‐
ment of exhaust sys‐
tem”, page 317
7 - Centre silencer
❑ Combined in one unit
with rear silencers as
original equipment. Can
be renewed individually
for repair purposes
❑ For removal on A5 Cabriolet/Sportback: Remove diagonal struts ⇒ page 314
❑ Cutting point ⇒ page 314
❑ Align exhaust system so it is free of stress ⇒ page 317
8 - Rear silencer (left-side)
❑ Combined as one unit with centre silencer as original equipment
312 Rep. gr.26 - Exhaust system

❑ Centre silencer and rear silencer can be renewed separately

❑ Cutting point: centre silencer / rear silencer ⇒ page 314
9 - Mounting
❑ Check preload ⇒ “1.5 Stress-free alignment of exhaust system”, page 317
10 - Nut
❑ 23 Nm
11 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 317
❑ Tighten bolted connections evenly
12 - Nut
❑ 23 Nm
13 - Nut
❑ 20 Nm
14 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 317
❑ Tighten bolted connections evenly
15 - Nut
❑ 23 Nm
16 - Mounting
❑ Check preload ⇒ “1.5 Stress-free alignment of exhaust system”, page 317
17 - Nut
❑ 23 Nm
18 - Rear silencer (right-side)
❑ Combined as one unit with centre silencer as original equipment
❑ Centre silencer and rear silencer can be renewed separately
❑ Cutting point: centre silencer / rear silencer ⇒ page 314
1. Exhaust pipes/silencers 313

Installation position of front clamps

– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp.
• Installation position: bolted connections face outwards.
Installation position of rear clamps

bottom of clamp.
• Installation position: bolted connections face forwards.
Diagonal struts (Audi A5 Cabriolet/Sportback)

– Remove diagonal struts -1- and -2- before removing Y-pipe
and rear silencer unit.
– Install diagonal struts ⇒ Running gear, axles, steering; Rep.
gr. 42 ; Subframe; Exploded view - subframe .
1.2 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at the cutting point in
order to renew the centre or rear silencer separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.

♦ Chain pipe cutter - VAS 6254-
Procedure
view - subframe .
– Cut through exhaust pipes at right angle at the position marked
-arrows- using chain pipe cutter - VAS 6254- .
– Position centre of clamps -arrows- over cutting location.

bottom of clamp.
• Installation position: bolted connections face forwards.
– Align the exhaust system so it is free of stress ⇒ page 317 .
Tightening torques
♦ ⇒ “1.1 Exploded view - silencers”, page 312
♦ Diagonal struts ⇒ Running gear, axles, steering; Rep. gr. 42 ;
Subframe; Exploded view - subframe
1.3 Removing and installing front silencers


♦ Special wrench 12 mm -T40252-
Removing
– Remove noise insulation (rear) ⇒ General body repairs, ex‐
noise insulation .
– Unscrew nuts -arrows- for front silencer (left or right) using tool
-T40252- .
Caution

than 10°.
– Release and push back clamp -1- or -2- and detach relevant
front silencer.
Installing
Note
Renew gaskets and self-locking nuts after removal.

Tightening torques

1.4 Removing and installing silencers

Removing
view - subframe .
Caution

than 10°.
– Release clamps -1 and 2- and push to rear.
WARNING
Risk of accident caused by weight of silencer.

♦ A second mechanic is required for removal of the silencer.
– Unscrew bolts -1, 2- and remove silencers.

Installing
Note

Tightening torques
♦ Diagonal struts ⇒ Running gear, axles, steering; Rep. gr. 42 ;
Subframe; Exploded view - subframe
1.5 Stress-free alignment of exhaust system

Procedure
• The exhaust system must be aligned when it is cool.
Vehicles without clamps between centre silencer and rear silenc‐
ers
– Loosen bolted connections on front clamps.
– Push exhaust system towards front of vehicle -arrow- until
mountings in front of centre silencer are preloaded by -a- =
6 ... 10 mm.
– Tighten bolted connections on clamps evenly.
– Align tailpipes ⇒ page 318 .

Vehicles with clamps between centre silencer and rear silencers
Note
On a vehicle with clamps fitted between the centre silencer and

rear silencers, it is also necessary to align the centre silencer.
– Loosen bolted connections on front and rear clamps.

– Push exhaust system towards front of vehicle -arrow- until
mountings in front of centre silencer are preloaded by -a- =
6 ... 10 mm.
– Tighten bolted connections on front clamps evenly.
– Push rear section of exhaust system towards front of vehicle

-arrow-, so that mountings (rear) for rear silencers are preloa‐
ded by -a- = 11 ... 15 mm.
– Align rear silencers so they are horizontal.
– Tighten bolted connections on rear clamps evenly.
– Align tailpipes ⇒ page 318 .
Aligning tailpipes
• Dimension -x- (left-side) = dimension -x- (right-side)
If necessary, correct dimension “x” as follows:

– Loosen connection -arrow- on strut between exhaust pipes.
– Adjust the distance between the rear silencers.
Tightening torques
1.6 Checking exhaust system for leaks

– Start the engine and run at idling speed.
– Plug tailpipes during leak test (e.g. with cloth or plugs).

– Listen for noise at connection points (cylinder head/exhaust

manifold, exhaust manifold/catalytic converter, etc.) to locate
any leaks.
– Rectify any leaks that are found.

2 Emission control system

⇒ “2.1 Exploded view - emission control system”, page 320
⇒ “2.2 Removing and installing catalytic converter”, page 321
2.1 Exploded view - emission control system
1 - Front silencer
❑ With flexible joint; do not
bend flexible joint more
than 10° – otherwise it
can be damaged
⇒ page 315
❑ Align exhaust system so
it is free of stress
⇒ page 317
2 - Exhaust manifold
⇒ page 332
3 - Gasket
4 - Nut
❑ Coat thread with high-
temperature paste; for
high-temperature paste
refer to ⇒ Electronic
parts catalogue
❑ 23 Nm
5 - Catalytic converter
❑ Protect against knocks
and impact
❑ Removing and instal‐
ling: left-side
⇒ page 321 , right-side
⇒ page 322
❑ Mounting components
⇒ page 321
6 - Nut
❑ 23 Nm
7 - Gasket

Components of mountings for catalytic converter

1- Nut, 23 Nm
2- Spacer sleeve
3- Compression spring
4- Washer
5- Bolt
6- Bolt, 23 Nm
7- Spacer sleeve
8- Buffer
9- Bracket
10 - Bolt, 23 Nm
11 - Bracket
Note
The illustration shows the mountings on the right side as an ex‐

ample.
2.2 Removing and installing catalytic con‐

verter
⇒ “2.2.1 Removing and installing catalytic converter (left-side)”,
page 321
⇒ “2.2.2 Removing and installing catalytic converter (right-side)”,
page 322
2.2.1 Removing and installing catalytic con‐

verter (left-side)
Removing
Note

clear.
Note
Disregard -item 1-.
2. Emission control system 321

– Unscrew nuts -arrows- and detach catalytic converter (left-

side).
Note
Disregard -item 1-.
Installing
Note
Tightening torques
♦ ⇒ “2.1 Exploded view - emission control system”, page 320
2.2.2 Removing and installing catalytic con‐

verter (right-side)
Removing
Note
– Take electrical connector -1- for Lambda probe after catalytic

clear.
Note
Disregard -item 2-.
– Detach catalytic converter (right-side).
Note
Catalytic converter (right-side) is already unbolted for removal of

gearbox.
Installing
Note
Tightening torques
♦ ⇒ “2.1 Exploded view - emission control system”, page 320

3 Secondary air system

⇒ “3.1 Exploded view - secondary air system”, page 323
⇒ “3.2 Removing and installing secondary air pump motor V101
”, page 325
⇒ “3.3 Checking combination valve”, page 325
⇒ “3.4 Removing and installing combination valve”, page 327
3.1 Exploded view - secondary air system

Secondary air pump motor - V101-
1 - Bonded rubber bush

❑ 3x
2 - Secondary air pump motor
- V101-
❑ Fitting location: At front
left of engine compart‐
ment below longitudinal
member
⇒ page 325
3 - Hose
❑ For secondary air
4 - O-ring
5 - Nut
❑ 9 Nm
6 - Pipe
❑ For secondary air
7 - Bolt
❑ 8 Nm
8 - Nut
❑ 9 Nm
9 - O-ring
10 - O-ring
11 - Bracket
❑ For secondary air pump motor - V101-
12 - Nut
❑ 9 Nm
13 - Nut
❑ 9 Nm
Combination valves for secondary air system
3. Secondary air system 323

1 - Gasket
ondary air system (left-side)
❑ Check operation and
check for leaks
⇒ page 325
⇒ page 327
3 - Gasket
4 - Hose
❑ From secondary air
pump motor - V101-
5 - Bolts
❑ 9 Nm
6 - Gasket
7 - Vacuum hose
ondary air system (right-side)
❑ Check operation and
check for leaks
⇒ page 325
⇒ page 329
9 - Gasket
10 - Heat shield
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 9 Nm
13 - Bolt
❑ 9 Nm
14 - Heat shield
15 - Bolt
❑ 9 Nm
16 - Vacuum hose
17 - Bolts
❑ 9 Nm

3.2 Removing and installing secondary air

pump motor - V101-
Removing
Note

noise insulation .
– Unplug electrical connector -2- at secondary air pump motor -
V101- .
– Press release tabs and detach secondary air hoses -1- and
-3-.
– Remove air intake grille (right-side) ⇒ General body repairs,
exterior; Rep. gr. 63 ; Bumper (front); Removing and installing
attachments .
– Remove bolts -arrows- and detach secondary air pump.
Note

the bumper cover removed.
Installing
Note
– Install closure plate for bumper cover and air intake grille ⇒
General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Removing and installing attachments .
Tightening torques
3.3 Checking combination valve


Procedure
• Vacuum hoses and hose connections do not leak.
• Vacuum hoses are not clogged.
– Release fasteners -arrow- and press wiring duct -1- towards
rear.
– Detach vacuum hose -1- or -2- from combination valve to be

checked.
– Connect hand vacuum pump - VAS 6213- to vacuum hose of
combination valve to be checked.

– Press release tabs and detach secondary air hose -arrow-

from secondary air pump motor - V101- .
– Extend secondary air hose with a test hose and blow lightly
into secondary air hose with your mouth (do not use com‐
pressed air).
• The combination valves for secondary air should be closed; it
should not be possible to blow through the hose.
– Operate hand vacuum pump.
• The combination valve should open; it should now be possible
to blow through the hose.
Note
It is necessary to overcome slight initial resistance before it is

possible to blow through the hose.
– Renew combination valve for secondary air system if it does

not open ⇒ page 327 .
Assembling
Note
3.4 Removing and installing combination

valve
⇒ “3.4.1 Removing and installing combination valve (left-side)”,
page 327
⇒ “3.4.2 Removing and installing combination valve (right-side)”,
page 329
3.4.1 Removing and installing combination

valve (left-side)
Removing
Note
– Remove front silencer (left-side) ⇒ page 315 .



clear.
Note
Disregard -item 1-.
– Remove bolt -1- and nuts -arrows-, detach catalytic converter

(left-side) from exhaust manifold and move to rear.
– Remove bolts -arrows- and detach heat shield -1-.
– Remove bolts -3- for secondary air system hose.

– Detach vacuum hose -2- from combination valve for secon‐
dary air system.
– Unscrew bolts -1- and detach combination valve for secondary
air system.
Installing
Note
Tightening torques

3.4.2 Removing and installing combination

valve (right-side)
Removing
Note
– Remove front silencer (right-side) ⇒ page 315 .

– Unplug electrical connectors:
1- For Lambda probe after catalytic converter - G130-
2- For Lambda probe - G39-
– Remove bolt -1- and nuts -arrows-, detach catalytic converter

(right-side) from exhaust manifold and move to rear.
– Remove bolts -arrows- and detach heat shield -1-.

– Detach vacuum hose -3- from combination valve for secon‐

dary air system.
air hose -2-.
– Remove bolts -4- and detach combination valve (right-side) for
secondary air system and bolts -1- for secondary air hose.
Installing
Note
Tightening torques

4 Exhaust manifolds
⇒ “4.1 Exploded view - exhaust manifold”, page 331
⇒ “4.2 Removing and installing exhaust manifolds”, page 332
4.1 Exploded view - exhaust manifold
1 - Nut
❑ Coat thread with high-
temperature paste; for
high-temperature paste
refer to ⇒ Electronic
parts catalogue
tightening sequence:
left-side ⇒ page 332 ;
right-side ⇒ page 332
2 - Bracket
❑ For heat shield
3 - Exhaust manifold
⇒ page 332
4 - Gasket
5 - Bolt
❑ 9 Nm
6 - Heat shield
7 - Washer
8 - Bolt
❑ 9 Nm
9 - Lambda probe
❑ Before catalytic convert‐
er
⇒ page 303
10 - Nut
❑ Coat thread with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 23 Nm
11 - Gasket
4. Exhaust manifolds 331

Exhaust manifold (left-side) - tightening torque and sequence
Note
♦ Renew nuts after removing.

♦ Coat threads of nuts with high-temperature paste; for high
temperature paste refer to ⇒ Electronic parts catalogue .
– Tighten nuts in stages in the sequence shown:

Stage Nuts Tightening torque
2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm
Exhaust manifold (right-side) - tightening torque and sequence
Note
♦ Renew nuts after removing.

– Tighten nuts in stages in the sequence shown:

Stage Nuts Tightening torque
2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm
4.2 Removing and installing exhaust mani‐

folds
⇒ “4.2.1 Removing and installing exhaust manifold (left-side)”,
page 332
⇒ “4.2.2 Removing and installing exhaust manifold (right-side)”,
page 334
4.2.1 Removing and installing exhaust mani‐

fold (left-side)
Removing
Note
– Remove front silencer (left-side) ⇒ page 315 .

– Remove Lambda probe 2 - G108- ⇒ page 304 .
– Detach poly V-belt from air conditioner compressor
⇒ page 52 .
left side ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐

tioner compressor; Detaching and attaching air conditioner

compressor at bracket .
– Remove bolt -1- and nuts -arrows- and push catalytic convert‐
er towards rear of vehicle.
– Remove bolt -1- and nut -2- and push coolant pipe (left-side)
clear to side.
Note
Disregard -arrows-.
– Remove bolt -1- and move coolant valve to side with hoses
-2, 3- attached.
– Remove engine mounting (left-side) ⇒ page 42 .

– Unscrew bolts -arrows- and remove engine support (left-side).

– Remove bolts -1 … 4- and detach heat shield towards front.
– Remove nuts -1- and -8- and detach bracket for heat shield.
– Remove nuts -2 … 7- and -9- and detach exhaust manifold.
Installing
Note
♦ Renew seals and nuts after removing.

– Fit exhaust manifold with gasket for catalytic converter and

tighten nuts ⇒ page 332 .
– Install engine support and engine mounting (left-side)
⇒ page 42 .
– Install Lambda probe 2 - G108- ⇒ page 304 .
Tightening torques
♦ ⇒ “4.1 Exploded view - exhaust manifold”, page 331
♦ ⇒ Fig. ““Exhaust manifold (left-side) - tightening torque and
4.2.2 Removing and installing exhaust mani‐

fold (right-side)
Removing
– Remove Lambda probe - G39- ⇒ page 303 .
noise insulation .
– Remove front silencer (right-side) ⇒ page 315 .

– Remove front wheel (right-side) ⇒ Running gear, axles, steer‐

ing; Rep. gr. 44 ; Wheels, tyres .
– Take electrical connector -1- for Lambda probe after catalytic
clear.
Note
Disregard -item 2-.
– Remove bolt -1- and nuts -arrows- and push catalytic convert‐
er clear towards right side.
Note

the engine removed.
– Remove nut -1- and bolt -2- and push coolant pipe clear to one
side.
Note
Disregard -arrows-.

air hoses -arrows-.
– Remove nuts -1, 3- and bolt -2-, move secondary air pipe to
side.

– Remove bolts -1, 3, 4- and detach heat shield.
Note
Disregard -item 2-.
– Remove nuts -7- and -9- and detach bracket for heat shield.
– Remove nuts -1 … 6- and -8- and detach exhaust manifold
upwards.
Installing
Note
♦ Renew seals and nuts after removing.

– Fit exhaust manifold with gasket for catalytic converter and

tighten nuts ⇒ page 332 .
– Install Lambda probe - G39- ⇒ page 303
Note

Tightening torques
♦ ⇒ “4.1 Exploded view - exhaust manifold”, page 331 .
♦ ⇒ Fig. ““Exhaust manifold (right-side) - tightening torque and
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres

28 – Ignition system
1 Ignition system
⇒ “1.1 Exploded view - ignition system”, page 337
⇒ “1.2 Test data, spark plugs”, page 338
⇒ “1.3 Removing and installing ignition coils with output stages”,
page 338
⇒ “1.4 Removing and installing knock sensor”, page 340
⇒ “1.5 Removing and installing Hall senders”, page 341
⇒ “1.6 Removing and installing engine speed sender G28 ”, page
341
1.1 Exploded view - ignition system
1 - Bolt
❑ 9 Nm
2 - Hall sender
side)
♦ Inlet side: Hall sender -
G40-
♦ Exhaust side: Hall sender 3
- G300-
⇒ page 341
3 - O-ring
4 - Knock sensor
❑ Contact surfaces be‐
tween knock sensor and
cylinder block must be
free of corrosion, oil and
grease
♦ Cylinder bank 1 (right-side):
knock sensor 1 - G61-
♦ Cylinder bank 2 (left-side):
knock sensor 2 - G66-
⇒ page 340
5 - Bolt
❑ 25 Nm
6 - Spark plug
❑ Remove and install with
spark plug socket and
extension - 3122 B-
let 811 , ⇒ Maintenance ; Booklet 812 or ⇒ Maintenance ; Booklet 818
❑ Tightening torque ⇒ Maintenance ; Booklet 811 , ⇒ Maintenance ; Booklet 812 or ⇒ Maintenance ;
Booklet 818
❑ Change interval ⇒ Maintenance tables
1. Ignition system 337

7 - Ignition coil with output stage

❑ Ignition coil 1 with output stage - N70-
8 - Bolt
❑ 5 Nm
9 - Electrical wiring harness
10 - Engine speed sender - G28-
11 - Bolt
❑ 9 Nm
12 - O-ring
13 - Hall sender
❑ Cylinder bank 2 (left-side)
♦ Inlet side: Hall sender 2 - G163-
♦ Exhaust side: Hall sender 4 - G301-
14 - Bolt
❑ 9 Nm
1.2 Test data, spark plugs

3.0 ltr. TFSI engine
Idling speed Cannot be adjusted; regulated by idling speed sta‐
bilisation
Ignition timing Not adjustable (determined by control unit)
Ignition system Multi-coil system with 6 ignition coils (output stages
integrated) connected directly to spark plugs via
spark plug connectors
Spark plugs Designations ⇒ Electronic parts catalogue
Tightening torque ⇒ Maintenance ; Booklet 811 , ⇒ Maintenance ;
Booklet 812 or ⇒ Maintenance ; Booklet 818
Firing order 1-4-3-6-2-5
1.3 Removing and installing ignition coils

with output stages
338 Rep. gr.28 - Ignition system

♦ Puller - T40039-
Removing
– Disconnect coolant hose -2- from coolant expansion tank.
– Remove bolts -arrows-, unplug electrical connector at coolant
shortage indicator switch - F66- and move coolant expansion
tank to one side with coolant hose -1- attached.

– Remove bolts -arrows- and unplug electrical connectors at ig‐
nition coils.
– Move electrical wiring harness -1- down slightly.
Note
Illustration shows the installation position for cylinder bank 2 (left-

side) as an example.
Note
♦ To remove ignition coils, fit puller - T40039- onto upper (thick)

rib -arrow- of ignition coil with output stage.
♦ The lower ribs can be damaged if they are used.

– Pull out ignition coil -arrow-.

Installing
Tightening torques
tem”, page 253
♦ ⇒ “1.1 Exploded view - ignition system”, page 337
1.4 Removing and installing knock sensor

Removing
Knock sensor 1 - G61- , cylinder bank 1 (right-side):
– Remove FSI injector for cylinder 2 ⇒ page 286 .
– Take electrical connector -arrow- out of bracket, unplug it and
move electrical wiring clear.
Knock sensor 2 - G66- , cylinder bank 2 (left-side):

– Remove FSI injector for cylinder 5 ⇒ page 286 .
– Take electrical connector -arrow- out of bracket, unplug it and
move electrical wiring clear.

– Remove bolt -1- for knock sensor 1 - G61- or bolt -2- for knock
sensor 2 - G66- and detach knock sensor.
Installing
– Install FSI injector ⇒ page 286 .
Tightening torques
340 Rep. gr.28 - Ignition system

1.5 Removing and installing Hall senders

Removing
– Unplug electrical connector -1- (cylinder bank 1).
– Unscrew bolt -arrow- and remove Hall sender - G40- .
– Unplug electrical connector -1- (cylinder bank 2).

– Remove bolt -arrow- and detach Hall sender 2 - G163- .
Installing
Note

Tightening torques
1.6 Removing and installing engine speed

sender - G28-
Removing
– Remove noise insulation (rear) ⇒ General body repairs, ex‐
noise insulation .
– Unscrew bolt -1- and pull out engine speed sender - G28- .
Installing
Install in reverse order.
Tightening torques

6-Cylinder Direct Injection Engine (Evo) With Supercharger (3 0 LTR 4-Valve TFSI)

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

4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 167

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

3.1 Exploded view - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

1.1 Engine identification number/engine da‐

The engine cover panel must be removed to make the engine

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

♦ The 4-character engine code can be found on the type plate

2.1 Safety precautions when working on the fuel supply system

Risk of fire due to escaping fuel

2.2 Safety precautions when working on vehicles with start/stop system

2 Rep. gr.00 - Technical data

2.4 Safety precautions when working on the cooling system

2.5 Safety precautions when working on the ignition system

Risk of damage to components

2.6 Safety precautions when working on the

Risk of damage to running gear components.

2.7 Safety precautions when working on the

Risk of damage to flexible joint.

4 Rep. gr.00 - Technical data

3.1 Rules for cleanliness

3.2 Foreign particles in engine

3.3 Contact corrosion

Note the following:

3.4 Routing and attachment of pipes, hoses

3.5 Installing radiators and condensers

6 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

1. Removing and installing engine 7

♦ Support set for Audi - VAS 6131/10-

♦ Support set, Audi A8 >2002 - VAS 6131/11-

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

♦ Special wrench 12 mm -T40252-

8 Rep. gr.10 - Removing and installing engine

♦ The engine is removed from underneath together with the

– Set front wheels to straight-ahead position.

Electronic components are susceptible to damage.

– Switch off ignition.

1. Removing and installing engine 9

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

– Open filler cap on coolant expansion tank.

– Place drip tray for workshop hoist - VAS 6208- underneath.

10 Rep. gr.10 - Removing and installing engine

– Remove drain plug -1- and drain off coolant.

– Unplug electrical connector -3- from charge air cooling pump

Disregard -items 1, 2-.

– Position used oil collection and extraction unit - VAS 6622A-