4-Cylinder TDI Engine (2 0 LTR 4-Valve Common Rail)

Service
4-cylinder TDI engine (2.0 ltr. 4-valve common rail)

Engine ID
CAG CAG CAG CAH CAH CME
A B C A B A
Edition 10.2016
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
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug 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.
A005A401320
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail) - Edition 10.2016
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 . . . . . . . . . . . . . . . . 3
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 4
2.4 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.2 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3 Removing and installing torque reaction support and cross member . . . . . . . . . . . . . . . . 33
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Exploded view - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.7 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.8 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Renewing needle bearing in drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4 Pulling spur gear off crankshaft and shrink-fitting new spur gear . . . . . . . . . . . . . . . . . . . . 64
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Contents i
4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.2 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.4 Separating parts of new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.5 Bearing shells - installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.6 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.2 Exploded view - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.6 Identification of cylinder head gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Exploded view - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.2 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.4 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.1 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3 Oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.1 Exploded view - oil filter housing/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.4 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4 Balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.1 Removing and installing balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.1 Exploded view - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.2 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 152
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.4 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.5 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ii Contents
2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 159

2.7 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 160
3 Radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.1 Exploded view - radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.3 Removing and installing radiator fan control unit J293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.4 Removing and installing radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.4 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.1 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.2 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.3 Exploded view - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.4 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.5 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.6 Checking fuel pressure (low pressure) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.1 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.2 Removing and installing air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.3 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5 Injectors/high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.1 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.2 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.3 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
5.4 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 215
5.5 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 218
5.6 Checking pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.7 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5.8 Removing and installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5.9 Removing and installing high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
6.1 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
6.2 Performing first fuel filling operation after installing high-pressure pump . . . . . . . . . . . . . . 234
7 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
7.1 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
7.2 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 237
7.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
7.4 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
7.5 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 242
Contents iii
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

8.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
9.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 247
9.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
1.4 Renewing tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.1 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.2 Removing and installing exhaust gas temperature sender . . . . . . . . . . . . . . . . . . . . . . . . 264
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.2 Exploded view - exhaust gas recirculation valve N18 with exhaust gas recirculation
potentiometer G212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.3 Removing and installing exhaust gas recirculation valve N18 . . . . . . . . . . . . . . . . . . . . . . 272
4.4 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.5 Removing and installing vacuum unit for exhaust gas recirculation cooler . . . . . . . . . . . . 274
5 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.3 Different types of glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.4 Handling ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
iv Contents
00 – Technical data
1 Identification
(ARL004979; Edition 10.2016)
⇒ “1.1 Engine identification number/engine data”, page 1
1.1 Engine identification number/engine da‐

ta
Engine number
♦ The engine number (“engine code” and “serial number”)
-arrow- can be found on the left side (seen in the direction of
travel) at the joint between engine and gearbox.
♦ There is also a sticker with “engine code” and “serial number”
attached to the toothed belt cover.
♦ Engine codes starting with the letter “C” have four letters (pre‐
viously three letters).
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped onto 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 four-letter engine code is found on the type plate (country

specific version), vehicle data sticker and engine control unit.
♦ Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 811 or
⇒ Maintenance ; Booklet 812 .
For engine data refer to:

♦ A4 ⇒ Technical data for diesel engines; Rep. gr. 00 ; Overview
of engines
♦ A5 Coupé ⇒ Technical data for diesel engines; Rep. gr. 00 ;
Overview of engines
♦ A5 Cabriolet ⇒ Technical data for engines; Rep. gr. 00 ;
Overview of engines
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 3
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
⇒ “2.4 Safety precautions when working on the subframe”,
page 4
⇒ “2.5 Safety precautions when working on the cooling system”,
page 4
⇒ “2.6 Safety precautions when working on the exhaust system”,
page 5
2.1 Safety precautions when working on the

fuel supply system
When working on the fuel system note the following warnings:
WARNING
Fuel under pressure - risk of injuries!

♦ Put a clean cloth around the connection before opening
the fuel system. Then carefully loosen the connection to
relieve the pressure.
♦ Put on protective gloves.
♦ Put on safety goggles.
Very hot fuel - risk of burn injuries!
♦ After switching off the engine, the temperature of fuel
pipes and the fuel itself can be up to 100 °C in extreme
cases. Let fuel cool off before opening any connections;
otherwise there is a danger of scalding!
♦ Put on protective gloves.
Caution
The high-pressure pump has very close tolerances and must

not be allowed to run without fuel. To prevent this and to enable
the engine to start quickly after parts have been renewed, it is
important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure pump are removed or renewed, the
fuel system must be bled ⇒ page 197 .
♦ If the high-pressure pump is removed or renewed, the first
fuel filling operation must be performed before the engine
is started for the first time ⇒ page 197 .
2 Rep. gr.00 - Technical data

Observe the following points to prevent personal injuries and

damage to the injection and glow plug system:
♦ Persons wearing a cardiac pacemaker must at all times main‐
tain a safe distance from high-voltage components such as
injectors and gas-discharge headlights.
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off ignition before washing engine.
♦ Erase any entries in event memory resulting from repairs
⇒ Vehicle diagnostic tester, Guided Functions , then In-
terrogate event memory .
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
WARNING
Escaping fuel can cause a risk.

♦ The power supply for the fuel system pressurisation pump
- G6- must be disconnected before opening the fuel sys‐
tem, since -G6- will be activated briefly when the driver's
door is opened with the battery still connected.
2.2 Safety precautions when working on ve‐

hicles with start/stop system
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (indicated by
a message in the instrument cluster), the engine may start
automatically if it needs to.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
2. Safety precautions 3
2.3 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
Accidents can be caused if the driver is distracted by test

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

subframe
Please note the following warnings when working on the sub‐
frame:
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.

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

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.

Caution
Overheating can occur if the filler cap is not fitted properly.

♦ The filler cap must engage positively and audibly when it
is closed.

exhaust system
WARNING
Please note the following warnings when working on all parts

of the exhaust system:
♦ Wear gloves (e.g. rubber, not textile) and safety goggles
to avoid contact with eyes and skin - risk of injury.
♦ Do not dismantle exhaust gas temperature sender - risk
of injury.
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.
2. Safety precautions 5
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 6
⇒ “3.2 General notes”, page 6
⇒ “3.3 General repair instructions”, page 7
⇒ “3.4 Foreign particles in engine”, page 8
⇒ “3.5 Contact corrosion”, page 8
⇒ “3.6 Routing and attachment of pipes, hoses and wiring”, page
8
⇒ “3.7 Installing radiators and condensers”, page 8
3.1 Rules for cleanliness

Even small quantities of dirt can lead to defects. For this reason,
please observe the following rules when working on the fuel sup‐
ply system, injection system and turbocharger:
♦ Clean connections and surrounding area thoroughly with en‐
gine cleaner or brake cleaner and dry cleaned area before
loosening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Do not remove sealing caps from components until immedi‐
ately prior to installation. Keep components that are to be re-
used in new, sealable plastic bags.
♦ After removal, place parts on a clean surface and cover them.
Use lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ Do not work with compressed air when the system is open. If
possible, do not move vehicle.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
3.2 General notes

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.

♦ The vehicles are fitted with a crash/fuel shut-off system. This

system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump via the fuel pump relay.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system ⇒ page 2 .
3.3 General repair instructions
Caution
The high-pressure pump has very close tolerances and must

not be allowed to run without fuel. To prevent this and to enable
the engine to start quickly after parts have been renewed, it is
important to observe the following:
and the high-pressure pump are removed or renewed, the
fuel system must be filled and bled before the engine is
started for the first time ⇒ page 197 .
♦ Clean tools and workbench etc. before working on the injection

system.
♦ Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
♦ If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
♦ Take care not to damage the injectors when removing the old
copper seals.
♦ Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
♦ Position high-pressure pipes so they are free of stress. Tighten
all unions lightly to start with before tightening to final torque.
♦ Never attempt to bend high-pressure fuel lines to shape.
♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely and sealed properly by
pulling them by hand from above.
♦ Do not dismantle individual common rail components. If there
is a fault, the complete components must be renewed.
♦ When the engine is running, do not perform any repairs to the
common rail system.
♦ Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
♦ All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
3. Repair instructions 7
♦ Fuel hoses in engine compartment must only be secured with

spring-type clips. O-type clips or screw-type clips must not be
used.
3.4 Foreign particles in engine

When performing assembly work on the engine, all open passag‐
es 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.
3.5 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi Genuine Parts.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.
3.6 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).
3.7 Installing radiators and condensers

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

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 9
⇒ “1.2 Securing engine to engine and gearbox support”,
page 23
⇒ “1.3 Installing engine”, page 24
1.1 Removing
Protected byengine
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Special tools and workshop equipment
with respect required
to the correctness of information in this document. Copyright by AUDI AG.
♦ Removal lever - 80 - 200-
♦ Hose clip pliers - V.A.G 1921-
♦ Drip tray for workshop hoist - VAS 6208-
1. Removing and installing engine 9

♦ Locking tool - T40098-
♦ Support bracket - 10 - 222 A-
♦ Shackle - 10-222 A/12-
♦ Workshop hoist - VAS 6100-
10 Rep. gr.10 - Removing and installing engine

♦ Lifting tackle - 2024 A-
Procedure
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
♦ Lift out engine without gearbox.

♦ Collect drained coolant in a clean container for re-use or dis‐
posal.
♦ Fit all cable ties in the original positions when installing.
♦ On four-wheel drive vehicles the electromechanical parking
brake must be released before disconnecting the battery, so
that the propshaft can be turned during removal.
Caution

♦ Observe notes on procedure for disconnecting the battery
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting
and connecting battery .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Remove both front wheels.
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove front exhaust pipe ⇒ page 254 .
– Set lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Setting service position
and returning to normal position .

– Remove air cleaner housing

⇒ “3.3 Removing and installing air cleaner housing”,
page 204 .
– Remove engine cover panel -arrows-.
– Remove seal -arrow-.

– Unclip and detach plenum chamber covers -1, 2, 3-.
– Lift off foam plastic block -1- on both sides of vehicle

-arrows-.
– Release retainer -arrow A- and open cover -arrow B-.

– Remove nuts -1 ... 3- for electrical wiring.

– Detach electrical connector -4- from bracket and unplug.
– Remove bolt -5- and detach wiring junction 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 catch -arrow B- and move wiring duct forwards

-arrow A- to open wiring duct and move electrical wiring clear.
– Remove nut -1- and swivel filler neck for washer fluid reservoir
slightly upwards -arrow A-.
– Pull filler neck -2- 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-.
– Unplug electrical connectors -4- and unscrew nut -3- for wiring.
– If fitted, unplug electrical connector -2-.
– Release catches -arrow- and detach relay carrier with fuse
holder -1-.

– Release catches -arrows A- and lift off wiring protector -1-

-arrow B-.
– Disengage engine wiring harness at electronics box in engine
compartment and move clear.
– Place wiring harness on engine and secure engine control unit
to prevent it from dropping.
WARNING

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.

– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– Unscrew radiator drain tap -1- at connection and drain off

coolant, then detach connection -2- from radiator.
– Remove nuts -3- and longitudinal struts -2- on both sides.
– Remove bolts -1- and remove torque reaction support.

– Remove bolts -2- on both sides and remove cross member
-3-.

– Open hose clip -arrow-, detach air hose and swivel to side.
– Remove nut -2- for bracket with wiring on right-hand side of

vehicle.
– Unscrew nut -arrow- on longitudinal member (right-side) and

move earth cables clear.
– Unplug electrical connector -1- for radiator fan (push retainer

to the rear -arrow- and press down release catch).
– Place wiring harness on engine and secure to prevent it from
dropping.

– Disconnect vacuum hose -2- on rear of plenum chamber par‐

tition panel -arrow- and detach vacuum connection -1- from
plenum chamber partition panel.
– Remove nut -5-.

– Detach coolant hoses -1- to -4- and remove plenum chamber
partition panel.
– Remove bolts -2 ... 6-.
Note
♦ Bolt -2- secures the starter to the gearbox and is provided with
an additional spacer sleeve -arrow-.
♦ Pay attention to the spacer sleeve -arrow- when removing and
installing the engine. The spacer sleeve must be fitted be‐
tween starter and gearbox.

– Detach coolant hose -2- and permanent breather -1-.
– Detach permanent breather -1- and coolant hose -2- from

coolant expansion tank.
– Release hose clips -arrows- and detach air hose.

– Unplug electrical connector for charge pressure sender - G31-
-1- and move clear.
– Unplug electrical connector -1- for Lambda probe - G39- and

electrical connector -2- for exhaust gas temperature sender 3
- G495- and move clear.
– Unplug electrical connector -3- for exhaust gas pressure sen‐
sor 1 .
– Remove bolt -4- and unclip air hoses for exhaust gas pressure
sensor 1 .

– Remove nuts -1- and detach bracket -2-.
– Remove nuts -1- to -3- on turbocharger.
Note
Nut -1- is accessible from below on vehicles with auxiliary heater.
– Open clips -arrows- and remove toothed belt cover.
Note
Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tip pen. If the belt runs in the opposite direction when
it is refitted, this can cause breakage.
– Swivel tensioner in direction of -arrow-, detach poly V-belt from

alternator pulley and lock tensioner using locking tool -
T40098- .
– Take off poly V-belt.

– Remove bolts -arrows- and detach pulley.
– Unbolt power steering pump -arrows- and tie up to one side;

the hoses/pipes remain connected.
Caution
Observe rules for cleanliness when working on the fuel supply

system ⇒ page 6 .
– Disconnect fuel supply hose -1- and fuel return hose -2-.
– Unplug electrical connectors -1-, -2- and -3- and move clear.
– Remove bolts -arrows- and tie air conditioner compressor up
to one side; the hoses/pipes remain connected.

– Support gearbox using engine and gearbox jack - V.A.G 1383

A- with gearbox support - T10337- attached.
– Remove bolts -arrows- for tunnel cross member.
– Lower gearbox using engine and gearbox jack - V.A.G 1383

A- as far as distance -a-.
• Dimension -a- = 80 mm (maximum).
– Use release tool -T40138- to unplug electrical connector -1- at

reversing light switch - F4- and move clear.

– Unclip electrical wiring -A- from gearbox and unplug electrical

connector -C-.
– Raise gearbox using engine and gearbox jack - V.A.G 1383

A- and fit bolts -arrows- for tunnel cross member.
– Detach bottom cover -1- from gearbox -arrow-.
– Remove 3 bolts -arrow- for drive plate. Turn crankshaft each

time by 120° in direction of engine rotation.

– Remove bolt -1- securing starter (work from side facing en‐
gine).
– Detach starter from gearbox, place starter on engine support
and secure to prevent it from dropping out.
Note
♦ It is not possible to remove the starter completely.

♦ When installing the engine, the starter must therefore be put
back into position before joining the engine to the gearbox.
– Unscrew remaining bolts -7 ... 10- securing engine to gearbox.
– Set up support bracket - 10 - 222 A- with stands - 10-222 A/8-

on suspension turrets (left and right) as illustrated.
– Use shackle - 10-222 A/12- to hook spindle onto gearbox.
Note
Shown in illustration with engine removed.
– Pre-tension spindle of support bracket - 10-222 A- slightly.
– Attach lifting tackle - 2024 A- to engine and workshop hoist -

VAS 6100- as shown in illustration.
– Tighten bolts -1- for left and right engine mountings.
Note
Check that all hoses and other connections between engine and
body have been detached.
– Raise engine until engine mountings are clear.

– Tighten spindle of support bracket - 10-222 A- further.
– Separate engine from gearbox and lift engine out of engine
compartment.
1.2 Securing engine to engine and gearbox

support
Special tools and workshop equipment required

♦ Engine and gearbox support - VW 540-
♦ Engine and gearbox support - VAS 6095-
Procedure
– Secure engine to engine and gearbox support - VW 540- .
– Secure engine to engine and gearbox support - VAS 6095-
using -VW 540- .
1.3 Installing engine

Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gear 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
M8 20
M10 40

Component Nm
M12 65
Securing engine to manual gearbox
Item Bolt Nm
1 3) M10 x 50 1) 65
2 4) M12 x 100 2) 30 + 90°
3 5), 6 M12 x 75 2) 30 + 90°
4 … 5 5) M12 x 120 2) 30 + 90°
7…9 M10 x 75 2) 15 + 90°
10 M12 x 50 2) 30 + 90°
A Dowel sleeves for centralising
• 1) Steel bolt - is not renewed
• 2) Renew bolts.
• 3) Also secures starter
• 4)Also secures starter, with additional spacer sleeve be‐
tween starter and gearbox
• 5) Also secures cable retainer
Procedure
Note
♦ Renew the bolts tightened with specified tightening angle.

♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings.
♦ Hose connections and hoses for charge air system must be
free of oil and grease prior to fitting.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ To secure the charge air hoses at their connections, spray rust
remover onto the worm thread of the used hose clips before
installing.
– Check that dowel sleeves for centring engine and gearbox are
fitted in the cylinder block; install missing dowel sleeves.
– Before installing gearbox, remove residue from threaded holes
for engine/gearbox bolts in cylinder block using a thread tap.
– The following preparations are required before joining engine
and gearbox:

– Insert assembly aid - T40169- into gearbox housing between

flywheel/torque converter and gearbox housing from below, as
illustrated.
• The assembly aid -T40169- 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 retainer -T40170- into gearbox housing from below and

clamp onto flange shaft -1-.
Note
The next work step is only required if a drive plate with locating
pins -2- is fitted.
– In addition, align drive plate relative to clutch module so that

locating pins -2- (if fitted) on drive plate are in position to en‐
gage in large holes -1- in clutch module.
Caution
Incorrect installation will cause the clutch mechanism to mal‐

function.
♦ If the locating pins of the drive plate -2- do not engage in
the holes in the clutch module -1-, this can cause serious
malfunctioning of the clutch mechanism.

Note
♦ Bolt -2- secures the starter to the gearbox and is provided with
an additional spacer sleeve -arrow-.
♦ Pay attention to the spacer sleeve -arrow- when removing and
installing the engine. The spacer sleeve must be fitted be‐
tween starter and gearbox.
– Place starter in engine support and secure to prevent it from

dropping out.
Note
After the engine has been joined to the gearbox, the starter can
no longer be installed without removing the engine support.
– Join engine onto gearbox, screw in bolts -2 … 6- and tighten.
– Release spindle of support bracket - 10-222 A- .

– Lower workshop hoist and place engine/gearbox assembly
onto engine mounting.
– Fit bolts -1- for left and right engine mountings.

– Detach workshop hoist - VAS 6100- and lifting tackle - 2024
A- .

– Screw in bolt -1- and bolts -7 … 10- of engine/gearbox as‐

sembly and tighten.
Note
Disregard -item A-.
– Remove retainer -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.
– Use assembly lever -1- to press clutch module -2- slightly

against drive plate -3- in direction of -arrow-.

Tightening sequence - clutch module to drive plate

– Screw in first bolt -arrow- hand-tight (2 Nm).
– Turn crankshaft by 120° in direction of engine rotation and fit
second bolt hand-tight.
– Turn crankshaft by 120° in direction of engine rotation once
again.
– Then tighten third bolt to final torque ⇒ Rep. gr. 30 ; Clutch;
Exploded view - clutch module .
– Now tighten remaining bolts securing clutch module to drive
plate to final torque.
The remaining installation steps are carried out in the reverse se‐
quence. Note the following:
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Install particulate filter ⇒ page 259 .
– Install front exhaust pipe ⇒ page 254 .
– Install torque reaction support and cross member
⇒ page 33 .
– Align the exhaust system so it is free of stress ⇒ page 257 .
– Observe electrical connections and routing ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations.
– Install engine control unit ⇒ page 248 .
– Install electrical wiring, terminal 30 wiring junction 2 - TV22-
and cover for electronics box in engine compartment ⇒ Elec‐
trical system; Rep. gr. 97 ; Relay carriers, fuse carriers,
electronics boxes .
– Install body brace ⇒ Running gear, axles, steering; Rep. gr.
40 ; Suspension strut, upper links; Removing and installing
body brace .
– Install filler neck for washer fluid reservoir ⇒ Electrical system;
Rep. gr. 92 ; Windscreen washer system .
– Observe steps required after re-connecting battery ⇒ Electri‐
cal system; Rep. gr. 27 ; Battery; Disconnecting and connect‐
ing battery .
Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– Install air cleaner housing ⇒ page 204 .

Checking oil level (Audi A4) ⇒ Maintenance ; Booklet 812
– Fill up with coolant ⇒ page 144 .

Note
♦ Do not use drained coolant again if:

♦ the cylinder head or cylinder block have been renewed.
♦ the coolant is contaminated or dirty.
– Install wheel housing liners ⇒ General body repairs, exterior;

Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
– 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 31
⇒ “2.2 Removing and installing engine mountings”, page 32
⇒ “2.3 Removing and installing torque reaction support and cross
member”, page 33
2.1 Exploded view - assembly mountings
1 - Bolt
❑ 20 Nm
2 - Retaining plate
❑ For engine mounting
❑ Always renew when re‐
newing engine mount‐
ings
3 - Bolt
❑ 40 Nm
4 - Engine support
5 - Bolt
❑ 10 Nm
6 - Heat shield
7 - Bolt
❑ 90 Nm + 90°
❑ Renew
8 - Engine mounting
❑ Left electrohydraulic en‐
gine mounting solenoid
valve - N144-
❑ Always renew on both
sides together
❑ Removing and installing
⇒ page 32
9 - Subframe
10 - Bolt
❑ 55 Nm
Torque reaction support and cross member

1 - 25 Nm
2 - 40 Nm
2. Assembly mountings 31
2.2 Removing and installing engine mount‐

ings
Removing
Note
♦ Renew engine mountings on both sides together.

♦ Also renew corresponding brackets.
– Set up support bracket - 10 - 222 A- with adapters -10 - 222

A /3- 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.
– Remove wheel.
tion .
– Remove wheel housing liner ⇒ General body repairs, exterior;

– Release and unplug electrical connector -3- on left electrohy‐

draulic engine mounting solenoid valve - N144- .
– Remove bolts -1, 4, 5- for engine mounting.
– Move retaining plate -2- for engine mounting clear to the side.
– Detach engine mounting.
Installing
Install in reverse sequence. When doing so, note the following:
Tightening torques
Note
Renew the bolts tightened with specified tightening angle.
– Install wheel housing liners ⇒ General body repairs, exterior;

– Install noise insulation panels ⇒ General body repairs, exte‐
insulation .
2.3 Removing and installing torque reaction

support and cross member
Removing
– Remove front noise insulation ⇒ General body repairs, exte‐
insulation .
Vehicles with auxiliary heater:
– Remove nut -1-, loosen clamp -3- and detach exhaust pipe
-2- for auxiliary heater.
Continued for all vehicles:

– Remove bolt -1- and nut -3- and detach strut -2- for lock carrier.
Vehicles with multitronic gearbox:

– Position used oil collection and extraction unit - V.A.G 1782-
below connection point.
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.
– Seal off open pipes/lines and connections with clean plugs

from engine bung set - VAS 6122- .
Continued for all vehicles:
– Move electrical wiring -3- clear at cross member.

– Remove bolts -1- and take torque reaction support out of cross
member.
– Remove bolts -2- on both sides of cross member.
– Loosen subframe bolts -2- (left-side as seen in direction of

travel) only as much as is necessary for cross member -1- to
move freely in direction of -arrow-.
WARNING
Accident risk if subframe mountings are detached.

♦ Subframe bolts must not be fully removed.

– Push cross member -1- slightly towards left side -arrow- so

that cross member can be removed from below at longitudinal
member (right-side).
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Renew bolts tightened with specified tightening angle.

♦ Remove and renew subframe bolts one after the other.
– Push torque reaction support -1- upwards -arrow- until it

makes contact with cross member.
– Push torque reaction support -1- upwards -arrow- until it

makes contact with cross member.
• The buffer stop -2- must be free of stress and must lie against
the cross member without play.
– Tighten bolts -3- in this position.
Tightening torques
♦ ⇒ “2.1 Exploded view - assembly mountings”, page 31
♦ Subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Sub‐
frame; Exploded view - subframe
♦ Lock carrier brace ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier; Exploded view - lock carrier
♦ Exhaust pipe for auxiliary heater ⇒ Auxiliary heater, supple‐
mentary heater; Rep. gr. 82 ; Overview of fitting locations -
auxiliary/supplementary heater; Overview of fitting locations -
components not located in passenger compartment
– Install noise insulation (front) ⇒ General body repairs, exterior;
tion .
3 Engine cover panel

⇒ “3.1 Removing and installing engine cover panel”, page 36
3.1 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel off four retaining pins one
after the other “arrows”. Do not jerk the 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 (note locations of oil
filler neck and oil dipstick).
– First press engine cover panel into rear rubber grommets and
then into front rubber grommets with both hands.

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - poly V-belt drive”, page 37
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 39
⇒ “1.3 Removing and installing poly V-belt”, page 40
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 41
⇒ “1.5 Removing and installing vibration damper”, page 43
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 44
⇒ “1.7 Renewing crankshaft oil seal (pulley end)”, page 46
⇒ “1.8 Removing and installing sealing flange (pulley end)”, page
48
1.1 Exploded view - poly V-belt drive
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
⇒ page 40
❑ When installing, make
sure it is properly seated
on pulleys
2 - Vibration damper with poly
V-belt pulley
❑ Can only be installed in
one position
⇒ page 43
3 - Cover cap for vibration
damper
4 - Bolt
❑ Renew
❑ 10 Nm + 90°
5 - Bolt
❑ Tightening torque ⇒
Running gear, axles,
steering; Rep. gr. 48 ;
Hydraulic power steer‐
ing; Exploded view -
power steering pump
6 - Poly V-belt pulley for power
steering pump
7 - Poly V-belt tensioner
❑ Use locking tool -
T40098- to lock tension‐
er.
1. Cylinder block (pulley end) 37

❑ Removing and installing ⇒ page 41

8 - Bracket for ancillaries
9 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
10 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
11 - Bolt
❑ Bolt can be re-used; tightening torque for re-used bolt: 20 Nm + 90°
❑ New bolt: 20 Nm +180°
12 - Power steering pump
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power steering; Re‐
moving and installing power steering pump
13 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 39
14 - Dowel sleeve
❑ Ensure correct seating in bracket
15 - 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
❑ Pay attention to dowel sleeves ⇒ Item 14 (page 38) when installing
16 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
17 - Bolt
❑ Tightening torque ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power steering; Exploded
view - power steering pump
18 - Idler roller for poly V-belt
❑ Note installation position
19 - Bolt
❑ Renew
❑ 20 Nm + 90°
38 Rep. gr.13 - Crankshaft group

Bracket for ancillaries - tightening torque and tightening sequence

– Renew bolts for bracket for ancillaries and fit as follows:
♦ Bolts -1, 5, 6- M10x60.
♦ Bolt -2- M10x40
♦ Bolts -3, 4- M10x155.
– Tighten bolts for bracket for ancillaries in the sequence
-1 ... 6- in 5 stages as follows:
1. Screw in all bolts by hand until they make contact.
2. Tighten all bolts to 40 Nm.
3. Turn bolts -1- and -2- 60° further.
1.2 Exploded view - sealing flange (pulley end)
1 - Cylinder block
2 - Sealing flange
⇒ page 48
3 - Bolt
❑ Tightening sequence
⇒ page 40
4 - Oil seal
❑ Renewing ⇒ page 46
5 - Dowel sleeve
6 - Bolt
❑ Tightening torque
⇒ page 40

Tightening sequence on sealing flange

1. Screw in bolts in the sequence -1 ... 10- hand-tight.
2. Tighten bolts in the sequence -1 ... 6- to 15 Nm.
3. Tighten bolts in the sequence -7 ... 10- to 15 Nm.
1.3 Removing and installing poly V-belt

Removing

Caution
Wrong direction of rotation for a used poly V-belt can lead to

irreparable damage.
♦ Before removing the poly V-belt mark the direction of ro‐
tation with chalk or a felt-tip pen for re-installation.
– Swivel tensioner in direction of -arrow-, detach poly V-belt from

alternator pulley and lock tensioner using locking tool -
T40098- .
– Take off poly V-belt.
Installing
Fit poly V-belt as illustrated.

1- Vibration damper
2- Air conditioner compressor
3- Power steering pump pulley
4- Idler roller
5- Poly V-belt tensioner
6- Alternator
Note
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Start engine and check that poly V-belt(s) run properly.
1.4 Removing and installing tensioner for

poly V-belt
♦ Ratchet wrench 13 mm - T10384-

Removing

– Remove poly V-belt ⇒ page 40 .
– Remove bolt -1-.
Note
♦ If bolt -1- makes contact with engine bracket, leave bolt in in‐
stallation position.
♦ Due to lack of space, the tensioner must be guided out up‐
wards by rotating it.
– Lift out poly V-belt tensioner -2-.

Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - poly V-belt drive”, page 37

1.5 Removing and installing vibration damp‐

er
Removing
– Remove front noise insulation -1- ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
– Vehicles with torque reaction support: remove cross member

for torque reaction support ⇒ page 33 .
– Remove radiator fan control unit - J293- ⇒ page 167 .
– Detach cover cap for vibration damper.
– Remove bolts -arrows- (counterhold at central bolt).

– Remove vibration damper.
Installing
Tightening torques
⇒ “1.1 Exploded view - poly V-belt drive”, page 37
Tightening torques
Note

• Installation position: hole -arrow- in vibration damper must be

positioned over raised section of crankshaft sprocket.
– Install radiator fan control unit - J293- ⇒ page 167 .
– Install poly V-belt ⇒ page 40 .
– Vehicles with torque reaction support: install cross member for
torque reaction support ⇒ page 33 .
1.6 Removing and installing bracket for an‐

cillaries
♦ Pin wrench - 3212-
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove high-pressure pump ⇒ page 232 .
– Drain coolant ⇒ page 144 .
– Remove bolt -arrow-.
– Remove bolts -1- and -2- and remove idler rollers for toothed
belt.

– Mark position of pulley on hub. To do so, make a marking

-arrow-.
– Remove bolts -arrows-. Use pin wrench - 3212- as counterhold

tool.
– Unscrew bolts -1- (3x) and bolt -3-.

– Tie up power steering pump to one side with hydraulic lines
attached.
– Detach air conditioner compressor from bracket for ancillaries
and tie up to one side ⇒ Heating, air conditioning; Rep. gr.
87 ; Air conditioner compressor; Detaching and attaching air
conditioner compressor at bracket .
– Using articulated wrench, 10 mm - 3185- and socket -

T10058- , loosen bolts -4- of connection -3- and remove
connection -3- with thermostat -1-.

– Remove bolts -1 ... 6- and detach bracket for ancillaries.

Installing
Note
– Check that dowel sleeve at top right between bracket for an‐
cillaries and cylinder block is fitted; insert dowel sleeve if
necessary.
– Tighten bolts for bracket for ancillaries ⇒ page 39 .
– To install power steering pump it is necessary to slightly knock

back sleeve -2- for bolt -3- in bracket.
– Install high-pressure pump ⇒ page 232 .
– Install toothed belt ⇒ page 87 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
1.7 Renewing crankshaft oil seal (pulley

end)
♦ Oil seal extractor - 3203-

♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
Procedure
– Remove toothed belt ⇒ page 87 .
– Loosen bolt for crankshaft sprocket using counterhold tool -
3415- .
– Remove bolt and detach crankshaft sprocket.
– Adjust inner section of oil seal extractor -3203- so it is flush

with the outer section and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
oil seal.
– Clean contact surface and sealing surface for oil seal.
– Remove oil residue from crankshaft journal with a clean cloth.
Note
Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.

– Fit guide sleeve -T10053/1- onto crankshaft journal.

– Push oil seal over guide sleeve onto crankshaft journal.
– Press in oil seal using bolt for crankshaft sprocket and thrust
sleeve of assembly tool - T10053- until flush.
– Install crankshaft sprocket ⇒ page 86 .
1.8 Removing and installing sealing flange

(pulley end)
♦ Counterhold tool - 3415-
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
– Loosen bolt for crankshaft sprocket using counterhold tool -
3415- .
– Remove bolt and detach crankshaft sprocket.

– Remove bolts -1 ... 10- and carefully release sealing flange

from bonded joint.
– Drive out oil seal with sealing flange removed.
Installing
• Tightening torques
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 39
Caution
Make sure sealant residue does not enter lubrication system.

♦ Place a clean cloth over the exposed section of the sump.
– Carefully remove sealant residue on cylinder block and sump.
WARNING
Risk of eye injury.

– Use e.g. rotating plastic brush to remove sealant residue on

sealing flange.
– 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.

2 mm).
– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.

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 clean sealing surface of

sealing flange as shown in illustration.
• Thickness of sealant bead: 2 ... 3 mm
– Apply a thin coat of sealant to bottom sealing surface

-shaded- on sealing flange.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing the sealant.
– Carefully fit sealing flange onto dowel pins in cylinder block.
– Tighten sealing flange bolts ⇒ page 40 .

– Install crankshaft oil seal (pulley end) ⇒ page 46 .

2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 51
⇒ “2.2 Removing and installing drive plate”, page 52
⇒ “2.3 Removing and installing sealing flange (gearbox end)”,
page 53
⇒ “2.4 Renewing needle bearing in drive plate”, page 61
2.1 Exploded view - cylinder block (gearbox end)
1 - Cylinder block
2 - Dowel sleeves
3 - Engine speed sender -
G28-
4 - Bolt
❑ 4.5 Nm
5 - Sealing flange with oil seal
⇒ page 53
❑ With sender ring for en‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
gine speed sender permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renew only as com‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
plete unit
❑ Do not additionally oil or
grease sealing lip of oil
seal
❑ Before installing, re‐
move oil residue from
crankshaft journal with a
clean cloth.
❑ Use support sleeve sup‐
plied when fitting
6 - Bolt
❑ 15 Nm
7 - Drive plate
❑ Lock with counterhold
tool - 3067- to slacken
off bolts
8 - Bolt
❑ 60 Nm + 90°
❑ Renew
9 - Needle bearing
❑ Removing and installing needle bearing ⇒ page 61
10 - Intermediate plate
❑ Is fitted onto sealing flange ⇒ page 52
❑ Must be positioned on dowel sleeves
❑ Do not damage/bend when assembling
2. Cylinder block (gearbox end) 51

Installing intermediate plate

– Fit intermediate plate on sealing flange and push onto dowel
sleeves -arrows-.
2.2 Removing and installing drive plate

♦ Counterhold tool - 10 - 201-

Removing
• Gearbox removed
– 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.

Installing
Tightening torques
Note
♦ Renew bolts for drive plate.

♦ On vehicles with manual gearbox, a needle bearing is fitted in
the drive plate. Before installing, check that the needle bearing
is fitted. Removing and installing needle bearing in drive plate
(pressing in and out) ⇒ page 61 .
– Pay attention to dowel pin when installing drive plate.

– Fit counterhold tool - 10 - 201- the other way round to tighten
bolts.
2.3 Removing and installing sealing flange

(gearbox end)
♦ Depth gauge
♦ M6 x 35 bolt (3x)
♦ M7 x 35 bolt (2x)
Pressing out sealing flange with sender wheel
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .

– Remove drive plate ⇒ page 52 .

– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine and drain engine oil.
– Detach intermediate plate.
– Turn crankshaft to TDC for cylinder 1 as illustrated.
– Remove sump ⇒ page 120 .
Note
♦ The engine is shown removed for illustration purposes.

♦ The procedure is identical with the engine installed and the
gearbox removed.
– Remove engine speed sender - G28- -item 1- using a standard

ball head hexagon key.
– Unscrew bolts -1 ... 6- for sealing flange.

Note
The sealing flange is pressed off the crankshaft together with the
sender wheel.
– To press out, screw in three M6 x 35 bolts -arrows- alternately

into sealing flange not more than 1/2 turn at a time.
– Remove sealing flange together with the sender wheel.
Pressing in sealing flange with sender wheel
Note
♦ The sealing flange with PTFE oil seal is fitted with a sealing lip
support ring. This support ring acts as an assembly sleeve and
must not be removed before installation.
♦ The sealing flange and sender wheel must not be separated
or twisted after removal from the replacement parts packag‐
ing.
♦ The sender wheel is held in its installation position by a locat‐
ing pin on the assembly tool - T10134- .
♦ The sealing flange and oil seal are a single unit and must only
be replaced together with the sender wheel.
♦ The assembly tool - T10134- is held in its installation position
for the crankshaft by a guide pin which is inserted into a hole
on the crankshaft.
Construction of assembly tool - T10134-

A - Tensioning flats
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket-head bolt
F - Guide pin for diesel engines (black handle)
G - Guide pin for petrol engines (red handle)
A - Fitting sealing flange with sender wheel onto assembly tool -

T10134- :
– Turn hexagon nut -B- until it is just in front of flats -A- on threa‐
ded spindle.

– Clamp assembly tool - T10134- in a vice on tightening flats

-A- of threaded spindle.
– Press assembly housing -C- downwards so that it lies on hex‐
agon nut -B-.
Note
Inner part of assembly device and assembly housing must align

(be level) with each other.
– Remove the securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be removed from the sealing flange
or twisted.
• The locating hole -A- on the sender wheel -C- must align with
the marking -B- on the sealing flange.
– Place the sealing flange (with the front side downwards) on a
clean flat surface.
– Press the sealing lip support ring -A- downwards in direction

of -arrows- until it lies against the flat surface.

• The upper edge of the sender wheel and the front edge of the
sealing flange must align -arrows-.
– Place front side of sealing flange on assembly tool - T10134-

so that locating pin -B- can be inserted in hole -A- in sender
wheel.
Note
Ensure the sealing flange lies flat on the assembly tool.
– Press the sealing flange and sealing lip support ring -B- onto
the surface of the assembly tool - T10134- when tightening the
three knurled screws -A- so that the locating pin will not slip
out of the hole on the sender wheel.
Note
Ensure the sender wheel remains fixed on the assembly tool

when installing the sealing flange.
B - Installing assembly tool - T10134- with sealing flange on

crankshaft flange:
• Crankshaft flange free of oil and grease.
• Engine positioned at TDC (cylinder 1).
– Screw hexagon nut -B- to end of threaded spindle.
– Press the threaded spindle of assembly tool - T10134- in di‐
rection of -arrow- until the hexagon nut -B- lies on the assem‐
bly housing -A-.
– Position flat edge of assembly housing towards sealing sur‐
face for sump on cylinder block.

– Secure assembly tool - T10134- to crankshaft flange by screw‐

ing hexagon socket head bolts -A- approx. 5 threads into
crankshaft flange.
– Screw two bolts M7×35 mm -A- into cylinder block to guide

sealing flange.
C - Securing assembly tool - T10134- onto crankshaft flange:

– Press the assembly housing -C- by hand in the direction of the
-arrow- until the sealing lip support ring -B- lies on the surface
of the crankshaft flange -A-.
– Press the guide pin for diesel engines (black handle) -D- into
hole of crankshaft. This ensures that the sender wheel is in its
final installation position.
Note
The guide pin for PETROL engines (red handle) -F- MUST NOT
be inserted into the threaded hole in the crankshaft.
– Tighten both hexagon socket head bolts on assembly tool fin‐

ger-tight.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies against the assembly housing -C-.
D - Pressing sender wheel onto crankshaft flange with assembly

tool - T10134- :
– Tighten hexagon nut of assembly tool - T10134- to 35 Nm.
Note
A small air gap must be present between cylinder block and seal‐
ing flange after tightening hexagon nut to 35 Nm.

E - Checking sender wheel installation position on crankshaft:

– Screw hexagon nut -E- to end of threaded spindle.
– Unscrew the 2 bolts -A- out of cylinder block.
– Unscrew the three knurled screws -B- from sealing flange.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
• The sender wheel is positioned correctly on the crankshaft if

the distance -a- between the crankshaft flange -A- and sender
wheel -B- is 0.5 mm.
– Apply a depth gauge on the crankshaft flange.

– Measure the distance “a” between crankshaft flange and
sender wheel.
If dimension “a” is too small:
– Press in the sender wheel further ⇒ page 59 .
When dimension “a” is achieved:
– Perform remaining assembly steps ⇒ page 60 .
F - Pressing sender wheel in further:

– Secure the assembly tool - T10134- -A- to crankshaft flange
by tightening hexagon socket head bolts finger-tight.
– Press the assembly tool - T10134- towards the sealing flange
by hand.

– Screw hexagon nut -E- onto threaded spindle by hand until it

lies against the assembly housing -C-.

– Check installation position of sender wheel on crankshaft
again ⇒ page 59 .
If dimension “a” is too small again:
– Check installation position of sender wheel on crankshaft
again ⇒ page 59 .
Assembling:
Tightening torques
– Tighten new bolts -1 ... 6- for sealing flange alternately in di‐
agonal sequence.
– Secure engine speed sender - G28- -item 1-.

– Install sump ⇒ page 120 .

– Fit intermediate plate on sealing flange and push onto dowel

sleeves -arrows-.
– Install drive plate ⇒ page 52 .
– Install gearbox. ⇒ Rep. gr. 34 ; Removing and installing gear‐
box; Installing gearbox
2.4 Renewing needle bearing in drive plate

This procedure is only necessary for vehicles with manual gear‐
box.
♦ Tube - VW 418 A-
♦ Tube - VW 421-
♦ Support - 40 - 103-

Procedure
• Gearbox removed
– Remove drive plate ⇒ page 52 .
– Place support - 40 - 103- under drive plate when pressing out
and pressing in needle bearing.
– Use tube - VW 421- and workshop press and press out needle
bearing.
• Smaller diameter of tube -VW 421- faces drive plate.
– Carefully press in needle bearing as far as stop, using tube -

VW 418 A- and workshop press.
• Installation position: closed side of needle bearing faces en‐
gine.
– Install drive plate ⇒ page 52 .

3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 63
⇒ “3.2 Crankshaft dimensions”, page 63
⇒ “3.4 Pulling spur gear off crankshaft and shrink-fitting new spur
gear”, page 64
3.1 Exploded view - crankshaft
1 - Bearing shell
❑ For cylinder block (with
oil groove)
❑ Do not interchange
used bearing shells
(mark positions)
2 - Spur gear
spur gear ⇒ page 64
3 - Bearing shell
❑ For bearing cap (without
oil groove)
used bearing shells
(mark positions)
4 - Thrust washer
❑ For bearing cap 3
❑ Note location
5 - Bolt
❑ 65 Nm + 90°
❑ Renew
❑ When measuring radial
clearance, tighten used
bolt to 65 Nm and turn
90° further
6 - Bearing caps
❑ Bearing cap 1: Pulley
end
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ Bearing shell retaining
lugs (cylinder block/
bearing cap) must be on the same side
7 - Crankshaft
❑ Axial clearance when new: 0.07...0.17 mm; wear limit: 0.37 mm
❑ Check radial clearance with Plastigauge: New: 0.03...0.08 mm; wear limit: 0.17 mm
❑ Do not rotate the crankshaft when checking the radial clearance
❑ Crankshaft dimensions ⇒ page 63
3.2 Crankshaft dimensions

(in mm)
3. Crankshaft 63
Crankshaft main Conrod

bearing journal ∅ bearing journal ∅
Basic dimension 54.00 -0.022 50.90 -0.022
-0.042 -0.042
3.3 Measuring radial clearance of crank‐

shaft
♦ Plastigauge
Procedure
Note
♦ Mark used bearing shells for re-installation (but do not mark

bearing surface).
♦ If bearing shells are worn down to nickel layer they must be
renewed.
– Remove bearing cap and clean bearing journal.

– Place a length of Plastigauge corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
• The Plastigauge must be positioned in the centre of the bear‐
ing shell.
– Fit bearing cap and secure with old bolts ⇒ Item 5 (page 63)
without rotating crankshaft.
– Remove bearing cap again.
– Compare width of Plastigauge with measurement scale.
Radial clearance:
• New: 0.03 ... 0.08 mm.
• Wear limit: 0.17 mm.
3.4 Pulling spur gear off crankshaft and

shrink-fitting new spur gear
♦ Hotplate (commercially available)

♦ Fitting tool - 10 - 203-
♦ Puller - T10392- with thrust piece - T10392/1-
♦ Temperature gauge - VAS 6519-

– Remove sealing flange (pulley end) ⇒ page 48 .
– Remove balance shaft assembly ⇒ page 133 .
Note
If the balance shaft assembly does not have to be renewed, it is

sufficient just to detach the idler gear.
Pulling off spur gear

– Insert thrust piece -T10392/1- in end of crankshaft.
3. Crankshaft 65
– Insert puller -T10392- into holes in spur gear, turn clockwise

-arrow- and screw in locating pins -A-.
– Counterhold crankshaft with ring spanner -A-. Pull spur gear

off end of crankshaft by screwing in spindle with ring spanner
-B-.
Shrink-fitting spur gear
Note
♦ While heating up the new spur gear, monitor the temperature

with the temperature gauge -VAS 6519- .
♦ When the temperature reaches 200 ℃, you have approx. 4
seconds to fit the spur gear on the crankshaft.
♦ A higher temperature increases the amount of time available
(220 ℃ = approx. 6 seconds).
♦ Make sure the end of the crankshaft is clean.
Caution
Do not exceed a maximum temperature of 240 ℃; otherwise

the spur gear can become discoloured and distorted.
– Place the new spur gear flat on a commercially available hot‐

plate and heat it up to at least 200 °C, but not more than 240 °
C. Lettering faces upwards.
– Set temperature gauge -VAS 6519- to measuring range 2.
– Position temperature sensor -VAS 6519/1- on collar of spur
gear (as shown) and read off temperature at temperature
gauge.
WARNING
Risk of burns. Use suitable protective gloves for the following

steps.

– When the required temperature has been reached, pick up the

spur gear with pliers as illustrated.
Note
Take care not to damage the teeth of the spur gear.
– With the aid of fitting tool - 10 - 203- , slide spur gear by hand
onto end of crankshaft as far as stop. This must be done with‐
out delay, taking care to keep the gear straight.
– Wait a few minutes to allow the spur gear to cool down, and
then install the balance shaft assembly.
⇒ “4.1.2 Installing a new balance shaft assembly”, page 134
⇒ “4.1.3 Re-installing a used balance shaft assembly”,
page 136
3. Crankshaft 67
4 Pistons and conrods

⇒ “4.1 Exploded view - pistons and conrods”, page 68
⇒ “4.2 Measuring piston projection at TDC”, page 71
⇒ “4.3 Piston and cylinder dimensions”, page 72
⇒ “4.4 Separating parts of new conrod”, page 72
⇒ “4.5 Bearing shells - installation position”, page 73
4.1 Exploded view - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
remove and install
❑ Inscription “TOP” faces
towards piston crown
❑ Checking ring gap
⇒ page 69
❑ Checking ring-to-groove
clearance ⇒ page 70
2 - Piston
❑ With combustion cham‐
ber
❑ Mark installation posi‐
tion and cylinder num‐
ber
❑ Installation position and
allocation of piston/cyl‐
inder ⇒ page 71
❑ Arrow on piston crown
points to pulley end
❑ Install using piston ring
clamp
❑ If cracking is visible on
piston skirt, renew pis‐
ton
❑ Checking piston projec‐
tion at TDC
⇒ page 71
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C
❑ Remove and install us‐
ing drift - VW 222 A-
4 - Retaining ring
5 - Conrod
❑ Mark cylinder allocation -A- with coloured pen
❑ Installation position: Marking -B- faces towards pulley end
❑ With industrially cracked conrod bearing cap
6 - Bearing shell
❑ Note version: Upper bearing shell (closest to piston) is constructed from a more wear-resistant material;
refer to ⇒ Electronic parts catalogue

❑ Do not interchange used bearing shells

❑ Insert bearing shells centrally
❑ Check that it is securely seated
❑ Axial clearance: wear limit: 0.37 mm
❑ Check radial clearance with Plastigauge; Wear limit: 0.08 mm
❑ Do not rotate crankshaft when checking radial clearance
7 - Cylinder block
❑ Checking cylinder bore ⇒ page 70
❑ Piston and cylinder dimensions ⇒ page 72
8 - Conrod bearing cap
❑ Due to the cracking method used to separate the bearing cap from the conrod in manufacture, the cap
only fits in one position and only on the appropriate conrod
9 - Oil spray jet
❑ For piston cooling
10 - Bolt for oil spray jet
❑ 25 Nm
❑ Insert without sealant
11 - Conrod bolt
❑ Renew
❑ Lubricate threads and contact surface
❑ 30 Nm + 90°
❑ When measuring radial clearance, tighten used bolt to 30 Nm and turn 90° further
Oil spray jet and pressure relief valve
Checking piston ring gap

♦ Feeler gauge
4. Pistons and conrods 69

– Insert piston ring at right angles from above and push down
into cylinder approx. 15 mm from bottom end of cylinder.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.20...0.40 1.0
2nd compression ring 0.20...0.40 1.0
Oil scraper ring 0.25...0.50 1.0
Checking ring-to-groove clearance

♦ Feeler gauge
– Clean groove in piston before checking clearance.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.06...0.09 0.25
2nd compression ring 0.05...0.08 0.25
Oil scraper ring 0.03...0.06 0.15
Checking cylinder bore

♦ Cylinder gauge, 50 ... 100 mm
– Make measurements at three positions diagonally in trans‐
verse direction -A- and in longitudinal direction -B-. Difference
between actual and nominal diameter: not more than 0.10 mm.

Note
Do not measure the cylinder bores when the cylinder block is

mounted on a repair stand with engine and gearbox support -
VW 540- , as incorrect measurements would then be possible.
Piston installation position and piston/cylinder allocation

The arrow faces towards cylinder 1 -arrows-.
4.2 Measuring piston projection at TDC

♦ Measuring tool - VW 382/7-
♦ Gauge plate - VW 385/17-
♦ Dial gauge

Test sequence
Piston projection at TDC must be measured when installing new
pistons or a short engine. Depending upon piston projection, in‐
stall the corresponding cylinder head gasket according to follow‐
ing table:
Note
♦ Turn engine in clockwise direction to measure piston projec‐

tion at TDC.
♦ If differing figures are obtained when measuring piston pro‐
jection, the highest figure should be taken when selecting the
gasket.
Piston projection Identification

Holes/notches
0.91 mm ... 1.00 mm 1
1.01 mm ... 1.10 mm 2
1.11 mm ... 1.20 mm 3
4.3 Piston and cylinder dimensions

Piston ∅ Cylinder bore ∅
Basic di‐ mm 80.96 81.01
mension
4.4 Separating parts of new conrod

It is possible that the two parts of a new conrod are not completely
separated as intended. If it is not possible to take off the conrod
bearing cap by hand, proceed as follows:
– Protected
Clampbythe conrod in a vice using aluminium jaw covers as
copyright. Copying for private or commercial purposes, in part or in whole, is not
shown in illustration.
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
♦ To avoid any risk of damage, the conrod should only be clam‐

ped lightly.
♦ The conrod is clamped in position below the dotted line.
– Unscrew bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock conrod bearing cap

loose in direction indicated by -arrow-.

4.5 Bearing shells - installation position

Bearing shell -1- with oil drilling -arrow- for conrod.
Bearing shell -2- without oil drilling for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Dimension -a- must be identical on both sides.
4.6 Measuring radial clearance of conrods

♦ Plastigauge
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
– Place a length of Plastigauge corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap and secure with old bolts
⇒ Item 11 (page 69) without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigauge with measurement scale.
Radial clearance:
• Wear limit: 0.08 mm.
– Renew conrod bolts.

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Exploded view - cylinder head”, page 74
⇒ “1.2 Exploded view - cylinder head cover”, page 77
⇒ “1.3 Removing and installing cylinder head”, page 78
⇒ “1.4 Removing and installing cylinder head cover”, page 82
⇒ “1.5 Checking compression”, page 83
⇒ “1.6 Identification of cylinder head gasket”, page 85
1.1 Exploded view - cylinder head
Note
♦ The plastic protectors fitted to protect the open valves must

not be removed until immediately before fitting the cylinder
head.
♦ If the cylinder head is replaced, all the coolant in the system
must also be renewed.
74 Rep. gr.15 - Cylinder head, valve gear

1 - Cylinder head
⇒ page 78
❑ If renewed, change
coolant in entire system
2 - Washer
❑ For cylinder head bolt
3 - Cylinder head bolt
❑ Note correct sequence
when loosening
⇒ page 76
when tightening
⇒ page 76
❑ Prior to installation, in‐
sert washer in cylinder
head
⇒ Item 2 (page 75)
4 - Bolt
❑ 25 Nm
5 - Lifting eye
6 - Gasket
❑ Renew
7 - Vacuum pump
8 - Bolt
❑ 10 Nm
9 - Coolant hose connection
10 - Bolt
❑ 10 Nm
11 - Gasket
❑ Renew
12 - Bolt
❑ 25 Nm
13 - Lifting eye
14 - Cylinder head gasket
❑ Renew
❑ Note marking ⇒ page 77
❑ If renewed, change coolant in entire system
15 - Hall sender - G40-
❑ For camshaft position
❑ To remove and install, detach toothed belt from camshaft sprockets and loosen idler roller.
16 - Bolt
❑ 10 Nm
1. Cylinder head 75
Slackening cylinder head bolts

– Remove cylinder head bolts in the sequence -1 ... 10-.
Tightening sequence for cylinder head

1. Tighten with torque wrench to 40 Nm.
2. Tighten with torque wrench to 60 Nm.
3. Use rigid wrench to turn 90° further.
4. Use rigid wrench to turn 90° further.
Note
Cylinder head bolts do not have to be torqued down again later

after repair work.
Checking cylinder head for distortion

♦ Straight edge
♦ Feeler gauge
Max. permissible distortion: 0.1 mm

Note
The cylinder heads of diesel engines must not be machined.
Identification of cylinder head gasket

1- Part number
2- Holes
3- Ignore
Note
♦ If the measured values for piston projection are not the same
for all pistons, use the highest value to determine the correct
gasket size.
♦ Cylinder head gaskets of different thicknesses are fitted de‐
pending on piston projection. When replacing the cylinder
head gasket, install a new gasket with the same identification
-arrow 2-.
1.2 Exploded view - cylinder head cover
1 - High-pressure reservoir
(rail)
❑ With injector pipes
❑ Do not attempt to bend
injector pipes to a differ‐
ent shape
2 - Bolt
❑ 22 Nm
3 - Injector (piezo injector)
⇒ page 220
4 - Bolt
⇒ page 193
5 - Retaining clip
6 - Cylinder head cover
⇒ page 82
7 - Bolt
❑ 10 Nm
8 - Fuel lines
9 - Gasket
❑ Renew if damaged or
leaking
10 - Bolt
❑ Slackening
⇒ page 78
❑ Observe correct tighten‐
ing sequence
1. Cylinder head 77
⇒ page 78
11 - Filler cap
12 - Bush
❑ To secure high-pressure reservoir (rail)
❑ Renew if damaged
Loosening cylinder head cover

1. Loosen bolts in the sequence -7 ... 1-.
Tightening sequence for cylinder head cover

1. Fit bolts in the sequence -1 ... 7- and hand-tighten in several
stages.
2. Tighten bolts in the sequence -1 ... 7- to 10 Nm using torque
wrench.
Note
Take care to keep cylinder head cover straight.
1.3 Removing and installing cylinder head

Removing
Caution

♦ Observe notes on procedure for disconnecting the battery
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting
and connecting battery .
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Remove air cleaner housing ⇒ page 204 .
– Remove exhaust gas recirculation cooler ⇒ page 273 .
– Remove turbocharger ⇒ page 171 .
– Remove cylinder head cover ⇒ page 82 .


– Detach guide tube for oil dipstick from throttle valve housing.
Caution
Observe rules for cleanliness when working on the fuel supply

system ⇒ page 6 .
– Disconnect fuel supply hose -1- and fuel return hose -2-.
– Detach coolant hoses -3- and -4-.
– Detach hose clips -1- and -2- and remove coolant hose.
1. Cylinder head 79
– Remove nut -3- for exhaust gas recirculation pipe.

– Remove bolts -4- and -5-, move exhaust gas recirculation pipe
aside.
– Remove bolt on cylinder head for oil pressure pipe to turbo‐
charger.
Note
It is not possible to remove exhaust gas recirculation pipe.
sensor 1 .
– Disconnect vacuum hose -2- on rear of plenum chamber par‐

tition panel -arrow- and detach vacuum connection -1- from
plenum chamber partition panel.
– Unplug the following electrical connectors:

3 - Variable intake manifold motor - V183-
4 - Intake manifold flap motor - V157-
5 - Exhaust gas recirculation valve - N18-
– Remove camshaft toothed belt sprocket and use puller -
T10052- to detach hub from camshaft.
– Remove bolt securing toothed belt cover.
– Remove nut securing toothed belt tensioning roller.

– Unscrew bolt for Hall sender - G40- -arrow- and move Hall
sender - G40- to one side.
– Remove cylinder head bolts in the sequence -1 ... 10-.
Note
♦ A second mechanic is required when removing the cylinder

head.
♦ The toothed belt tensioning roller is detached from the stud
when the cylinder head is lifted out.
– Lift cylinder head at gearbox end first and guide out of toothed
belt cover. Make sure toothed belt tensioning roller does not
drop out.
Installing
Note
♦ Always renew cylinder head bolts.

♦ If repairing, carefully remove any remaining gasket material
from the cylinder head and cylinder block. Ensure that no long
scores or scratches are made on the surfaces. If using sand‐
paper, grain size must be at least 100.
♦ Carefully remove any remaining emery and abrasive material.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
– Before fitting cylinder head, remove crankshaft stop - T10050-

and turn crankshaft in opposite direction of normal rotation
until all pistons are almost evenly positioned below TDC.
– Fit cylinder head gasket with marking facing upwards.
1. Cylinder head 81
– To centralise, screw guide pins - 3070- into outer holes on inlet

side.
Note
Position tensioning roller on dowel pin when fitting cylinder head.
– Fit cylinder head, screw in 8 remaining cylinder head bolts and

tighten by hand.
– Unscrew guide pins through bolt holes in cylinder head using
fitting tool from 3070 and install remaining cylinder head bolts.
– Tighten cylinder head in four stages. ⇒ page 76
– Secure toothed belt cover (rear) to cylinder head.
– Install hub and camshaft sprocket.
– Lock camshaft and high-pressure pump with diesel injection
pump locking pin - 3359- .
– Rotate crankshaft to TDC in direction of engine rotation and

lock in position with crankshaft stop - T10050- .
– Install cylinder head cover ⇒ page 82 .
– Install poly V-belt ⇒ page 40 .
1.4 Removing and installing cylinder head

cover
Removing
– Take out noise insulation at injectors.
– Remove injectors ⇒ page 220 .
– Remove fuel rail ⇒ page 229 .

– Detach bracket -1- with wiring for Lambda probe and temper‐
ature sender before particulate filter from cylinder head cover.
– Detach crankcase breather line -3- and move clear.
– Unscrew bolts for fuel lines -arrows-.
– Remove bolts -1- to -7- and detach cylinder head cover.

Installing
⇒ “1.2 Exploded view - cylinder head cover”, page 77
Note
Renew gasket for bolts if damaged.
– Install cylinder head cover, tightening sequence ⇒ page 78 .
1.5 Checking compression

1. Cylinder head 83
♦ Compression tester - V.A.G 1763- with adapter - V.A.G

1763/8-
Procedure
• Operating temperature
• Battery voltage at least 12.5 V
– Unplug electrical connector -arrow- for fuel pressure regulat‐

ing valve - N276- at fuel rail.
– Briefly start engine to relieve fuel pressure in fuel rail.
– Remove all glow plugs ⇒ page 279 .

– Screw in adapter - V.A.G 1763/8- in place of corresponding

glow plug and connect compression tester - V.A.G 1763- .
Note
Using the compression tester ⇒ Operating instructions .
– Have a second mechanic operate starter until tester shows no

further pressure increase.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 25.0 … 31.0
Wear limit 19.0
Maximum difference between cylinders 5.0
Assembling
– Install glow plugs ⇒ page 279 .
– Entries are stored in event memory of engine control unit be‐
cause electrical connectors were unplugged and the engine
was started: Interrogate event memory in Vehicle self-
diagnosis ⇒ Vehicle diagnostic tester.
1.6 Identification of cylinder head gasket

1- Part number
2- Holes
3- Ignore
Note
♦ If the measured values for piston projection are not the same
for all pistons, use the highest value to determine the correct
gasket size.
♦ Cylinder head gaskets of different thicknesses are fitted de‐
pending on piston projection. When replacing the cylinder
head gasket, install a new gasket with the same identification
-arrow 2-.
1. Cylinder head 85
2 Toothed belt drive

⇒ “2.1 Exploded view - toothed belt”, page 86
⇒ “2.2 Removing and installing toothed belt”, page 87
2.1 Exploded view - toothed belt
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
⇒ page 87
2 - Nut
❑ 20 Nm
❑ Make sure that stud is
fitted securely
❑ Stud, 15 Nm
3 - Idler roller
4 - Bolt
❑ Renew
❑ 50 Nm + 90°
5 - Nut
❑ Renew nut
❑ 20 Nm + 45°
❑ Make sure that stud is
fitted securely
❑ Stud, 15 Nm
6 - Tensioning roller
7 - Bolt
❑ Renew
❑ 20 Nm +45°
8 - Camshaft sprocket
9 - Idler roller
10 - Bolt
❑ 20 Nm
11 - Bolt
❑ 100 Nm
12 - Hub
❑ Use counterhold tool - 3415- to loosen and tighten
❑ To remove, use puller - T10052-
13 - Bolt
❑ 5 Nm
14 - Toothed belt cover (rear)
15 - Bolt
❑ 20 Nm

16 - Bolt
❑ 5 Nm
17 - Idler roller
18 - Hub
❑ With sender wheel
❑ Use counterhold tool - T10051- to loosen and tighten
19 - Nut
❑ 100 Nm
20 - High-pressure pump sprocket
21 - Toothed belt cover (top section)
22 - Bolt
❑ Tightening torque ⇒ page 193
23 - Coolant pump
24 - Bolt
❑ 15 Nm
25 - Crankshaft sprocket
26 - Bolt
❑ Renew
❑ Use counterhold tool - 3415- to loosen and tighten
❑ Do not additionally oil or grease the threads and shoulder
Tighten in three stages as follows:
♦ 1st stage: 180 Nm
♦ 2nd stage: Use rigid wrench to turn 90° further
♦ 3rd stage: Use rigid wrench to turn 45° further
27 - Toothed belt cover (bottom section)
28 - Toothed belt cover (centre section)
29 - Bolt
❑ 10 Nm
30 - Belt pulley/vibration damper
❑ Can only be installed in one position (holes are off-set)
31 - Bolt
❑ Renew
❑ 10 Nm + 90°
2.2 Removing and installing toothed belt

2. Toothed belt drive 87

♦ Locking pin - 3359- or commercially available M6x50 bolt
♦ Crankshaft stop - T10050-
♦ Counterhold tool - T10172-
♦ Locking tool - T10265- (not required for all tensioning rollers)
♦ M10 bit
♦ Torque wrench

♦ Angle driver - T10264- for tensioning roller A
♦ Angle driver 8 mm - T10409- for tensioning roller B
Differences between tensioning roller versions
Note
Two different tensioning roller versions are installed. It is possible

to switch between them. When making adjustments, first check
which tensioning roller version is installed.
Note different directions of rotation when tensioning

Features of tensioning roller A:
♦ Locking tool - T10265- is required for installation
♦ Make sure tensioning roller is positioned correctly in toothed
belt cover
♦ Toothed belt is tensioned by turning eccentric adjuster on ten‐
sioning roller clockwise
Features of tensioning roller B:
♦ No locking tool required
♦ Tensioning roller is not located in toothed belt cover
♦ Toothed belt is tensioned by turning eccentric adjuster on ten‐
sioning roller anti-clockwise

Removing
Note
Perform adjustments on toothed belt only when engine is cold;

position of tensioner varies according to temperature of engine.

– Remove vibration damper ⇒ page 43 .
– Remove bolts -arrows-.

– Detach toothed belt cover (bottom).
Caution
Irreparable damage can be caused if the toothed belt slips.

♦ Only turn crankshaft in direction of engine rotation.
– Rotate crankshaft by turning bolt on crankshaft sprocket until

camshaft sprocket is positioned at “TDC”.
– Lock camshaft hub with diesel injection pump locking pin -
3359- or an M6x50 bolt (commercially available).
Note
♦ If it is not possible to push the diesel injection pump locking

pin - 3359- in (lack of space), use an M6x50 bolt (commercially
available).
♦ Disregard -arrows-.

– Lock crankshaft sprocket in position with crankshaft stop -

T10050- .
• The markings on the sprocket -2- and the crankshaft stop -1-
must align -arrow-. The pin of the crankshaft stop must engage
in the aperture in the sealing flange.
Note
The crankshaft stop can only be pushed onto the sprocket from
the front face of the teeth.
– Slacken bolts -arrows- for camshaft sprocket approx. 90°.
– Using an M10 bit , loosen bolts -arrows- for toothed belt

sprocket on high-pressure pump by approx. 90°.
– Slacken nut -1- for tensioning roller.

– Turn eccentric adjuster of tensioning roller with angle driver -
T10264- anti-clockwise -arrow- until tensioning roller can be
secured with locking tool - T10265- .
Note
♦ Different tensioning roller versions: Not all tensioning rollers

can be locked with the locking tool - T10265- .
♦ Tensioning rollers which cannot be locked must be loosened
with the angle driver - T10264- without being locked.

– Then use angle driver - T10264- to turn eccentric adjuster of

tensioning roller clockwise -arrow- as far as stop and tighten
nut -1- by hand.
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 toothed belt
with chalk or felt-tip pen for re-installation.
– Take off toothed belt first from idler roller and then from re‐
maining sprockets.
Installing (adjusting valve timing)
• Tightening torques
⇒ “2.1 Exploded view - toothed belt”, page 86
Note
Perform adjustments on toothed belt only when engine is cold.
Caution
Risk of damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshaft is turned.
Requirements:
• Different tensioning roller versions: Not all tensioning rollers
can be locked with the locking tool - T10265- .
• Tensioning roller is locked with locking tool - T10265- and se‐
cured at right stop with nut -1-.
• Lock camshaft hub with diesel injection pump locking pin -

3359- or an M6x50 bolt.
• Bolts -arrows- are fitted but not tightened.
• It should just be possible to turn the sprocket on the camshaft
without axial movement.
Note
♦ If it is not possible to push the diesel injection pump locking

pin - 3359- in (lack of space), use an M6x50 bolt (commercially
available).
♦ Disregard -arrows-.

• Crankshaft is locked in position with crankshaft stop -

T10050- .
• Hub of high-pressure pump locked with diesel injection pump

locking pin - 3359- .
• Bolts -1- are fitted but not tightened.
• The high-pressure pump sprocket should still just turn, but
there must be no axial movement.
Note
If necessary, apply a screwdriver -arrows- to bolt heads -1- and

turn the high-pressure pump hub until it can be locked with the
locking pin.

– Turn the camshaft sprocket and high-pressure pump sprocket

in their elongated holes clockwise as far as the stop.
– Install toothed belt in the specified sequence:
1- Crankshaft sprocket
2- Tensioning roller
3- Camshaft sprocket
4- Coolant pump sprocket
5- High-pressure pump sprocket
6- Idler roller
– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .
Note
♦ This applies if locking tool - T10265- is attached.

♦ Disregard -arrow-.
Note
Ensure that tensioning roller is seated properly in toothed belt

cover (rear) -arrow-.
– Position counterhold tool - T10172- on camshaft sprocket as

– Apply force to counterhold tool in anti-clockwise direction
-arrow- and maintain tension.
– Tighten bolts -1- for camshaft sprocket and bolts -2- for high-
pressure pump sprocket in this position.
♦ Initial tightening torque: 20 Nm

– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using offset screwdriver - T10264- until pointer -2-
aligns with centre of slot on base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.
– Remove diesel injection pump locking pin - 3359- or M6x50
bolt and crankshaft stop - T10050- .
Checking valve timing:
Caution

– Turn crankshaft two rotations in direction of engine rotation by

turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Fit crankshaft stop - T10050- to crankshaft sprocket again.

– Turn crankshaft in direction of engine rotation until pin
-arrow- on crankshaft stop engages in sealing flange as crank‐
shaft rotates.
• Lock camshaft hub with diesel injection pump locking pin -

3359- or an M6x50 bolt.
Note
Disregard -arrows-.
• It is very difficult to reproduce the locking position of the high-

pressure pump hub. However, a slight deviation -arrow- does
not influence engine operation.

• Pointer -2- on tensioner roller must be centred between tabs

-1- and -3- on base plate.
Note
The maximum permissible sideways deviation from the specified

position is 5 mm.
♦ Re-adjust valve timing if requirements are not met

⇒ page 96 .
♦ If requirements are met, continue with procedure after adjust‐
ing valve timing correctly as described below ⇒ page 96 .
Re-adjusting valve timing:
– If camshaft hub cannot be locked, withdraw crankshaft stop -
T10050- until pin is clear of bore.
– Turn crankshaft in opposite direction of engine rotation slightly
past “TDC”.
– Now turn crankshaft slowly in direction of engine rotation until

it is possible to lock camshaft hub with diesel injection pump
locking pin - 3359- or M6x50 bolt.
– Loosen bolts for camshaft sprocket after locking hub.
A - If pin of crankshaft stop - T10050- is on left side of bore:

– Turn crankshaft in direction of engine rotation until pin
-arrow- on crankshaft stop engages in sealing flange as crank‐
shaft rotates.
– Tighten camshaft sprocket bolts to 20 Nm initially.
B - If pin of crankshaft stop - T10050- is on right side of bore:
– Turn crankshaft slightly in opposite direction to engine rota‐
tion.
– Turn crankshaft in direction of engine rotation again until pin
of crankshaft stop engages in sealing flange as crankshaft ro‐
tates.
– Tighten camshaft sprocket bolts to 20 Nm initially.
Procedure after adjusting valve timing correctly:
– Remove diesel injection pump locking pin - 3359- or M6x50
bolt and crankshaft stop - T10050- .
– Turn crankshaft two rotations in direction of engine rotation by
turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Check valve timing once again ⇒ page 95 .

– If camshaft hub can now be locked, tighten camshaft sprocket

bolts -1- to final torque ⇒ Item 7 (page 86) .
– Tighten bolts -2- for high-pressure pump sprocket to final tor‐
que ⇒ Item 11 (page 196) .
– Check valve timing once again ⇒ page 95 .
Assembling
Note
♦ Renew seals and/or gaskets.

– Install vibration damper ⇒ page 43 .

– Install engine cover panel.

3 Valve gear
⇒ “3.1 Exploded view - valve gear”, page 98
⇒ “3.2 Removing and installing camshaft oil seal”, page 100
⇒ “3.3 Removing and installing camshaft”, page 101
⇒ “3.4 Removing and installing valve stem oil seals”, page 109
3.1 Exploded view - valve gear
1 - Oil seal
❑ Do not additionally oil or
grease sealing lip of oil
seal
❑ Before installing, use
clean cloth to wipe oil
residue off camshaft
journal.
❑ When fitting, mask
groove on taper of cam‐
shaft (using e.g. trans‐
parent adhesive tape)
⇒ page 100
2 - Bolt
when loosening
⇒ page 99
when tightening
⇒ page 99
3 - Nut
❑ 10 Nm
4 - Retaining frame
❑ With integrated cam‐
shaft bearings
when loosening
⇒ page 99
when tightening
⇒ page 99
❑ Clean sealing surface;
machining not permitted
5 - Exhaust camshaft
6 - Inlet camshaft
7 - Roller rocker finger
❑ Mark installation position
❑ Check roller bearings for ease of movement
❑ Lubricate contact surface
8 - Hydraulic compensation element
❑ Mark installation position
❑ Lubricate contact surfaces before installing

9 - Valve
❑ Do not machine, only grinding-in is permitted
❑ Mark installation position for re-installation
❑ Valve dimensions ⇒ page 116
❑ Checking valve guides ⇒ page 116
10 - Cylinder head
❑ See note ⇒ page 74
11 - Valve stem oil seal
❑ Renewing valve stem oil seals ⇒ page 109
12 - Valve spring
13 - Valve spring plate
14 - Valve cotter
15 - Sealing cap
❑ Renew
Loosening retaining frame

– Remove bolts securing retaining frame in the sequence
-24 ... 1-.
Tightening sequence for retaining frame

– Tighten cylinder head bolts in the sequence -1 ... 24- as fol‐
lows:
1. Fit bolts in the sequence -1 ... 24- and hand-tighten in sev‐
eral stages.
2. Tighten bolts in the sequence -1 ... 24- to 10 Nm using tor‐
que wrench.
3. Valve gear 99
3.2 Removing and installing camshaft oil seal
Special tools and workshop

equipment required
♦ Fitting tool - 10-203-
♦ Oil seal extractor - 3240-
♦ Torque wrench - V.A.G
1331/-
♦ Torque wrench - V.A.G
1332/-
♦ Bolt M12×1.5×75
Removing
– Detach toothed belt from camshaft and high-pressure pump
⇒ page 87 .
– Remove camshaft sprocket and hub ⇒ page 101 .
– Insert thrust piece -3240/1- in camshaft.
– Screw inner section of oil seal extractor 3240 out of outer sec‐
tion by two turns (approx. 3 mm) and lock with knurled screw.

– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner section against camshaft
until oil seal is pulled out.
Installing
Note
The sealing lip of the oil seal must not be additionally oiled or
greased.
– Apply guide sleeve -10-203- to camshaft as shown in illustra‐

tion.
– Carefully push oil seal -1- over guide sleeve and onto cam‐
shaft.
– Press in oil seal onto stop using thrust piece of fitting tool
10-203 and bolt M12×1.5×75.
– Install camshaft sprocket and hub ⇒ page 101 .
– Fit toothed belt and adjust valve timing ⇒ page 87 .
3.3 Removing and installing camshaft
3. Valve gear 101

♦ Diesel injection pump lock‐

ing pin - 3359-
♦ Counterhold tool - T10051-
♦ Puller - T10052-
♦ Camshaft fitting tool -
T40094-
♦ Camshaft fitting tool -
T40095-
♦ Clamping tool -T40096/1-
Removing
– Take out noise insulation at injectors.
– Remove injectors ⇒ page 220 .
– Detach toothed belt from camshaft and high-pressure pump
⇒ page 87 .
– Detach cylinder head cover ⇒ page 82 .

– Unscrew bolts -1- on camshaft sprocket.

– Detach camshaft sprocket from hub.
– Counterhold hub with counterhold tool - T10051- and loosen

bolt -1- securing hub.
– Unscrew securing bolt of hub approx. 2 turns.
– Set up puller - T10052- and align it with holes in hub.

– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
Use 30 mm spanner to hold puller.
– Detach hub from taper of camshaft.

– Remove vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vac‐
uum system; Removing and installing vacuum pump .
– Disconnect vacuum hose -1-.
3. Valve gear 103

– Remove bolts -2- and -4-.
Note
Coolant hoses -1- and -2- must not be detached.
– Remove bolts -arrows- and tie up exhaust gas recirculation

cooler.
– Unfasten bolts -arrows- and remove bracket for exhaust gas

recirculation.

– Remove bolts securing retaining frame in the sequence

-24 ... 1-.
– Detach retaining frame.
– Mark fitting location of camshafts for re-installation and re‐
move.
Installing
Tightening torques ⇒ “3.1 Exploded view - valve gear”, page 98
Note
Use silicone sealant to seal sealing surface between retaining

frame and cylinder head.
Caution
Make sure axial bearings in retaining frame are not damaged.

♦ The camshafts MUST be installed using the camshaft fit‐
ting tool - T40094- as described in the following.
– Remove remaining sealant from cylinder head and retaining

frame using rotating plastic brush or similar.
Caution
Protect lubrication system and bearings against contamina‐

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

– Remove remaining sealant from cylinder head and retaining

frame using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
Note
– Oil running surfaces of both camshafts.
3. Valve gear 105

Set up camshaft fitting tool - T40094- as follows:

– Secure supports -T40094/9- and -T40094/10- (with -
T40094/11- ) to base plate, as shown in illustration. If neces‐
sary, remove any supports already attached at these posi‐
tions.
– Fit support -T40094/1- onto position -F- and support -

T40094/2- onto position -A-.
– Place inlet camshaft in supports -T40094/1- and -T40094/2- .

– Turn inlet camshaft in such a way that it can be locked in “TDC”
position using locking device -arrow 1-.
• Recess -arrow 2- for cylinder head bolt must face outwards.

– Place exhaust camshaft in supports -T40094/9- and -

T40094/11- .
– Lock exhaust camshaft with top section -T40094/11- .
• The lug -1- on the top section must engage in the slot -2- in
the camshaft,
– Place clamping tool -T40096/1- on teeth of exhaust camshaft
so that the two arms of the tool engage in the two halves of
the gear.
• The wider arm must engage in the wider half of the gear.
– Tighten the clamping tool using the knurled wheel so that the
faces of the gear teeth are in alignment.
– Slide inlet camshaft towards exhaust camshaft until gear teeth
-arrows- engage.
– Fit retaining frame on camshafts.

• All camshaft bearings must be seated on the camshafts.
– Position camshaft fitting tool - T40095- and fix camshafts in
position in retaining frame, as shown in illustration.
– Detach top section -T40094/11- .
– Cut off nozzle of tube at front marking (∅ of nozzle approx.

2 mm).
– Apply beads of sealant (approx. 2 ... 3 mm width) -arrows- onto
clean sealing surfaces of cylinder head as illustrated.
3. Valve gear 107

Note
The sealant beads must not be thicker than specified, otherwise

excess sealant could enter the camshaft bearings.
– Take camshafts together with retaining frame, camshaft fitting

tool - T40095- and clamping tool -T40096/1- out of camshaft
fitting tool - T40094- and insert components carefully into cyl‐
inder head.
– Tighten retaining frame bolts in the sequence -1 ... 24- hand-

tight initially.
• The retaining frame should make contact with the cylinder
head over the full surface.
– Tighten retaining frame bolts in the sequence -1 ... 24- to final
torque. Tightening torque ⇒ page 99
– Remove camshaft fitting tool - T40095- and clamping tool -
T40096/1- .
Perform further installation in reverse order, paying attention to
the following:
– Renew camshaft oil seal ⇒ page 100 .
– Use suitable drift to drive in new sealing cap
⇒ Item 15 (page 99) at cylinder head until flush.
– Install vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vacuum
system; Removing and installing vacuum pump .
– Install cylinder head cover ⇒ page 82 .
Caution
Risk of damage to valves and piston crowns after working on

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.

3.4 Removing and installing valve stem oil

seals
⇒ “3.4.1 Removing and installing valve stem oil seals with cylinder
head installed”, page 109
⇒ “3.4.2 Removing and installing valve stem oil seals with cylinder
head removed”, page 112
3.4.1 Removing and installing valve stem oil seals with cylinder head installed

equipment required
♦ U/J extension and socket,
10 mm - 3220-
♦ 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 5161/23- and
knurled spacer ring -VAS
5161/23-1-
Procedure
– Remove glow plugs using U/J extension and socket - 3220-
⇒ page 279 .
– Remove camshafts ⇒ page 101 .
– Attach guide plate - VAS 5161/23- to cylinder head.
3. Valve gear 109

– Secure guide plate - VAS 5161/23- hand-tight with knurled

screw - VAS 5161/12- on the intake manifold side and with
flangeless M6 nuts -1- on the studs.
– Screw sealing pin - VAS 5161/10- into guide plate -
VAS 5161/23- .
– Screw adapter - VAS 5161/11- hand-tight into corresponding

glow plug thread.
– Insert drift - VAS 5161/3- in guide plate - VAS 5161/23- and

use plastic-headed hammer to release valve cotters that are
stuck.
– Screw engaging fork - VAS 5161/5- with snap-in device -

VAS 5161/6- into guide plate - VAS 5161/23- .
– Slide knurled spacer ring -VAS 5161/23-1- onto assembly car‐
tridge - VAS 5161/8- .

– Connect adapter - VAS 5161/11- to compressed air line using

a commercially available connection piece, and apply constant
air pressure.
• Minimum pressure: 6 bar
– Attach pressure fork - VAS 5161/2- to snap-in device and push
assembly cartridge - VAS 5161/8- 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
- VAS 5161/8- .
– Release pressure fork.
– Take out assembly cartridge - VAS 5161/8- with knurled
spacer ring, valve spring plate and valve spring.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto the valve stem to prevent damage
to the new valve stem oil seal -B-.
– Lightly 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 -A-.
– Install valve spring and valve spring plate in cylinder head.
– If valve cotters have been removed from assembly cartridge -

VAS 5161/8- , they need to be put into valve insertion device
- VAS 5161/18- first.
Note
Larger diameter of valve cotters faces upwards.
– Press assembly cartridge - VAS 5161/8- onto insertion device

from above and pick up valve cotters.
3. Valve gear 111

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

– Press down assembly cartridge - VAS 5161/8- using pressure
fork - VAS 5161/2- . Turn knurled screw of assembly cartridge
back and forth while pulling upwards.
– Release pressure fork - VAS 5161/2- with knurled screw still
in pulled position.
– Install glow plugs ⇒ page 279 .
– Install camshafts ⇒ page 101 .
Note
♦ Engine is not to be rotated for approx. 30 minutes after instal‐

ling camshafts. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
3.4.2 Removing and installing valve stem oil

seals with cylinder head removed
♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-

♦ Removal and installation device for valve cotters - VAS 5161/

A- with knurled spacer ring -VAS 5161/23-1- and guide plate
-VAS 5161/23-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-

Procedure
Proceed as follows:
– Remove camshafts ⇒ page 101 .
– 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
– Connect cylinder head tensioning device to compressed air
supply.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seal is to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
3. Valve gear 113

– Fit guide plate -VAS 5161/23- onto cylinder head.

– Secure guide plate on intake manifold side with knurled screw
-VAS 5161/12- and at studs by screwing on 2 nuts M6 without
shoulder by hand until they make contact.
– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Slide knurled spacer ring -VAS 5161/23-1- onto assembly car‐
tridge -VAS 5161/8- .
– 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 off assembly cartridge with knurled spacer ring.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .

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- .
– Take off 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.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert assembly cartridge in guide plate -VAS 5161/23- again.

– 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 camshafts ⇒ page 101 .
3. Valve gear 115

4 Inlet and exhaust valves

⇒ “4.1 Machining valve seats”, page 116
⇒ “4.2 Checking valve guides”, page 116
⇒ “4.3 Valve dimensions”, page 116
4.1 Machining valve seats
Note
Valve seats may not be machined due to the very small toleran‐
ces.
4.2 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
– Insert new valve into guide. End of valve stem must be flush
with guide. Only insert inlet valve into inlet valve guide and
exhaust valve into exhaust valve guide, as the stem diameters
are different.
– Determine wear limit (sideways play): max. 1.3 mm.
– Renew cylinder head if the determined sideways play is above
wear limit.
4.3 Valve dimensions
Note
Valves must not be machined. Only grinding-in is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 28.10 26.00
∅b mm 5.975 5.965
c mm 99.30 99.10
α ∠° 45 45

17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 117
⇒ “1.2 Engine oil”, page 120
⇒ “1.3 Removing and installing sump”, page 120
⇒ “1.4 Removing and installing oil pump”, page 124
1.1 Exploded view - sump/oil pump
1 - Seal
❑ Renew
2 - Oil drain plug
❑ 30 Nm
3 - Sump
⇒ page 120
4 - O-ring
❑ Renew
5 - Suction pipe
❑ Clean strainer if dirty
6 - Bolt
❑ 9 Nm
7 - Oil pump
⇒ page 124
❑ Before installing, check
that the two dowel
sleeves for centring oil
pump are fitted onto bal‐
ance shaft assembly
8 - Drive shaft
❑ For oil pump
9 - Circlip
❑ Must fit securely in
groove
❑ Renew circlip if dam‐
aged or stretched
10 - Spur gear
❑ For balance shaft
11 - Bolt
❑ Renew
❑ 20 Nm + 90°
12 - Thrust washer
❑ For idler gear
❑ Renew
❑ Installation position ⇒ page 120
❑ When installing idler gear, apply grease to hold washer on balance shaft assembly
1. Sump/oil pump 117

13 - Idler gear
❑ Renew
❑ To achieve the correct backlash a suitably thick coating is already applied to the new idler gear; the
required clearance is achieved as the coating is worn down
❑ Installation position: Part No. must be visible.
❑ Make sure thrust washer is properly seated ⇒ page 120
14 - Bolt
❑ With washer
❑ Renew
❑ 90 Nm + 90°
15 - Hub
❑ For idler gear
❑ Renew
16 - Crankshaft gear
17 - Cover
❑ Installation position for cover of oil level and oil temperature sender - G266- ⇒ page 119
18 - Dowel sleeves
19 - Balance shaft assembly
❑ Removing ⇒ “4.1 Removing and installing balance shaft assembly”, page 133
❑ Re-installing "old" balance shaft assembly
⇒ “4.1.3 Re-installing a used balance shaft assembly”, page 136
❑ Installing new balance shaft assembly ⇒ “4.1.2 Installing a new balance shaft assembly”, page 134
❑ Before installing, check that the two dowel sleeves for centring balance shaft assembly are fitted on
cylinder block
20 - Bolt
❑ Renew
❑ Tightening torque and sequence for balance shaft assembly with eight attachment points ⇒ page 119
❑ Tightening torque and sequence for balance shaft assembly with six attachment points ⇒ page 120
21 - Dowel sleeves
22 - Bolt
❑ 9 Nm
23 - Oil intake pipe
24 - Bolt
❑ 9 Nm
25 - Seal
❑ Renew
26 - Oil level and oil temperature sender - G266-
27 - Cover
❑ For oil level and oil temperature sender - G266-
28 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
29 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 119
118 Rep. gr.17 - Lubrication

Installation position for cover of oil level and oil temperature send‐
er - G266-
– Clip in cover for oil level and oil temperature sender - G266-
-arrow-, as shown in illustration.
Note
For greater clarity, item -1- shows oil level and oil temperature
sender .
Sump - tightening torque and sequence

– Tighten bolts in stages:
Stage Bolts Tightening torque
1. -1 to 20- 5 Nm in diagonal sequence
2. -arrows- 15 Nm + turn 90° further (renew bolts)
3. -1 to 7-, Tighten in stages and in diagonal se‐
-9 and 10-, quence; final torque 13 Nm
-12 to 20-
4. -8 and 11- 23 Nm
Tightening sequence - balance shaft assembly with eight attach‐

ment points
– Tighten bolts securing balance shaft assembly as follows:
Stage Bolts Tightening torque/angle specification
1. -1 to 8- Screw in hand-tight in this sequence
2. -1 to 8- Pre-tighten in this sequence to 6 Nm
3. -1 to 4- Tighten to 20 Nm
4. -5- Tighten to 13 Nm
8. -1 to 8- Use rigid wrench to turn 90° further in
this sequence

Tightening sequence - balance shaft assembly with six attach‐

ment points
– Tighten bolts securing balance shaft assembly as follows:
Stage Bolts Tightening torque/angle specification
1. -1 to 6- Screw in hand-tight in this sequence
2. -1 to 6- Pre-tighten bolts in this sequence to
6 Nm
3. -1 to 4- Tighten to 20 Nm
4. -5 and 6- Tighten to 13 Nm
5. -1 to 6- Use rigid wrench to turn 90° further in
this sequence
Removing and installing oil level and oil temperature sender -

G266-
1- Bolt, 9 Nm
2- Seal; renew
3- Electrical connector
4- Oil level and oil temperature sender - G266-
Installation position of thrust washer
Caution
Make sure that the thrust washer -A- does not slip out of the
recesses in the balance shaft assembly -arrows- when fitting
the idler gear. If this is neglected, the thrust washer can be‐
come stuck. If necessary, apply grease to the thrust washer
and attach it to the balance shaft assembly.
1.2 Engine oil

Refer to ⇒ Maintenance tables for engine oil capacity, oil speci‐
fications and viscosity grades.
1.3 Removing and installing sump


♦ Articulated wrench, 10 mm - 3185-
♦ Socket - T10058-
♦ Used oil collection and extraction unit - V.A.G 1782-

Removing
– Set up support bracket - 10 - 222 A- with adapters -10 - 222

A /3- 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.
– Remove front wheels.
tion .
– Remove subframe cross brace ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Subframe; Removing and installing subframe
cross brace .
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe .
– Place used oil collection and extraction unit - V.A.G 1782- be‐
low engine and drain off engine oil.
Note
Please observe requirements for disposal.
– Unplug electrical connector -2- from oil level and oil tempera‐
ture sender - G266- .


– Unscrew bolts -1 to 20- in diagonal sequence and remove.
– Carefully release sump from bonded joint.
Installing
– Remove sealant remaining on crankcase with flat scraper.
WARNING
Put on safety goggles.
– Remove sealant residue on the sump with a rotating brush,

e.g. an electric drill with a plastic brush attachment.
– Clean sealing surfaces; they must be free of oil and grease.
Note
♦ Note the use-by date of the sealant.

♦ The sump must be installed within 5 minutes after applying the
silicone sealant.
– Cut off nozzle of tube at front marking (∅ of nozzle approx.

3 mm).
– Apply silicone sealant onto clean sealing surface of sump as
illustrated. Sealant bead must:
♦ be 2...3 mm thick.
♦ Pass round bolt holes on inside as shown in illustration
-arrows-.
Note
The bead of sealant must not be thicker than specified, otherwise

excess sealant can enter the sump and block the strainer in the
oil intake pipe.

– Apply bead of silicone sealant onto clean sealing surface of

sump, as illustrated. (The illustration shows the position of the
sealant bead on the crankcase.)
– Immediately fit sump and lightly tighten bolts securing sump
to gearbox and all bolts securing sump. The sump must make
flush contact with spacer plate/gearbox flange.
Note
When installing sump with engine removed from vehicle, ensure

that sump is positioned flush with crankcase at flywheel end.
– Tighten sump bolts in diagonal sequence.

– Tighten sump/gearbox bolts.
Tightening torques
Note
After fitting sump assembly, the sealant must dry for approx. 30
minutes. Then (and only then) fill the engine with engine oil.
– Fill with engine oil and check oil level (Audi A4) ⇒ Mainte‐
nance ; Booklet 812 .
– Fill with engine oil and check oil level (Audi A5) ⇒ Mainte‐
nance ; Booklet 811 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .
– Install subframe cross brace ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Subframe; Removing and installing subframe
cross brace .
– Install steering rack ⇒ Running gear, axles, steering; Rep. gr.
48 ; Steering rack; Removing and installing steering rack .
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe .
Further assembly is basically carried out in reverse order of dis‐
mantling.
1.4 Removing and installing oil pump

Removing
– Remove bolt -4- and detach intake connecting pipe from oil
pump.
– Remove circlip -1- using circlip pliers.
– If there is a thread in the drive shaft, screw an M3 bolt -2- into
drive shaft and pull drive shaft out of oil pump -arrow-.

Note
♦ If there is no thread in the drive shaft, use a magnet -arrow-

and pull the drive shaft out of the oil pump.
♦ Pull drive shaft -2- out of oil pump using a magnet -arrow-.
– Remove bolts -3, 4, 5- and detach oil pump.
Caution
The bolt on the idler gear must NOT be loosened.
Installing
Tightening torques
Note
♦ Renew O-ring.
♦ Renew circlip if damaged or stretched.
♦ Circlip must fit securely in groove.
– Insert dowel sleeves -arrows- in oil pump, if not fitted.

– If no dowel sleeves for centring the oil pump are fitted in the
balance shaft assembly, install missing dowel sleeves.

2 Engine oil cooler

⇒ “2.1 Removing and installing engine oil cooler”, page 126
2.1 Removing and installing engine oil cool‐

er
Removing
tion .
– Unscrew sealing cap -3- and take out oil filter element.

– Remove bolt -1- and swivel pump for exhaust gas recirculation
cooler - V400- to the side.
WARNING

The cooling system is under pressure when the engine is hot.
Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.
– Clamp off coolant hoses with hose clamps up to 25 mm - 3094-

as shown in illustration.
– Disconnect coolant hoses -1-.
– Unscrew sealing cap -2- and take out engine oil cooler -3-.
Installing
Tightening torques
⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”, page
128
2. Engine oil cooler 127

3 Oil filter/oil pressure switch

128
⇒ “3.2 Checking oil pressure and oil pressure switch”,
page 130
⇒ “3.3 Removing and installing oil filter housing”, page 131
⇒ “3.4 Checking oil level”, page 132
3.1 Exploded view - oil filter housing/oil pressure switch
1 - Gasket
❑ Renew
2 - Bolt
❑ 15 Nm + 90°
❑ Renew
❑ First fit bolts on top left
and bottom right, then
tighten all four bolts in
diagonal sequence
3 - Oil filter bracket
❑ Ensure clearance from
surrounding compo‐
nents
4 - Seal
❑ Renew
5 - Connection
❑ 30 Nm
6 - Oil supply line
❑ 22 Nm
❑ To turbocharger
7 - Oil pressure switch - F1-
❑ 22 Nm
❑ Identification: brown
❑ 0.7 bar
❑ In case of leakage, cut

open seal and renew

❑ Checking ⇒ page 130
8 - Sealing cap
❑ 25 Nm
9 - O-ring
❑ Renew
10 - Oil filter element
❑ See note
❑ Observe change intervals
11 - Seal
❑ Renew
❑ Lubricate before installing
❑ Engage in lugs on engine oil cooler
12 - Engine oil cooler
❑ Ensure clearance from surrounding components
13 - Seal
❑ Renew
14 - Plug
❑ 25 Nm
15 - Bolt
❑ 10 Nm
16 - Bracket
❑ For wiring harness
Installation position of seal for engine oil cooler

– Fit seal -2- so it can be attached to all tabs on engine oil cooler
-1-.
• The oil drilling -arrow- must not be covered by the seal.
3. Oil filter/oil pressure switch 129

3.2 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Voltage tester - V.A.G
1527/B-
♦ Auxiliary measuring set -
V.A.G 1594C-
Checking oil pressure switch

Test conditions
• Oil level OK
• Operating temperature
Note
Functional check and servicing the visual and acoustic oil pres‐
sure warning ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations

– Remove oil pressure switch - F1- -brown insulation- from oil

filter bracket and screw it onto tester.
– Screw tester into oil filter bracket in place of the oil pressure
switch.
– Connect brown wire of tester to earth (–).
– Connect voltage tester - V.A.G 1527B- to positive battery ter‐
minal (+) and oil pressure switch using adapter leads from
auxiliary measuring set - V.A.G 1594C- . LED must not light
up.
– Start engine and increase engine speed slowly. The LED
should light up at 0.55...0.85 bar. If it does not, renew oil pres‐
sure switch.
Checking oil pressure
• Oil pressure at idling speed: at least 0.8 bar
• Oil pressure at 2000 rpm: at least 2.0 bar
3.3 Removing and installing oil filter housing

Removing

– Detach coolant hoses -arrows-.

– Remove bolts -1- and -2- and take out coolant pipe.
3. Oil filter/oil pressure switch 131


– Unscrew sealing cap -3- and take out oil filter element.
– Unplug electrical connector -1-.

– Disconnect oil supply line -2-.
– Unscrew bolts -arrows- and remove oil filter bracket.

Installing
Tightening torques
128
3.4 Checking oil level


4 Balance shaft assembly

⇒ “4.1 Removing and installing balance shaft assembly”,
page 133
4.1 Removing and installing balance shaft

assembly
⇒ “4.1.1 Removing balance shaft assembly”, page 133
page 136
4.1.1 Removing balance shaft assembly

♦ Locking pin - 3359-
Procedure
Note
-Item 1- can be disregarded.
4. Balance shaft assembly 133

Caution

– Rotate crankshaft by turning bolt on crankshaft sprocket until

camshaft sprocket is positioned at “TDC”.
– Lock camshaft hub with diesel injection pump locking pin -
3359- .
• The toothed segment -arrow- must face upwards.
Balance shaft assembly with eight attachment points
– Unscrew bolts in the sequence -8 ... 1- and remove balance

shaft assembly with oil pump.
Balance shaft assembly with six attachment points
– Unscrew bolts in the sequence -6 ... 1- and remove balance
shaft assembly with oil pump.
page 136
4.1.2 Installing a new balance shaft assembly


♦ Bits - T10099-
♦ Insert tool for torque wrench -T10393- (not illustrated)

Procedure
Tightening torques
Note
♦ The spur gear drive of the balance shaft assembly must be

installed with a specified backlash.
♦ To achieve the correct backlash, a coating is already applied
to the new idler gear.
♦ The coating is worn down rapidly and the backlash is then
correct.
♦ Therefore, a new balance shaft assembly must always be in‐
stalled in conjunction with a new idler gear which has the
correct coating.
Caution
Before positioning balance shaft assembly slacken off idler

gear bolt. Do not loosen bolt too much, otherwise the thrust
washer can slip behind the idler gear. Installation position of
thrust washer ⇒ page 120
– Before positioning balance shaft assembly on cylinder block,

loosen bolt -1- for idler gear by approx. 45° (1/8 turn).
– Check that the two dowel sleeves are in place to ensure that
balance shaft assembly is located correctly on cylinder block.
Note
Take care not to damage coating on idler gear.
– Balance shaft assembly with eight attachment points: tighten

bolts ⇒ page 119 .
– Balance shaft assembly with six attachment points: tighten

– Lock balance shaft with locking tool - T10255- ; turn balance

shaft to do so, if necessary.
• The lug of the locking tool must engage in the groove of the
balance shaft.
– Carefully fit balance shaft gear onto balance shaft; to do so,

push idler gear slightly to one side.
Note
♦ Check that threaded holes of balance shaft align centrally with

elongated holes of balance shaft gear.
♦ If it is not possible to align the elongated holes in the balance
shaft gear with the threaded holes, you must turn the gear
some teeth further as required and then fit it again.
– Secure balance shaft gear -arrows-.

– Detach locking tool - T10255- .
The following three steps have to be performed simultaneously

(a second mechanic is therefore required).
– Push idler gear -3- firmly in direction of -arrow- into teeth on
drive gear -2- and balance shaft gear -1-. If necessary use a
suitable wooden tool.
– Turn balance shaft gear slightly anti-clockwise when doing
this.
– Tighten new bolt for idler gear ⇒ Item 14 (page 118) .
Note
After installation the idler gear must have no backlash. This can
be checked by exerting light pressure by hand.
quence. When doing so, note the following:
4.1.3 Re-installing a used balance shaft as‐

sembly

Caution
If the bolt for the idler gear has been loosened, the drive gear
on the crankshaft has been renewed or the crankshaft has
been removed, you must install a new idler gear with the ap‐
propriate coating and renew the hub ⇒ Item 15 (page 118) with
the bolt ⇒ Item 14 (page 118) and thrust washers. Otherwise
the backlash will not be correct.
Tightening torques
Note
♦ If re-installing the used balance shaft assembly and neither the

drive gear on the crankshaft nor the crankshaft itself have
been renewed, proceed as described in the following. It is also
essential that the idler gear has NOT been slackened.
– Lock balance shaft with locking tool - T10255- ; turn balance

shaft to do so, if necessary.
• The lug of the locking tool must engage in the groove of the
balance shaft.
– Check that the two dowel sleeves are in place to ensure that
balance shaft assembly is located correctly on cylinder block.
– Attach balance shaft assembly to cylinder block.
• With the balance shaft locked in position, the idler gear must
engage in the drive gear on the crankshaft.
• Idler gear must have noticeable backlash.
– Balance shaft assembly with eight attachment points: tighten
– Balance shaft assembly with six attachment points: tighten
quence. When doing so, note the following:

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 138
⇒ “1.2 Checking cooling system for leaks”, page 143
⇒ “1.3 Draining and filling cooling system”, page 144
1.1 Connection diagram - coolant hoses

⇒ “1.1.1 Connection diagram - coolant hoses without 4/2-way
valve, vehicles without auxiliary heater”, page 138
⇒ “1.1.2 Connection diagram - coolant hoses without 4/2-way
valve, vehicles with auxiliary heater”, page 140
⇒ “1.1.3 Connection diagram - coolant hoses with 4/2-way valve
with thermostat, vehicles without auxiliary heater”, page 141
⇒ “1.1.4 Connection diagram - coolant hoses with 4/2-way valve
with thermostat, vehicles with auxiliary heater”, page 142
1.1.1 Connection diagram - coolant hoses without 4/2-way valve, vehicles without
auxiliary heater
138 Rep. gr.19 - Cooling

1 - ATF cooler
❑ Not installed on vehicles
with manual gearbox
⇒ page 126
3 - Exhaust gas recirculation
cooler
⇒ page 273
4 - Radiator outlet coolant tem‐
perature sender - G83-
⇒ page 160
5 - Coolant temperature send‐
er - G62-
⇒ page 159
6 - Coolant shut-off valve
❑ Not fitted on all versions
❑ Depending on produc‐
tion period and version
of vehicle
❑ On vehicles with auxili‐
ary heater ⇒ Auxiliary
heater, supplementary
heater; Rep. gr. 82 ;
Coolant circuit with aux‐
iliary/supplementary
heater; Removing and
installing heater coolant
shut-off valve
7 - Bleeder hole
8 - Heat exchanger
❑ If renewed, refill system with fresh coolant
9 - Coolant circulation pump - V50-
❑ Only installed on vehicles with start/stop system
10 - Non-return valve
11 - Hose thermostat
13 - Coolant expansion tank
❑ With filler cap
❑ Checking cooling system for leaks ⇒ page 143
14 - Pump for exhaust gas recirculation cooler - V400-
❑ Depending on production period and version of vehicle
16 - Coolant pump
17 - Thermostat
1. Cooling system/coolant 139

18 - Cylinder head/cylinder block

19 - Radiator
1.1.2 Connection diagram - coolant hoses without 4/2-way valve, vehicles with
auxiliary heater
1 - ATF cooler
with manual gearbox
⇒ page 126
cooler
⇒ page 273
⇒ page 160
er - G62-
⇒ page 159
6 - Circulation pump - V55-
7 - Auxiliary heater
8 - Heater coolant shut-off
valve - N279-
10 - Bleeder hole
11 - Heat exchanger
❑ If renewed, refill system
with fresh coolant
❑ With filler cap
❑ Depending on production period and version of vehicle
17 - Coolant pump

18 - Thermostat
20 - Radiator
1.1.3 Connection diagram - coolant hoses with 4/2-way valve with thermostat,
vehicles without auxiliary heater
1 - ATF cooler
with manual gearbox
⇒ page 126
cooler
⇒ page 273
⇒ page 160
er - G62-
⇒ page 159
6 - Coolant shut-off valve
❑ Depending on produc‐
tion period and version
of vehicle
❑ Activated via Climatron‐
ic coolant shut-off valve
- N422-
7 - Bleeder hole
8 - Heat exchanger
with fresh coolant
9 - Coolant circulation pump -
V50-
❑ Only installed on vehicles with start/stop system
❑ With filler cap


14 - Coolant pump
15 - 4/2-way valve with thermostat
❑ The thermostat is located in the interior of the 4/2-way valve and cannot be renewed separately
17 - Radiator
1.1.4 Connection diagram - coolant hoses with 4/2-way valve with thermostat,
vehicles with auxiliary heater
1 - ATF cooler
with manual gearbox
⇒ page 126
cooler
⇒ page 273
⇒ page 160
er - G62-
⇒ page 159
6 - Circulation pump - V55-
7 - Auxiliary heater
8 - Heater coolant shut-off
valve - N279-
9 - Bleeder hole
10 - Heat exchanger
with fresh coolant
❑ With filler cap


15 - Coolant pump
16 - 4/2-way valve with thermostat
❑ The thermostat is located in the interior of the 4/2-way valve and cannot be renewed separately
18 - Radiator
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


– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.0 bar.
– If this pressure is not maintained, locate and rectify leaks.
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
WARNING


Note
♦ The cooling system is under pressure when the engine is hot.

If necessary, relieve pressure before commencing repair work.
♦ Hose clip pliers - V.A.G 1921- or hose clip pliers - VAS 6340-
are recommended for use when installing spring-type clips.
♦ Renew gaskets and seals.
♦ The arrow markings on coolant pipes and on ends of hoses
must align.

equipment required
♦ Adapter for cooling system
tester - V.A.G 1274/8-
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Hose clip pliers -
V.A.G 1921-
♦ Cooling system charge unit
- VAS 6096-
♦ Refractometer - T10007 A-

Draining
WARNING


tion .
gine.
– Remove drain plug -1- and drain off coolant.
Filling
Caution
To ensure optimal corrosion protection, only distilled water

may be mixed with coolant additives.

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

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . If you use other coolant additives, this can
significantly impair in particular the corrosion protection effect.
The resulting damage could lead to loss of coolant and con‐
sequently to serious 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.
♦ Do not reuse coolant.
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
Recommended mixture ratio for coolant

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

– Close drain plug -1-.
– Fill reservoir of -VAS 6096- with at least 8 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 supply.
• Pressure: 7 ... 10 bar.

– Open valve -B- by setting lever in direction of flow.

• The suction jet pump generates a vacuum in the cooling sys‐
tem. 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 will continue generating a vacuum in the
cooling system. The needle on the gauge should remain in the
green zone.
– Close valve -B-.
• The needle on the gauge should remain in the green zone.
The vacuum level in the cooling system is then sufficient for
subsequent 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.
– Fit pipe for cooling system tester - V.A.G 1274/10- onto adapt‐
er for cooling system tester - V.A.G 1274/8- .
– Fill up pipe for cooling system tester - V.A.G 1274/10- with
coolant.

– Unclip plenum chamber cover -2- and remove.
– Release coolant hose going to heat exchanger for heater and

pull back hose until bleeder hole -arrow- in hose is no longer
blocked by connection.
– Fill up with coolant until it comes out at bleeder hole in coolant
hose.
– Push coolant hose back onto connection and secure with
spring-type hose clip.
– Detach pipe for cooling system tester - V.A.G 1274/10- and
close filler cap on coolant expansion tank.
– Start engine.
– Set temperature to “HI” in all zones.
– Switch off air conditioner compressor (press ECON button).
– Set fresh air blower to lowest setting.
– 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 1 minute at 2000 rpm.
– Switch off ignition and allow engine to cool down.
tion .
WARNING


– 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.
– Top up with coolant again if necessary.

2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump/thermostat”, page 152
⇒ “2.2 Removing and installing pump for exhaust gas recirculation
cooler V400 ”, page 152
⇒ “2.3 Removing and installing coolant pump”, page 154
⇒ “2.4 Removing and installing thermostat”, page 155
⇒ “2.5 Removing and installing 4/2-way valve with thermostat”,
page 157
⇒ “2.6 Removing and installing coolant temperature sender G62
”, page 159
⇒ “2.7 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 160
2.1 Exploded view - coolant pump/thermostat
1 - Bolt
❑ 15 Nm
2 - Coolant pump
⇒ page 154
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - 4/2-way valve with thermo‐
stat
❑ Installed according to
version
⇒ page 157
❑ The thermostat is loca‐
ted in the interior of the
4/2-way valve and can‐
not be renewed sepa‐
rately
6 - Bolt
❑ 15 Nm
7 - Connection
❑ Installed according to
version
8 - Thermostat
⇒ page 155
❑ Only fitted on version
with connection -7-
2.2 Removing and installing pump for ex‐

haust gas recirculation cooler - V400-

♦ Hose clamps, up to 25 mm - 3094-
♦ Hose clip pliers - V.A.G 1921-
Removing
WARNING

2. Coolant pump/thermostat assembly 153

– Clamp off coolant hoses with hose clamps up to 25 mm - 3094-

as shown in illustration.
– Unscrew bolt -1- and remove pump for exhaust gas recircula‐
tion cooler - V400- with bracket.
– Detach pump for exhaust gas recirculation cooler from brack‐
et.
Installing
Note
♦ Hose connections and air pipes/hoses must be free of oil and

grease prior to fitting.
♦ 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.
2.3 Removing and installing coolant pump

♦ Refractometer - T10007-

Removing
Note
Always renew seals and gaskets.

– Remove toothed belt. ⇒ page 87
– Unscrew bolts -1- and pull out coolant pump -2-.
Installing
Tightening torques
– Moisten new O-ring -3- with coolant.

– Insert coolant pump -2- into cylinder block and tighten securing
bolts -1-.
Note
Sealing plug for coolant pump faces downwards.
2.4 Removing and installing thermostat

♦ Refractometer - T10007-

♦ Articulated wrench, 10 mm - 3185-
♦ Socket - T10058-
Removing
Note
Always renew seals and gaskets.

– Detach coolant hose from connection.

– Using articulated wrench, 10 mm - 3185- and socket -

T10058- , unscrew securing bolts -4- of connection -3- and
remove connection -3- with thermostat -1-.
– Turn thermostat -1- 90° in anti-clockwise direction and take
thermostat out of connection -3-.
Installing
Tightening torques
– Moisten new O-ring -2- with coolant.
– Fit thermostat -1- with O-ring -2- into connection -3- and turn
90° in clockwise direction.
Note
The brace on the thermostat must be almost vertical.
– Insert connection -3- with thermostat -1- into engine block.
– Use articulated wrench - 3185- to tighten securing bolts -4-.

2.5 Removing and installing 4/2-way valve

with thermostat
♦ Multi-point bit XZN 8 - T10445-
Removing
Note
The thermostat is located in the interior of the 4/2-way valve and

cannot be renewed separately.


– Remove nut -1- and move bracket with electrical connectors
to one side.
– Detach coolant hoses from connections -A, B and D-.

– Remove bolt -2- with multi-point bit XZN 8 - T10445- .
– Remove bolts -1-.
– Pull valve out of cylinder block and detach connection -C- from
coolant pipe to the left.
Installing
• Tightening torque
Note
Fit new O-ring.

2.6 Removing and installing coolant temper‐

ature sender - G62-
Removing
• Engine cold.
– Open filler cap on coolant expansion tank briefly and allow re‐
sidual pressure in cooling system to dissipate.
sensor 1 .
– Remove nuts -1- and detach bracket -2-.

– Remove vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vac‐
uum system; Removing and installing vacuum pump .

– Unplug electrical connector -2- at coolant temperature sender

- G62- .
– Pull off retaining clip -1- and pull out coolant temperature
sender - G62- .
Installing
Note
♦ Renew O-rings.
♦ Insert new coolant temperature sender - G62- immediately in‐
to connection to avoid loss of coolant.
– Check coolant level ⇒ page 144 .
2.7 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
– Unplug electrical connector -1- and unscrew radiator outlet

coolant temperature sender - G83- -2-.
WARNING

hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
Installing
– Top up coolant.

3 Radiator/radiator fans
⇒ “3.1 Exploded view - radiator/radiator fans”, page 161
⇒ “3.2 Removing and installing radiator”, page 162
⇒ “3.3 Removing and installing radiator fan control unit J293 ”,
page 167
⇒ “3.4 Removing and installing radiator fans”, page 168
3.1 Exploded view - radiator/radiator fans
1 - Bolt
❑ 4.5 Nm
2 - Radiator fan control unit -
J293-
⇒ page 167
3 - Bolt
❑ 5 Nm
4 - Radiator cowl
⇒ page 162
5 - Radiator fan - V7-
⇒ page 168
6 - Bolt
❑ 3.5 Nm
7 - Washer
8 - Rubber bush
❑ For radiator
9 - Coolant hose
❑ Lift retaining clip to de‐
tach
10 - O-ring
❑ Renew
11 - Coolant hose
❑ Lift retaining clip to de‐
tach
12 - O-ring
❑ Renew
13 - Coolant hose
❑ To coolant expansion tank
14 - O-ring
❑ Renew
15 - Radiator
❑ Remove and install together with radiator cowl ⇒ page 162
❑ If renewed, change coolant in entire system
16 - Retaining pin
❑ Use screwdriver to release and pull off
3. Radiator/radiator fans 161

17 - Rubber buffer
18 - Radiator bracket
19 - Bolt
❑ 5.5 Nm
20 - Radiator fan 2 - V177-
❑ Not fitted if fan runs with 400 W
21 - Bolt
❑ 5 Nm
Connecting coolant hose with plug-in connector to coolant pipe

– Remove old O-ring -2- from coolant hose -3-.
– Lubricate new O-ring with coolant additive and fit O-ring in
coolant hose.
– Press coolant hose onto coolant pipe -1- until it engages with
a click.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
3.2 Removing and installing radiator
WARNING

WARNING
Risk of injury as the radiator fans may start up automatically.

♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.
Note
♦ The cooling system is under pressure when the engine is hot.

If necessary, relieve pressure before commencing repair work.
(same as original equipment) ⇒ Parts catalogue .
♦ Hose clip pliers - V.A.G 1921- or hose clip pliers - VAS 6340-
are recommended for use when installing spring-type clips.
♦ Renew gaskets and seals.
♦ The arrow markings on coolant pipes and on ends of hoses
must align.

Note
Radiator and radiator cowl can only be removed and installed to‐
gether as one unit.

Removing
Note
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.

tion .
– Remove bumper cover (front) and bumper ⇒ General body
repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing and
installing bumper cover .
– Remove charge air cooler ⇒ page 177 .
A4 vehicles
– Remove headlight (right-side) ⇒ Electrical system; Rep. gr.
94 ; Headlights; Removing and installing headlights .
– If fitted, remove headlight washer jet (right-side) ⇒ Electrical
system; Rep. gr. 92 ; Headlight washer system; Removing
and installing washer jets .
– Unplug electrical connector -1- at front airbag crash sensor for
front passenger side - G284- ⇒ General body repairs, interior;
Rep. gr. 69 ; Crash sensors for airbags; Removing and in‐
stalling front airbag crash sensor for driver side - G283- .


– Unclip mounting for headlight (right-side) -arrows- and re‐
move.
All vehicles
gine.
– Remove drain plug -1- and drain off coolant.
– Then disconnect coolant hose -2- from radiator (pull out re‐
taining clip).
– Take electrical connector -1- for radiator fan out of bracket and
unplug connector (push retainer to the rear -arrow- and press
down release catch).
– Remove bolts -1, 2, 3, 5-.

– Lift cover -4- above lock carrier and detach from radiator grille
-arrow-.

– Detach connections -1- and -2- from radiator (lift retaining clip).
– Remove air duct -1- and intermediate flange -2-.
Vehicles with multitronic gearbox:

– Position used oil collection and extraction unit - V.A.G 1782-
below connection point.
Note
Observe rules for cleanliness when working on multitronic gear‐

box ⇒ Rep. gr. 00 ; Repair instructions; Rules for cleanliness .
– Unscrew bolts -arrows- and detach ATF lines from radiator.

– Seal off open pipes/lines and connections with clean plugs
from engine bung set - VAS 6122- .
Note
Tie ATF lines up onto longitudinal member to prevent fluid es‐

caping.
All vehicles

– Release catches -arrows A- and detach air duct -1- on left and
right -arrow B-.
– Release retaining pins for radiator on both sides and pull out
upwards -arrows-.
– Remove bolts -1- on both sides and detach radiator bracket

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

– Have a 2nd mechanic release retaining clips -1- in direction of

-arrow A- and lift condenser -2- out of mounts on radiator
-arrows B-.
Caution
Risk of damage to condenser, refrigerant lines and refrigerant

hoses.
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Pivot condenser forwards with pipes/hoses attached.

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

-arrow- and at the same time lift radiator cowl off radiator.
Installing
• Tightening torque ⇒ page 161
– Attach air duct to intermediate flange for air cleaner housing.
– On vehicles with multitronic gearbox: secure ATF lines ⇒ Rep.
gr. 37 ; ATF circuit; Removing and installing ATF lines .
– Install charge air cooler ⇒ page 177 .
– Install bumper and bumper cover (front) ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Removing and
installing bumper cover .
– Connect coolant hose with plug-in connector to coolant pipe
⇒ page 162 .
Note
The coolant in the entire system must be changed if the radiator

is renewed.
– On vehicles with multitronic gearbox: check ATF level ⇒ Rep.

gr. 37 ; ATF; Checking ATF level .
3.3 Removing and installing radiator fan

control unit - J293-
Removing
Note
Fit all cable ties in the original positions when installing.
– Remove front noise insulation ⇒ General body repairs, exte‐

insulation .

WARNING
Risk of injury as the radiator fan(s) may start up automatically.

♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.
– On vehicles with cross member -3-, remove bolts -1- for torque
reaction support.
– Remove bolts -2- from cross member -3- on both sides.
Note
♦ Due to the limited space available, the cross member cannot

be removed.
♦ Cross member must only be detached; leave it in installation
position.
– Take electrical connector -1- for radiator fan out of bracket and
unplug connector (push retainer to the rear -arrow- and press
down release catch).
– Move clear electrical wiring harness leading to radiator fan
control unit - J293- .
– Unplug electrical connectors -2- and -3-.

– Unscrew bolt -arrow- and remove radiator fan control unit -
J293- -1-.
Installing
– If previously fitted, re-install cross member
⇒ “2.3 Removing and installing torque reaction support and
cross member”, page 33 .
♦ Tightening torque
⇒ “3.1 Exploded view - radiator/radiator fans”, page 161
tion .
3.4 Removing and installing radiator fans

Removing
Note
– Remove radiator cowl ⇒ page 162 .

Radiator fan - V7-

– Unscrew bolts -arrows- and remove radiator fan - V7- .
Radiator fan 2 - V177-

– Unscrew bolts -arrows- and remove radiator fan 2 - V177- .
Installing
– Install radiator cowl ⇒ page 162 .

21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 170
⇒ “1.2 Removing and installing turbocharger”, page 171
1.1 Exploded view - turbocharger

– Observe rules for cleanliness ⇒ page 6 .
1 - Seal
❑ Renew
2 - Connection
❑ 40 Nm
3 - Oil return line
❑ To cylinder block
❑ Tighten union nut to
40 Nm
4 - Bolt
❑ 15 Nm
❑ Property class 10.9; use
only genuine bolts
(same as original equip‐
ment) ⇒ Electronic
parts catalogue
5 - Gasket
❑ Renew
6 - Bolt
❑ 20 Nm
7 - Gasket
❑ Renew
8 - Bolt
❑ 23 Nm
❑ Renew
9 - Diesel particulate filter with
catalytic converter
⇒ page 259
10 - Exhaust gas temperature
sender 1 - G235-
11 - Seal
❑ Renew
12 - Connection
❑ 30 Nm
13 - Bolt
❑ 10 Nm
14 - Oil supply line
❑ Tighten union nuts to 22 Nm
170 Rep. gr.21 - Turbocharging/supercharging

15 - Turbocharger
16 - Nut
❑ 25 Nm
❑ Securing turbocharger to exhaust manifold
❑ Renew
❑ Coat with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
17 - Vacuum hose
❑ From charge pressure control solenoid valve - N75-
18 - Hose clip
❑ 3.5 Nm
19 - Crankcase breather hose
20 - Air hose
21 - Hose clip
❑ 3.5 Nm
22 - Gasket
❑ Renew if damaged or leaking
23 - Support
24 - Bolt
❑ 40 Nm
25 - Bolt
❑ 10 Nm
26 - Connection
27 - Air intake hose to charge air cooler
28 - Hose clip
❑ 3.5 Nm
1.2 Removing and installing turbocharger

Removing
Caution
If the turbocharger has suffered mechanical damage (e.g.

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check air cleaner housing, air filter element and air hoses
for dirt and foreign particles.
♦ Check the entire charge air system (including the charge
air cooler) for foreign matter.
♦ If foreign matter is found in the charge air system, clean
all relevant ducts and hoses and renew charge air cooler
if necessary.
1. Turbocharger 171

– Detach crankcase breather line -1- and move clear.

– Open hose clip -2-, detach air hose and remove.
tion .
– Unfasten connection -1-, remove bolt -2- and take out mount‐
ing for particulate filter.

– Remove bolts -1- and -2- and remove support.

– Unplug electrical connector -3- for exhaust gas temperature
sender 1 - G235- and unclip from bottom of cylinder block.

1. Turbocharger 173
Note

cooler.
– Remove nuts -1- and -2- on turbocharger.
Note
♦ Nut -3- is removed later.

♦ Nut -1- is accessible from below on vehicles with auxiliary
heater.
– Remove union nut -1-.

– Unplug electrical connector -3- for position sender for charge
pressure positioner - G581- .
– Remove nut -4- securing turbocharger to exhaust manifold.
– Unclip electrical wiring from cylinder block -arrow-.

– Remove nuts -1-, pull turbocharger and particulate filter off

studs and swivel to side as far as possible.
– Remove nut -3- and disconnect turbocharger from particulate

filter.
Note
♦ Seal off open pipes/lines and connections on turbocharger

with clean plugs or protective caps to prevent dirt from enter‐
ing.
♦ After removing the turbocharger, do not put it down so it rests
on the top section of the oil return line – this could cause dam‐
age.
Installing
Tightening torques
Tightening torques ⇒ “1.1 Exploded view - silencers”, page 252
Note
♦ Renew gaskets, seals and O-rings.

♦ Fit all heat insulation sleeves in the original position when in‐
stalling.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ To secure the charge air hoses at their connections, spray rust
remover onto the worm thread of the used hose clips before
installing.
♦ After installing the turbocharger, allow the engine to idle for
approx. 1 minute without pressing the accelerator to ensure
that the turbocharger is supplied with oil.
1. Turbocharger 175
2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 176
⇒ “2.2 Removing and installing charge air cooler”, page 177
⇒ “2.3 Removing and installing charge pressure sender G31 ”,
page 180
⇒ “2.4 Checking charge air system for leaks”, page 180
2.1 Exploded view - charge air system

– Observe rules for cleanliness ⇒ page 6 .
1 - Charge air cooler

⇒ page 177
2 - Hose clip
❑ Reinforced
❑ 5.5 Nm
3 - Air hose
❑ To turbocharger
❑ Must be free of oil or
grease when installing
4 - Hose clip
❑ Reinforced
❑ 5.5 Nm
5 - Hose clip
❑ Reinforced
❑ 5.5 Nm
6 - Air hose
❑ To intake manifold
❑ Must be free of oil or
grease when installing
7 - Hose clip
❑ Reinforced
❑ 5.5 Nm
8 - O-ring
❑ Renew
9 - Charge pressure sender -
G31-
⇒ page 180
10 - Bolt
❑ 5 Nm
11 - Rubber grommet
12 - Bush
13 - Nut
❑ 9 Nm

14 - Rubber grommet
15 - Hose clip
❑ Reinforced
❑ 5.5 Nm
16 - Air pipe
17 - Hose clip
❑ Reinforced
❑ 5.5 Nm
18 - Air hose
❑ From charge air cooler
❑ Must be free of oil or grease when installing
19 - Hose clip
❑ Reinforced
❑ 5.5 Nm
20 - Bolt
❑ 7 Nm
21 - Resonator
22 - Rubber grommet
23 - Hose clip
❑ Reinforced
❑ 5.5 Nm
24 - Air hose
❑ To resonator
❑ Must be free of oil or grease when installing
2.2 Removing and installing charge air cool‐

er
Removing
The following step is only required on allroad models:
– On allroad models: Remove bumper cover (front) ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing
and installing bumper cover .
All vehicles except allroad models:
– Remove bolts -1, 2, 3, 5-.
– Lift cover -4- above lock carrier and detach from radiator grille
-arrow-.
2. Charge air system 177


– Detach air duct -1- from intermediate flange -2- for air cleaner
housing.
– Remove closure plate at bumper cover ⇒ General body re‐

pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover
– Release retaining clips -arrows A- and detach air intake grille

-1- on left and right from bottom section of bumper cover
-arrow B-.
All vehicles:
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-.

– Release hose clip -arrow- and detach air hose from charge air
cooler.
– Remove bolt -1-.
– Release hose clip -1- and detach air hose from charge air
cooler.
– Push catch down -arrow A- and move top of charge air cooler
slightly in direction of -arrow B-.
– Lift charge air cooler off radiator -arrows A- and press in di‐
rection of -arrow B-.
– Pull left side of charge air cooler downwards -arrow C- and
detach charge air cooler.
Installing
Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 176
Note

♦ To ensure that the charge air hoses can be properly secured
at their connections, spray rust remover onto the worm thread
of used hose clips before installing.
– Install lock carrier cover ⇒ General body repairs, exterior;

Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
– On allroad models: Install bumper cover (front) ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing
and installing bumper cover .

2.3 Removing and installing charge pres‐

sure sender - G31-
Removing
– Unplug electrical connector -1- from charge pressure sender
- G31- .
– Remove bolts -arrows- and pull charge pressure sender - G31-
out of air pipe.
Installing
Tightening torques
⇒ “2.1 Exploded view - charge air system”, page 176
Note
Fit new O-ring.
2.4 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-

tion .

– Depending on hose diameter, insert adapter - 1687/10- ,

-1687/11- or -1687/12- into air hose -1- and secure with hose
clip.
– Connect charge air system tester - V.A.G 1687- as shown on
illustration.
Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
Note
Make sure knob is pulled out before turning pressure control valve
-2-.

– Using a commercially available connection piece, connect

charge air system tester - V.A.G 1687- to compressed air -1-.
Note
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.
– 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
♦ A small amount of air escapes through the valves and enters

the engine. Therefore it is not possible to perform a pressure
retention test.
♦ Operation of ultrasonic tester - V.A.G 1842- ⇒ Operating in‐
structions .
♦ Release pressure in test circuit by detaching coupling from
adapter before removing adapter.
♦ Hose connections and air pipes/hoses must be free of oil and
grease prior to fitting.
♦ To secure the air hoses properly at their connections, spray
rust remover onto the worm thread of the used hose clips be‐
fore installing.

23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview of fitting locations - injection system”,
page 183
⇒ “1.2 Overview - fuel system”, page 191
⇒ “1.3 Exploded view - fuel system”, page 193
⇒ “1.4 Filling and bleeding fuel system”, page 197
⇒ “1.5 Checking fuel system for leaks”, page 198
⇒ “1.6 Checking fuel pressure (low pressure) system”,
page 198
1.1 Overview of fitting locations - injection

system
Components A to J are not shown on the exploded view.
1 - Air mass meter - G70-

⇒ page 242
2 - Lambda probe - G39- with
Lambda probe heater - Z19-
❑ Fitting location
⇒ page 191
⇒ page 245
sender 3 - G495-
⇒ page 191
⇒ page 264
4 - Electrical connector for ex‐
haust gas temperature send‐
er 3 - G495-
⇒ page 191
⇒ page 264
5 - Connector for Lambda
probe - G39-
⇒ page 191
6 - Exhaust gas pressure sen‐
sor 1 - G450-
⇒ page 188
❑ Adaption must be per‐
formed after renewing
1. Injection system 183

this component
7 - Radiator outlet coolant temperature sender - G83-
❑ Fitting location ⇒ page 188
8 - Fuel temperature sender - G81-
9 - Pressure retention valve
❑ The pressure retention valve maintains a residual pressure of approx. 10 bar in the return lines
❑ This residual pressure is required for the control function of the injectors
❑ The pressure retention valve may only be renewed together with the fuel return lines
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system
❑ Checking pressure retention valve ⇒ page 219
10 - Coolant temperature sender - G62-
11 - Fuel pressure regulating valve - N276-
❑ After renewing high-pressure pump and/or fuel pressure regulating valve - N276- , the learnt values must
be reset. The procedure is described in Guided Fault Finding or Guided Functions ; use ⇒ Vehicle
diagnostic tester.
❑ Guided Functions are not available for certain engine versions because it is not necessary to reset the
learned values on these engines.
❑ 80 Nm
❑ With variable intake manifold position sender - G513-
13 - Engine speed sender - G28-
❑ 4.5 Nm
14 - Intake manifold flap motor - V157-
❑ With throttle valve potentiometer - G69-
❑ Exploded view - intake manifold ⇒ page 207
15 - Engine control unit - J623-
16 - Charge pressure sender - G31-
❑ Combined with intake air temperature sender - G42-
18 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212-
19 - Fuel return line connection
184 Rep. gr.23 - Mixture preparation - injection

20 - High-pressure pump with fuel metering valve - N290-

❑ Do not open fuel metering valve - N290-
21 - Fuel supply line connection
22 - Glow plugs
❑ Glow plug 1 - Q10-
23 - Fuel pressure sender - G247-
❑ Always renew after removing
❑ 100 Nm
24 - Injectors
25 - Hall sender - G40-
26 - Fuel return lines
❑ The fuel return lines must not be dismantled; if necessary they must be renewed complete with pressure
retention valve.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system; then
check fuel return lines for leaks
27 - Charge pressure control solenoid valve - N75-
28 - Exhaust gas recirculation cooler change-over valve - N345-
29 - Electrical connector for exhaust gas temperature sender 1 - G235-
30 - Position sender for charge pressure positioner - G581-
31 - Air filter bypass flap valve - N275-
❑ These components (bypass flap with air filter bypass flap valve - N275- ) are not installed on certain
equipment versions or on vehicles for certain export markets
❑ Exploded view - air cleaner housing ⇒ page 202
A - Relay and fuse holder in electronics box in plenum chamber (left-side)
❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
B - Low heat output relay - J359- and high heat output relay - J360-
❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
C - Brake light switch - F- and brake pedal switch - F47-
❑ In footwell on brake pedal

D - Clutch position sender - G476-

❑ Only fitted on vehicles with manual gearbox
E - Accelerator position sender - G79- and accelerator position sender 2 - G185-
❑ Removing and installing ⇒ Fuel supply system; Rep. gr. 20 ; Accelerator mechanism; Removing and
installing accelerator pedal module with accelerator position sender -G79- / -G185-
F - Supplementary fuel pump - V393-
❑ Removing and installing ⇒ Fuel supply system; Rep. gr. 20 ; Fuel pump; Removing and installing fuel
pump
G - Exhaust gas temperature sender 1 - G235-
❑ Fitting location on turbocharger ⇒ page 190
❑ 45 Nm
H - Exhaust gas temperature sender 4 - G648-
❑ 45 Nm
I - Electrical connector for exhaust gas temperature sender 4 - G648-
J - Particulate filter
❑ Fitted on underbody
❑ Combined with catalytic converter
❑ Adaption must be performed after renewing this component
Adaption must be performed after renewing exhaust gas pressure

sensor 1 - G450- and/or particulate filter. The adaption procedure
is described in the Guided Functions; use ⇒ Vehicle diagnostic
tester.
Fitting location of engine control unit - J623-
♦ In left electronics box in engine compartment
Removing and installing ⇒ page 248

Accelerator position sender - G79- and accelerator position send‐

er 2 - G185-
Removing and installing ⇒ Fuel supply system; Rep. gr. 20 ;
Accelerator mechanism; Removing and installing accelerator
pedal module with accelerator position sender -G79- / -G185-
Note
The accelerator position sender - G79- and accelerator position

sender 2 - G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Brake light switch - F- and brake pedal switch - F47- -1-

2 - Clutch position sender - G476-
Integrated functions: clutch pedal switch for engine start - F194-
and clutch pedal switch - F36- (manual gearbox only)
Fitting locations
3 - Variable intake manifold motor - V183- with variable intake
manifold position sender - G513-
4 - Intake manifold flap motor - V157- with throttle valve potenti‐
ometer - G69-
5 - Exhaust gas recirculation valve - N18- with exhaust gas recir‐
culation potentiometer - G212-
6 - Fuel metering valve - N290-
Pump for exhaust gas recirculation cooler - V400-

Hall sender - G40-
Components at rear of engine

1 - Exhaust gas pressure sensor 1 - G450-
2 - Radiator outlet coolant temperature sender - G83-
Engine speed sender - G28- -arrow-
Supplementary fuel pump - V393- -3-

1 - Electrical connector for supplementary fuel pump - V393-
2 - Fuel filter
4 - Preheating valve

Components
Charge pressure sender - G31- with intake air temperature send‐

er - G42- -1-
Combined in one unit
Position sender for charge pressure positioner - G581- -1-
Injectors and glow plugs

1 - Injector, cylinder 1 - N30-
5 - Glow plug 1 - Q10-
9 - Fuel return line connections

Charge pressure control solenoid valve - N75- -arrow-
Coolant temperature sender - G62- -arrow-
Components
1 - Electrical connector for exhaust gas temperature sender 1 -
G235-
2 - Exhaust gas recirculation cooler change-over valve - N345-
Exhaust gas temperature sender 1 - G235- -1-

Components
1 - Electrical connector for Lambda probe - G39- with Lambda
probe heater - Z19-
G495-
5 - Lambda probe - G39- with Lambda probe heater - Z19-
6 - Exhaust gas temperature sender 3 - G495-
Exhaust gas temperature sender 4 - G648- -2-

G648-
1.2 Overview - fuel system
WARNING
♦ Always read rules for cleanliness and instructions for

working on fuel system ⇒ page 6 .
♦ Follow these instructions and rules for cleanliness before
starting work and while working on the fuel system.
Caution
To prevent the high-pressure fuel pump from running while it

is empty and to ensure that the engine starts quickly after parts
have been renewed, it is important to observe the following:
and the high-pressure fuel pump are removed or renewed,
the first fuel filling must be performed.
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐
sure fuel pump) or fuel filter is removed or renewed, the
fuel system must be bled before the engine is started for
the first time.
♦ If the high-pressure fuel pump is removed or renewed, the
the first time.
Procedure for first fuel filling ⇒ page 197

Note
The high-pressure pump will be damaged if the first fuel filling

operation is not performed.
1 - High-pressure fuel pump

❑ After renewing, first fuel
filling operation MUST
be performed (it is im‐
portant not to allow
pump to run while it is
still empty) ⇒ page 234
❑ After renewing high-
pressure pump and/or
fuel pressure regulating
valve - N276- , the learnt
values must be reset.
The procedure is descri‐
bed in Guided Fault
Finding or Guided
Functions ; use ⇒ Vehi‐
cle diagnostic tester.
❑ Guided Functions are
not available for certain
engine versions be‐
cause it is not necessary
to reset the learned val‐
ues on these engines. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 232
2 - Fuel metering valve - N290-
❑ Do not unscrew
3 - Filter strainer
4 - Fuel temperature sender -
G81-
5 - Fuel pressure sender -
G247-
❑ Always renew after re‐

moving
❑ 100 Nm
6 - Fuel rail
❑ Cannot be re-installed
diagnostic tester.
❑ 80 Nm
8 - Injectors
❑ The fuel return lines must not be dismantled; if necessary they must be renewed complete with pressure
retention valve
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system; then
check fuel return line for leaks
10 - Pressure retention valve
❑ The pressure retention valve maintains a residual pressure of approx. 10 bar in the return lines.
❑ This residual pressure is required for the control function of the injectors
❑ The pressure retention valve may only be renewed together with the fuel return lines
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system
❑ Checking pressure retention valve ⇒ page 219
11 - Fuel cooler
❑ Fitted on underbody
12 - Fuel tank
❑ With fuel system pressurisation pump - G6-
13 - Preheating valve
14 - Supplementary fuel pump - V393-
15 - Fuel filter
❑ Fuel filter - exploded view ⇒ Fuel supply system; Rep. gr. 20 ; Fuel filter; Exploded view - fuel filter
❑ Renewing fuel filter ⇒ Fuel supply system; Rep. gr. 20 ; Fuel filter; Removing and installing fuel filter
1.3 Exploded view - fuel system
WARNING


Caution
To prevent the high-pressure fuel pump from running while it

is empty and to ensure that the engine starts quickly after parts
have been renewed, it is important to observe the following:
and the high-pressure fuel pump are removed or renewed,
the first fuel filling must be performed.
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐
sure fuel pump) or fuel filter is removed or renewed, the
the first time.
♦ If the high-pressure fuel pump is removed or renewed, the
the first time.
Procedure for first fuel filling ⇒ page 197
Note
The high-pressure pump will be damaged if the first fuel filling

operation is not performed.

1 - Bolt
❑ 10 Nm
2 - High-pressure pipe
❑ 25 Nm
❑ Between high-pressure
pump and fuel rail
❑ To fuel tank
❑ Fuel return line must not
be kinked, damaged or
clogged
❑ The fuel return lines
must not be dismantled;
if necessary they must
be renewed complete
with pressure retention
valve
❑ The pressure retention
valve maintains a resid‐
ual pressure of approx.
10 bar in the return lines
❑ This residual pressure is
required for the control
function of the injectors
❑ Checking pressure re‐
tention valve
⇒ page 219
❑ After replacement, en‐
gine must be run at
idling speed for approx.
2 minutes to bleed fuel
system; then check fuel
return lines for leaks
4 - Bolt
❑ 10 Nm
5 - High-pressure pipes
❑ 25 Nm
❑ Between fuel rail and injectors
❑ Install free of stress
❑ Installing high-pressure pipes ⇒ page 226
diagnostic tester.
❑ Cannot be re-installed
❑ Remove and install using open-end spanner insert, 30 mm - T10553-
❑ 80 Nm
7 - Fuel rail

8 - Fuel supply line

9 - High-pressure pump
❑ With fuel metering valve - N290- (do not open)
❑ After renewing, first fuel filling operation MUST be performed (it is important not to allow pump to run
while it is still empty) ⇒ page 234
diagnostic tester.
10 - Bolt
❑ Renew
❑ 20 Nm
❑ Turn long bolts 180° further
❑ Turn short bolts 45° further
11 - Bolt
❑ 20 Nm
12 - Toothed belt sprocket for high-pressure pump
13 - Nut
❑ 95 Nm
14 - Hub
❑ With sender wheel
❑ Use counterhold tool - T10051- to loosen and tighten
❑ Always renew after removing
❑ 100 Nm
16 - Bolt
❑ 22 Nm
17 - Clamping piece
❑ Renew
18 - Hexagon flange nut
❑ For clamping piece
❑ 10 Nm
19 - Cover for injector
20 - Bolt
❑ 5 Nm
21 - Injector
❑ Use a coloured pen to mark injectors and corresponding high-pressure pipes and cylinder for re-instal‐
lation; pay attention to markings when installing
❑ Always renew copper seal when removing and installing
❑ To remove carbon deposits from the injector sealing surface, clean the injector bore in the cylinder head
with cleaning kit - VAS 6811- (it is important to do this to avoid leaks)

Installation position of clamping piece
1.4 Filling and bleeding fuel system

♦ Vehicle diagnostic tester
If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled.
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.
Proceed as follows to fill fuel system with fuel:

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
– Connect vehicle diagnostic tester .
– Switch on the ignition and select the following menu options
on the vehicle diagnostic tester :
♦ Systems with diagnostic capability
♦ Engine electronics
♦ Engine electronics functions
♦ Activate fuel pump
♦ Bleeding fuel system
– The fuel pump starts running.
– The fuel pump must run for approx. 3 minutes to ensure that
the fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.

– Run engine at moderate speed for several minutes and then

switch off.
– Check fuel system for leaks.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section again for leaks.
– Interrogate event memory.
1.5 Checking fuel system for leaks

– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Then inspect high-pressure section of fuel system again for
leaks.
1.6 Checking fuel pressure (low pressure)

system
♦ K-Jetronic pressure tester - V.A.G 1318-
Test conditions:
• Battery voltage at least 12.5 V
• Fuel filter OK.
• Fuel tank at least 1/2 full
• Ignition switched off.
Checking residual pressure
– Remove engine cover panel ⇒ page 36 .

WARNING

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.
– Disconnect fuel supply line -arrow- at connection point.
– Connect K-Jetronic pressure tester - V.A.G 1318- to fuel sup‐

ply line -1- with suitable adapter -2-. Connect the other adapter
-4- of K-Jetronic pressure tester - V.A.G 1318- to fuel supply
line -3-.

Note
In this way the K-Jetronic pressure tester - V.A.G 1318- is con‐

nected into the fuel supply line.
– Connect a ⇒ Vehicle diagnostic tester.

– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Open menu and select “Control unit self-diagnosis”.
– Then select “Basic setting”.
– Select “Checking fuel system pressurisation pump” from the
list.
– Press “Start” button.
– Fuel pumps will run for approx. 60 seconds.
– Let fuel pumps run until maximum fuel pressure has built up.
• Specification: at least 3.5 bar
If specification is not obtained:
Check union between pressure tester and fuel line for leaks.
Check pressure tester for leaks.
Check fuel lines and their connections for leaks.
Fuel filter is blocked.
Check delivery rate of fuel pump ⇒ Fuel supply system; Rep. gr.
20 ; Fuel pump; Checking fuel system pressurisation pump - G6- .
Note
Check fuel system for leaks.

2 Vacuum system
⇒ “2.1 Checking vacuum system”, page 201
2.1 Checking vacuum system

♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Porous or leaking lines
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check all vacuum lines
leading to the corresponding component, and also check the
remaining vacuum lines leading to other components.
– If it is not possible to build up pressure with the hand vacuum
pump - VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.
2. Vacuum system 201

3 Air cleaner
⇒ “3.1 Exploded view - air cleaner housing”, page 202
⇒ “3.2 Removing and installing air filter element”, page 203
⇒ “3.3 Removing and installing air cleaner housing”, page 204
3.1 Exploded view - air cleaner housing
1 - Hose clip
❑ 3.5 Nm
2 - Air hose
3 - Hose clip
❑ 3.5 Nm
4 - Air duct
❑ Clipped into air cleaner
housing
❑ Clean dirt and leaves
out of air duct
5 - Air duct
out of air duct
6 - Air duct
❑ Secure to lock carrier
(2 Nm)
out of air duct
7 - Rubber grommet
8 - Water drain hose
❑ Clean any leaves and
dirt out of water drain
hose (important)
9 - Guide for water drain hose
10 - Hot air intake (countries
with cold climates only)
❑ Slide hot air intake into
air cleaner as far as
stop; then turn clock‐
wise until it engages no‐

ticeably
11 - Air cleaner (bottom section)
❑ Clean any salt residue, leaves and dirt out of air cleaner (bottom section)
❑ Check for dirt in water drain and clean as required (important)
12 - Retainer for air cleaner (bottom section)
❑ Must engage positively
❑ Do not use any lubricants
13 - Air filter bypass flap valve - N275-
❑ With flap for variable intake manifold change-over
14 - Bolt
❑ For air filter bypass flap valve - N275-
15 - Air filter element
❑ Always use a genuine Audi air filter element
❑ For maintenance intervals refer to A4 ⇒ Maintenance ; Booklet 812 , or A5 Coupé ⇒ Maintenance ;
Booklet 811
❑ Also clean snow screen (if fitted)
16 - Frame insert for air cleaner (bottom section)
17 - Air cleaner (top section)
❑ Clean any salt residue, leaves and dirt out of air cleaner (top section)
18 - Bolt
19 - O-ring
20 - Air mass meter
❑ Removing and installing air mass meter - G70- ⇒ page 242
3.2 Removing and installing air filter ele‐

ment
Removing
– Unplug electrical connector -1- at air mass meter - G70- .
3. Air cleaner 203

– Open hose clip -2- on air hose leading to turbocharger and

disconnect hose at air mass meter - G70- .
– Remove all bolts -arrows- from air cleaner (top section) and lift
out air cleaner (top section).
– Take out old filter element.
Installing
To ensure the correct function of the air mass meter - G70- , it is
important to observe the following notes and instructions.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter - G70- and falsify the detected
air mass values. This will cause a loss of power, as the cal‐
culated injection quantities will be too low.
♦ Always use genuine air filter elements (same as original equip‐
ment).
♦ Hose connections and charge air system hoses must be free
of oil and grease prior to fitting. Do not use any lubricants con‐
taining silicone when assembling.
♦ Both sections of the air cleaner housing must be clean.
♦ To prevent malfunctions, cover all critical parts of the engine
air intake tract (air mass meter, intake pipes, etc.) with a clean
cloth when blowing out the air cleaner housing with com‐
pressed air.
♦ Please observe requirements for disposal.
– Blow out water drain -arrow- in air cleaner (bottom section)

with compressed air.
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check air mass meter and air hose (engine intake side) for salt
residue, dirt and leaves.
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
– When installing the air filter element, check that it is properly
centred in the retainer in the air cleaner (bottom section).
– Carefully fit air cleaner (top section) on air cleaner (bottom
section) without applying any force. Make sure the top section
of the air cleaner is fitted straight on the air filter element (note
position of sealing lip on air filter element).
– Ensure secure fit of intake hose at air mass meter - G70- .
quence.
3.3 Removing and installing air cleaner

housing
Removing
– Unplug electrical connector -1- at air mass meter - G70- .

– Open hose clip -2- on air hose leading to turbocharger and

disconnect hose at air mass meter - G70- .
– Remove air duct -3-.
– Detach vacuum hose -arrow- (if fitted).
– Release retainer -4- for bottom section of air cleaner (press in

rubber on left and right side and pull upwards).
Note
♦ These components (bypass flap with variable intake manifold

change-over valve - N335- -1-) are not installed on certain
equipment versions or on vehicles for certain export markets.
♦ Do not use lubricants when installing retainer.
– Disconnect electrical connector at variable intake manifold

change-over valve - N335- (if fitted).
– Carefully take out complete air cleaner housing.
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.
Note
ment).
♦ Use a silicone-free lubricant when installing the intake hose.
3. Air cleaner 205

– If hot air intake is fitted (for countries with cold climates only),
make sure that air intake connection has engaged properly
-arrows- (pay attention to marking).
– Check water drain hose -1- in air cleaner (bottom section) for
dirt and other obstructions (clean if necessary).
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check air mass meter and air hose (engine intake side) for salt
residue, dirt and leaves.
– Check intake duct as far as air filter element for dirt.
– Plug electrical connector at air filter bypass flap valve - N275-
in again (if fitted).
– Re-install air cleaner (bottom section).
Note
The water drain hose must be routed straight downwards; make

sure it is not kinked or twisted.
– Slide vacuum hose -3- (if fitted) back onto connection of air
filter bypass flap valve - N275- -1-.
– Carefully fit air cleaner (top section) on air cleaner (bottom
section) without applying any force.
Note
Before tightening bolts, make sure that top section of air cleaner
is inserted into groove on bottom section of air cleaner (to prevent
air leaks).
– Then secure top section of air cleaner to bottom section.

– Ensure secure fit of air hose at air mass meter - G70- .
– Re-attach electrical connector to air mass meter - G70- .
– The remaining installation steps are carried out in the reverse
sequence.

4 Intake manifold
⇒ “4.1 Exploded view - intake manifold”, page 207
⇒ “4.2 Removing and installing intake manifold”, page 207
4.1 Exploded view - intake manifold
1 - Intake manifold
❑ With variable intake
manifold motor - V183-
and variable intake
manifold position send‐
er - G513- (combined in
one component)
❑ Must not be dismantled
2 - Bolt
❑ 8 Nm
3 - Gasket
❑ Renew
4 - Seal
❑ Renew
5 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler
6 - Bolt
❑ 20 Nm
7 - Gasket
❑ Renew
8 - Bolt
❑ 10 Nm
9 - Intake manifold flap motor -
V157-
❑ With throttle valve po‐
tentiometer - G69-
10 - Bolt
❑ 10 Nm
11 - Bolt
❑ 10 Nm
12 - Oil dipstick
13 - Exhaust gas recirculation valve - N18-
❑ With exhaust gas recirculation potentiometer - G212-
4.2 Removing and installing intake manifold

4. Intake manifold 207

♦ Torque wrench - V.A.G 1331-
♦ Ratchet - V.A.G 1331/1-
♦ Open end spanner insert, AF 17 - V.A.G 1331/6-
♦ Socket - T40055-

♦ Pliers - 3314-
Vehicles with aluminium intake manifold
♦ Bit XZN 8 - T40159-
Vehicles with plastic intake manifold
♦ Socket Torx T30 - T10405-
Removing
WARNING


– Take noise insulation off cylinder head cover.

– Unplug electrical connectors -5, 6, 7 and 8- at glow plugs.
Caution
Make sure that no wire connection is damaged when unplug‐

ging the connectors; otherwise the entire wiring harness must
be renewed. When unplugging the connectors, do not com‐
press the pliers - 3314- with too much force so that the support
sleeve is not damaged.
– Apply groove -arrow A- of pliers - 3314- to collar of support

sleeve -arrow B- and pull connectors off glow plugs.
– Unscrew union nuts at high-pressure pump -1- and fuel rail

-5- and remove high-pressure fuel pipe -4-.
– Remove bolts -arrows- for high-pressure fuel pipe.
– Move wiring harness -6- clear.
– Pull fuel pipe connections -2 and 3- off high-pressure pump.

– Remove bolts -arrows- securing the two fuel pipes.
Note
Do not bend fuel lines.
Caution
♦ Rules for cleanliness when working on the injection sys‐

tem ⇒ page 6 .
♦ Plug open connections with suitable sealing caps imme‐
diately.
– Unplug following electrical connectors:

1- Fuel pressure sender - G247-
2- Fuel pressure regulating valve - N276-
3- Variable intake manifold motor - V183-
4- Intake manifold flap motor - V157-
5- Exhaust gas recirculation valve - N18-
Steps for vehicles with plastic intake manifold only
– Remove injector pipes leading to injectors.
– Remove high-pressure reservoir (rail) ⇒ page 229 .
All vehicles (continued)

– Open hose clip -arrow- securing air hose and disconnect hose
downwards from intake manifold flap motor - V157- .
– Remove bolt on bracket for oil dipstick.
– Detach connecting pipe for exhaust gas recirculation from ex‐
haust gas recirculation valve - N18- .
– Remove bolts securing intake manifold in diagonal sequence
starting from outside and working inwards.
To do so, use appropriate bit/socket:
♦ Vehicles with aluminium intake manifold: Bit XZN 8 - T40159-
♦ Vehicles with plastic intake manifold: Socket T30 - T10405-
– Remove intake manifold.
Installing
– Renew seals and/or gaskets.
– Tighten bolts securing intake manifold in diagonal sequence
starting from outside and working inwards.
Vehicles with plastic intake manifold
– Install high-pressure reservoir (rail) ⇒ page 229 .
– Install injector pipes leading to injectors.
Tightening torque
• Exploded view - intake manifold ⇒ Item 2 (page 207)
• ⇒ “4.1 Exploded view - intake manifold”, page 207
• ⇒ “1.3 Exploded view - fuel system”, page 193

5 Injectors/high-pressure reservoir
(rail)
⇒ “5.1 Checking injectors”, page 213
⇒ “5.2 Performing adaption of correction values for injectors”,
page 213
⇒ “5.3 Checking for injectors sticking open”, page 214
⇒ “5.4 Checking return flow rate of injectors with engine running”,
page 215
⇒ “5.5 Checking return flow rate of injectors at starter cranking
speed”, page 218
⇒ “5.6 Checking pressure retention valve in fuel return line”, page
219
⇒ “5.7 Removing and installing injectors”, page 220
⇒ “5.8 Removing and installing high-pressure pipes”, page 226
⇒ “5.9 Removing and installing high-pressure reservoir (rail)”,
page 229
5.1 Checking injectors

• Checking adaption of “Injector delivery calibration values” and
“Injector voltage calibration values” ⇒ page 213
• Checking for injectors sticking open ⇒ page 214
• Checking return flow rate of injectors with engine running
⇒ page 215
• Checking return flow rate of injectors at starter cranking speed
⇒ page 218
Perform the following tests first if the engine does not start at all:
♦ Checking for injectors sticking open ⇒ page 214
♦ Checking return flow rate of injectors at starter cranking speed
⇒ page 218
♦ Checking fuel pressure regulating valve - N276- ⇒ page 236
5.2 Performing adaption of correction val‐

ues for injectors
The “Injector delivery calibration” and “Injector voltage calibration”
functions serve to correct the injection rates for each cylinder of
a common rail system individually across the entire operating
range.
The 7-digit adaption values -1- (details in illustration are only an
example) are marked separately on each injector. They may con‐
sist of letters and/or numbers (ASCII code).
5. Injectors/high-pressure reservoir (rail) 213

Reference table for reading out letters and/or numbers on each

injector
When a new injector is installed, the adaption value for the new
injector must be written into the engine control unit.
When a new engine control unit is installed, the “Adaption values
for injectors” must be written into the new control unit.
Additionally, check that the “injector delivery calibration values”
with “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these calibra‐
tion values if the correct values are already stored in the engine
control unit.
The adaption procedure is described in the “Guided Fault Find‐
ing”. (The procedure is also described under “Guided Functions”.)
Use ⇒ Vehicle diagnostic tester
5.3 Checking for injectors sticking open

♦ Use a return line to make an -adapter-.
WARNING


– Clean all connections (with commercial cleaning solution or
similar) before removing.

Note
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.
♦ Check all cylinders in turn.
– Dry all components after cleaning.

Start with cylinder No. 1.
– Pull return line connections off injectors; to do so, press tabs
-1- and -2- down and at the same time pull release pin upwards
-arrow-.
– Connect adapter to return line connection of injector to be tes‐
ted after adapter has been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
If the vacuum reading remains the same for 30 seconds, the in‐
jector is OK.
If the injector is faulty, the vacuum reading will fall back to 0 bar
within 2 to 3 seconds.
Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 220 .
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
Note
Lubricate all seals with engine oil or assembly oil before installing.
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
pin down carefully.
Checking fuel system for leaks
– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage occurs.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.
5.4 Checking return flow rate of injectors

with engine running

♦ Return flow meter - VAS 6684-
Checking return flow rate of all injectors
WARNING


– Disconnect hose connection -3- downstream of pressure re‐
tention valve -2- in fuel return line.

– Seal off open return line connection with plug -1-.

– Hold end of this hose -3- (lengthen with hose -4- if necessary)
in a suitable container to measure total return flow rate.
– Start engine and let it idle for 2 minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐

tors are defective. Check return flow rate from each injector
individually.
Checking return flow rate of individual injectors
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.
– Clamp off fuel return line downstream of pressure retention

valve -1- using hose clamp up to 25 mm - 3094- .
– Pull return line connections off injectors; to do so, press both

tabs down and at the same time pull centre piece up to release
connection -arrow-.
– Connect hoses of return flow meter - VAS 6684- to return line
connections of all four injectors.
Caution
Risk of damage to injectors when return lines are disconnec‐

ted.
♦ Do NOT press the accelerator during this test; the engine
must only run at idling speed.
– Start engine and let it idle for several minutes.

– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 4 return lines must not differ by
more than a small amount.
– If one injector has a significantly higher return flow rate than
the others (example -2-), it must be renewed ⇒ page 220 .
deformation.
Note
– Push the return line connections carefully over the new seals
and onto the injectors. The catch should engage audibly. Then
press release pin down carefully.
automatically.
5.5 Checking return flow rate of injectors at

starter cranking speed
Only perform this test if the engine does not start at all.
♦ Return flow meter - VAS 6684-
WARNING


Procedure
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.
connection -arrow-.
– Connect hoses of return flow meter - VAS 6684- to return line
connections of all four injectors.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
♦ Specification of return flow rate: 0 ml
– If fuel comes out of an injector, that injector must be renewed.
deformation.
Note
– Push the return line connections carefully over the new seals
and onto the injectors. The catch should engage audibly. Then
press release pin down carefully.
automatically.
5.6 Checking pressure retention valve in

fuel return line
The pressure retention valve maintains a residual pressure of ap‐
prox. 10 bar in the fuel return line.
This residual pressure is required for the control function of the
injectors
♦ Tester for fuel return system - 6330-

WARNING


– Clean return line connection on cylinder 1 (with commercial
cleaning solution or similar) before removing.
– Dry return line connection on cylinder 1.
– Cover return line connection on cylinder 1 with a cloth.
– Pull return line connection off cylinder 1; to do so, press both
connection -arrow-.
Note
No dirt must be allowed to get into the disconnected return line or

the open connection on the injector.
– Connect tester for fuel return system - VAS 6330- between

return line connection on injector and return line.
– Start engine.
– Check pressure indicated on tester.
♦ Specification: approx. 10 bar
If the value does not match the specification, fit a new pressure
retention valve.
5.7 Removing and installing injectors

♦ Cleaning kit - VAS 6811-

♦ Open end spanner insert, AF 17 - V.A.G 1331/6-
♦ Socket - T40055-

♦ Puller - T10055- with adapter - T10055/1-
♦ Assembly sleeve - T10377-
Removing
WARNING


Caution
♦ Mark cylinder numbers on injector units. They must al‐

ways be re-installed on the same cylinders.
tem ⇒ page 6 .
diately.


connection -arrow-.
Note
No dirt must be allowed to get into the disconnected return lines

or the open connections on the injectors.
– Unplug electrical connectors -1- at injectors which are to be

removed.
– Loosen union nuts for high-pressure pipes at injectors using
socket - T40055- .
– Loosen union nuts for high-pressure pipes at fuel rail using
open end spanner insert, AF 17 - V.A.G 1331/6- .
– Unbolt covers for injectors -arrows-.

– Pull covers upwards and turn them 1/4 turn (90°).
Caution
When removing the securing nuts on the injectors there is a

risk that the nuts will drop into the cylinder head. Proceed very
carefully to prevent unnecessary dismantling or further dam‐
age.
– Unbolt clamping pieces for injectors -arrows-.

– Apply puller - T10055- with adapter - T10055/1- as shown in

illustration and pull injector out upwards by tapping gently.
– After removal, lay injectors on a clean cloth.
Important instructions for installing injectors:
When installing injectors, the following components must be re‐
newed:
♦ Clamping piece
♦ Copper seal
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
Note
♦ Note identification marks for cylinder allocation when re-in‐

stalling high-pressure pipes.
♦ The high-pressure pipes can be re-used after performing the
following checks:
♦ Check taper seats of high-pressure pipes for deformation and
cracks.
♦ The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
♦ Corroded pipes must not be used again.
If a used injector is being re-installed:

– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Continued (same procedure for used and new injectors):

– Fit seal for injector using assembly sleeve - T10377- .

– To prevent damage to the new O-ring, lubricate it with oil and
carefully push it onto the fuel return line connection.
Note
Lubricate all O-rings with assembly oil, engine oil or diesel fuel
before installing.
Caution
Risk of damage to injector sealing surface.

♦ To remove carbon deposits from the injector sealing sur‐
face, clean the injector bore in the cylinder head with
cleaning kit - VAS 6811- .
– Install injectors.
– Hand-tighten union nuts on high-pressure pipes. Make sure
that connections are not under tension.
– To tighten unions of high-pressure pipes at injectors, use tor‐

que wrench - V.A.G 1331- with ratchet - V.A.G 1331/1- and
socket - T40055- .

– To tighten unions of high-pressure pipes to fuel rail, use torque

wrench - V.A.G 1331- with tool insert, AF 17 - V.A.G 1331/6- .
♦ Tightening torques: refer to exploded view of fuel system
⇒ page 193 .
♦ Observe tightening torque: Installing high-pressure pipes
⇒ page 226 .
♦ Tightening torques: refer to exploded view of fuel system
⇒ page 193 .
– Press return line connections carefully over seals and onto in‐
jectors (check seal for damage before connecting return line).
The catch should engage audibly. Then press release pin
down carefully.
After renewing one or more injectors, the “injector delivery cali‐
bration values” and “injector voltage calibration values” for the
new injectors must be written into the engine control unit.
Additionally, check that the “injector delivery calibration values”
and “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these calibra‐
tion values if the correct values are already stored in the engine
control unit.
Bleeding fuel system and checking for leaks
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.
– Run engine at idling speed for several minutes and then switch
off.
– Check the complete fuel system including all 4 return line con‐
nections for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
Note
The return lines can only be renewed together with the pressure
retention valve as one unit.

Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.
5.8 Removing and installing high-pressure

pipes

♦ Socket - T40055-
Procedure
Note

following checks:
cracks.
erwise damaged.
Installing individual injector pipes (cylinders 1...4, between fuel

rail and injectors)
– Use vacuum cleaner to remove dirt from taper seat at fuel rail.

– Clean fuel pipe and end of pipe using cleaning solution and
dry with compressed air.
– Lubricate threads of union nuts with fuel.
– If necessary, the fuel rail can be slackened and moved slightly
so that the injector pipes are not installed under tension. Never
bend the injector pipes or subject them to tension. This would
ultimately cause the injector pipes to fracture.
– Take new injector pipe out of packaging, remove sealing plugs
and immediately install injector pipe between fuel rail and in‐
jector.
– Initially hand-tighten union nuts of injector pipe (do not use a
tool). Make sure that injector pipe is correctly seated.
Sequence for tightening injector pipes:
1- First tighten union nut to specified torque at injector.
2- Tighten union nut at fuel rail to specified torque.
– Follow the same procedure to install any further injector pipes.
– Tighten fuel rail again if it was slackened earlier.
• Tightening torque for fuel rail: refer to exploded view of fuel
system ⇒ page 193 .
– Tighten union nuts of all installed injector pipes using torque
wrench - V.A.G 1331- with ratchet - V.A.G 1331/1- and socket
- T40055- .
• Tightening torque for injector pipes: refer to exploded view of
fuel system ⇒ page 193 .
Installing fuel pipe between high-pressure pump and fuel rail
– Loosen bolts securing fuel rail and check that rail can be
moved.
– Then take new fuel pipe out of packaging, remove sealing
plugs and immediately install fuel pipe between high-pressure
pump and fuel rail without setting it down before installing it.
– Initially hand-tighten union nuts of fuel pipe (do not use a tool).
Make sure that fuel pipe is correctly seated.
– Fit all three securing clips to fuel pipe, making sure they are
aligned correctly.
– Screw in bolts on securing clips approx. 3 turns.
– Secure fuel rail again.
• Tightening torque for fuel rail: refer to exploded view of fuel
system ⇒ page 193 .
– Tighten securing clip (top) on intake manifold to 8 Nm.

– Tighten union nuts of fuel line using torque wrench - V.A.G

1331- with ratchet - V.A.G 1331/1- and socket - T40055- .
Tightening sequence for securing fuel line:
1- First tighten union nut to specified torque at high-pressure
pump.
2- Tighten union nut at fuel rail to specified torque.
• Tightening torque for fuel line: refer to exploded view of fuel
system ⇒ page 193
– Now tighten remaining two securing clips to 8 Nm.
– Fill fuel system ⇒ page 234 .
– Check fuel system for leaks ⇒ page 198 .

reservoir (rail)
♦ Socket - T40055-

Removing
WARNING


– Move wiring harness -6- clear.
– Unplug following electrical connectors:

1- Fuel pressure sender - G247-
2- Fuel pressure regulating valve - N276-
Caution
♦ Mark cylinder numbers on high-pressure pipes. They must

always be re-installed on the same cylinders.
tem ⇒ page 6 .
diately.
– Loosen union nuts for high-pressure pipes using socket -

T40055- .
– Detach fuel return line -1- from fuel rail.

– Unscrew bolts -2- and remove fuel rail.

Installing
– Install high-pressure pipes so they are free of stress.
Note

following checks:
cracks.
erwise damaged.
• Tightening torque for high-pressure pipes: exploded view - fuel

system ⇒ page 193

6 High-pressure pump
⇒ “6.1 Removing and installing high-pressure pump”, page 232
⇒ “6.2 Performing first fuel filling operation after installing high-
pressure pump”, page 234

pump
Caution
♦ Always observe rules for cleanliness and instructions for

♦ Running when dry causes irreparable damage to high-
pressure pump.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. The high-pressure pump must not
be allowed to run while still empty. First fuel filling
⇒ page 234 .
Removing
– Set service position ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier; Setting service position and returning to
normal position .
– Unplug electrical connector at fuel metering valve - N290- .
– Pull fuel pipe connections -2 and 3- off high-pressure pump.

– Remove bolts -arrows- securing the two fuel pipes.
Note
Do not bend fuel lines.

– Using bit XZN 10 - T10385- or M10 bit, unscrew bolts

-arrows- for high-pressure pump sprocket.
– Counterhold hub of high-pressure pump using counterhold

tool - T10051- and unscrew securing nut -1-.
– Apply puller - T40064- with thrust piece - T40064/1- and pin -

T40064/2- as shown in illustration and pull hub off high-pres‐
sure pump. If necessary, counterhold using an open-end
spanner (24 mm).
6. High-pressure pump 233

– Unscrew securing bolts -arrows- for high-pressure pump.

– Carefully take out high-pressure pump.
Installing
Install in reverse sequence.
• Tightening torques: refer to exploded view of fuel system
⇒ page 193 .
– Install toothed belt for high-pressure pump ⇒ page 87 .
– Install high-pressure pipes ⇒ page 226 .
– Return to normal position ⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier; Setting service position and return‐
ing to normal position .
Caution
♦ The high-pressure pump must first be filled with fuel before

the engine is started. The high-pressure pump must not
be allowed to run while still empty. First fuel filling
⇒ page 234 .
♦ Running when dry causes irreparable damage to high-
pressure pump.
Note
Guided Functions are not available for certain engine versions

because the routine is not necessary and the learned values need
not be reset.
After renewing high-pressure pump and/or fuel pressure regulat‐

ing valve - N276- , the learnt values must be reset. The procedure
is described in Guided Fault Finding or Guided Functions ;
use ⇒ Vehicle diagnostic tester.
6.2 Performing first fuel filling operation af‐

ter installing high-pressure pump
♦ Vehicle diagnostic tester
If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled.
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.
Proceed as follows to fill fuel system with fuel:

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.

– Connect vehicle diagnostic tester .

– Switch on the ignition and select the following menu options
on the vehicle diagnostic tester :
♦ Systems with diagnostic capability
♦ Engine electronics
♦ Engine electronics functions
♦ Activate fuel pump
♦ Bleeding fuel system
– The fuel pump starts running.
– The fuel pump must run for approx. 3 minutes to ensure that
the fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Then inspect high-pressure section again for leaks.
6. High-pressure pump 235

7 Senders and sensors

⇒ “7.1 Checking fuel pressure regulating valve N276 ”,
page 236
⇒ “7.2 Removing and installing fuel pressure regulating valve
N276 ”, page 237
⇒ “7.3 Removing and installing fuel pressure sender G247 ”, page
239
⇒ “7.4 Removing and installing air mass meter G70 ”, page 242
⇒ “7.5 Removing and installing exhaust gas pressure sensor 1
G450 ”, page 242
7.1 Checking fuel pressure regulating valve

- N276-
WARNING


– Remove noise insulation from injectors.
– Open hose clip -arrow- and detach fuel return line.
– Seal off open return line connection with a plug -1-.

– Attach a suitable hose -3- to return line -2-.

– Hold this hose -1- in a suitable container -2- to measure the

return flow rate.
1) Checking while engine is running
– Start the engine and run at idling speed.
• Specification: more than 75 ml in 30 seconds
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
2) Checking while engine is running
If condition for 1) is met, start engine and increase engine speed
to ≥ 2000 rpm.
• Fuel is still discharged in the first few seconds after the engine
is started
• Specification after a few seconds: return flow rate = 0 ml
• Drip leaks are permissible
If specification is not obtained, fuel pressure regulating valve - N
276- is defective.
3) If engine can no longer be started
Perform check at cranking speed.
• Specification of return flow rate: 0 ml
• Drip leaks are permissible
• If specification is not obtained, fuel pressure regulating valve
- N 276- is defective.
7.2 Removing and installing fuel pressure

regulating valve - N276-
♦ Open-end spanner insert, 30 mm - T10553-
♦ Torque wrench
7. Senders and sensors 237

The fuel pressure regulating valve - N276- -2- is located in the

fuel rail. It maintains a constant pressure in the fuel rail and the
injector pipes.
If the pressure in the high-pressure fuel circuit is too high, the fuel
pressure regulating valve - N276- opens to allow some of the fuel
to flow back from the fuel rail to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve - N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
Note
Fuel pressure regulating valve - N276- must always be renewed

after it has been removed.
Removing
WARNING
♦ Always observe rules for cleanliness and instructions for


– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using commercial cleaning solution
or similar (no dirt must enter opening in fuel rail).
Note
Clean carefully; cleaning solution must not enter the electrical

connector.
– Dry off fuel pressure regulating valve - N276- .

– Open cable tie securing wiring harness located above fuel
pressure regulating valve - N276- .
– Detach electrical connector at fuel pressure regulating valve -
N276- .
– Loosen union nut using open-end spanner insert, 30 mm -
T10553- (at the same time, counterhold at hexagon flats on
housing). Then unscrew and remove by hand.
– Extract dirt from opening in fuel rail (thread and sealing sur‐
face) using a vacuum cleaner. Do not use metal tools, etc.
– Seal off open fuel rail connection with clean plug.

Installing
Note
♦ The fuel pressure regulating valve - N276- has a deformable

sealing lip and no separate seal; it can therefore be used only
once.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N276- are not
damaged.
♦ Check sealing surface at opening in fuel rail.
♦ The beginning of the thread, the deformable sealing lip and
the O-ring of the fuel pressure regulating valve - N276- must
be coated with diesel fuel.
– Screw on union nut by hand.

– Align new regulating valve so that connecting wire is free of
tension after connector is attached.
– Hold regulating valve in this position by holding hexagon flats
on housing of regulating valve with open-end spanner or pliers
(water pump pliers or similar).
– Tighten union nut using open-end spanner insert, 30 mm -
T10553- (at the same time, counterhold at hexagon flats on
housing).
Tightening torques
♦ ⇒ “1.3 Exploded view - fuel system”, page 193
– Install fuel rail ⇒ page 229 .
After renewing high-pressure pump and/or fuel pressure regulat‐
ing valve - N276- , the learnt values must be reset. The procedure
is described in Guided Fault Finding or Guided Functions ;
use ⇒ Vehicle diagnostic tester.
Note
Guided Functions are not available for certain engine versions

because it is not necessary to reset the learned values on these
engines.
– After installation, run engine at moderate speed for several

minutes and then switch off.
– Interrogate event memory again.
7.3 Removing and installing fuel pressure

sender - G247-

♦ Bit (27 mm) - T40218- or commercially available socket

(27 mm)
♦ Torque wrench
Note
♦ The fuel pressure sender - G247- continuously measures the

fuel pressure in the high-pressure system. It transmits a cor‐
responding voltage signal to the engine control unit - J623- .
♦ Should the fuel pressure sender fail, the engine control unit
will control the fuel pressure via a mapped open-loop backup
function. Maximum engine speed in this mode is restricted.
♦ The fuel pressure sender - G247- has a deformable sealing lip
and no separate seal; it can therefore be used only once.
Removing
WARNING


– Before removal, clean area around thread for fuel pressure
sender using commercial cleaning solution etc. (no dirt must
enter opening in fuel rail).
Note
Clean carefully; cleaning solution must not enter the electrical

connector.
– Dry off fuel pressure sender - G247- .

– Unplug electrical connector -1- at fuel pressure sender -

G247- .
– Unscrew fuel pressure sender - G247- using socket, 27 mm -
T40218- .
Note
An open-end spanner must not be used for loosening or tighten‐

ing.
– Extract dirt from opening in fuel rail (thread and sealing sur‐
face) using a vacuum cleaner. Do not use metal tools, etc.
– Seal off opening in fuel rail with a plug.
Installing
Note
♦ Fuel pressure sender - G247- must always be renewed after

it has been removed.
♦ Check sealing surface at opening in fuel rail.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure sender - G247- must be coated with diesel
fuel.
– Screw in fuel pressure sender - G247- by hand.

– Then tighten fuel pressure sender - G247- to specified torque.
Tightening torques
• ⇒ “1.3 Exploded view - fuel system”, page 193
After installing fuel pressure sender - G247- , leave engine run‐
ning at moderate speed for a few minutes when bleeding fuel
system and then switch off again.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.
– Interrogate event memory and erase it if necessary.

– Carefully check the entire fuel system for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.

– After road test, interrogate event memory again.
7.4 Removing and installing air mass meter

- G70-
Removing
– Detach electrical connector -1- from air mass meter - G70- .
– Release hose clip securing air hose (coming from turbocharg‐
er) and disconnect hose from air mass meter - G70- .
– Unscrew both bolts from air mass meter - G70- .
– Then carefully pull air mass meter - G70- out of guide on air
cleaner housing.
Installing
To ensure the correct function of the air mass meter - G70- , it is
important to observe the following notes and instructions.
Note
ment).
♦ Use a silicone-free lubricant when installing the air hose.
– Check for salt residue, dirt and leaves in air mass meter and
air intake hose (engine intake side).
– Check intake duct as far as air filter element for dirt. If neces‐
sary, clean salt residue, dirt and leaves out of air cleaner
housing (top and bottom sections); wash out or use a vacuum
cleaner as required. Removing and installing air cleaner
⇒ page 203 .
quence.
7.5 Removing and installing exhaust gas

pressure sensor 1 - G450-
Exhaust gas pressure sensor 1 - G450- is connected via two pipes
to take-off points upstream and downstream of particulate filter.
Exploded view - Lambda probe ⇒ page 244
Exhaust gas pressure sensor 1 - G450- detects the amount of
deposits in the particulate filter.
Removing
– Before disconnecting, spray hoses coming from exhaust gas
pressure sensor 1 - G450- with suitable release agent.

– Detach electrical connector -3- from exhaust gas pressure

sensor 1 - G450- .
– Carefully pull hoses off connections (take care to keep the ho‐
ses straight; the connections can easily break off exhaust gas
pressure sensor 1 - G450- ).
– Unscrew bolt -4- and remove exhaust gas pressure sensor 1
- G450- .
Installing
– When installing, note the following:
• Tightening torque for bolt for exhaust gas pressure sensor 1 -
G450- ⇒ Item 4 (page 244)
Note
♦ Before installing, blow out hoses leading from exhaust gas

pressure sensor 1 - G450- to particulate filter towards partic‐
ulate filter with compressed air (hoses can become obstructed
or may ice up due to condensation).
♦ Make sure that hoses are securely fitted and seal properly.
♦ If pressure connections are detached from particulate filter,
tighten to 45 Nm.
After renewing exhaust gas pressure sensor 1 - G450- and/or

particulate filter, adaption must be performed in order to reset
learnt values. The adaption procedure is described in the Guided
Functions; use ⇒ Vehicle diagnostic tester.

8 Lambda probe
⇒ “8.1 Exploded view - Lambda probe”, page 244
⇒ “8.2 Removing and installing Lambda probe”, page 245
8.1 Exploded view - Lambda probe
1 - Turbocharger
❑ With position sender for
charge pressure posi‐
tioner - G581-
❑ New Lambda probes
are coated with an as‐
sembly paste
❑ In the case of a used
Lambda probe, coat on‐
ly thread with high-tem‐
perature paste; refer to
⇒ Parts catalogue for
high-temperature paste
❑ The assembly paste /
high-temperature paste
must not make contact
with the slots on the
Lambda probe body
⇒ page 245
❑ 50 Nm
sender 3 - G495-
⇒ page 264
❑ 45 Nm
sor 1 - G450-
❑ Tighten bolt to 4.5 Nm
⇒ page 242
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
❑ 45 Nm
6 - Particulate filter
❑ Adaption must be performed after renewing particulate filter. Use ⇒ Vehicle diagnostic tester
❑ 45 Nm

Components
1 - Electrical connector for Lambda probe - G39- with Lambda
probe heater - Z19-
G495-
5 - Lambda probe - G39- with Lambda probe heater - Z19-
8.2 Removing and installing Lambda probe

♦ Lambda probe open ring spanner set - 3337-
Removing
WARNING
When working on all parts of the exhaust system:

♦ Observe safety precautions when working on the exhaust
system
⇒ “2.6 Safety precautions when working on the exhaust
system”, page 5 .
8. Lambda probe 245

– Unplug electrical connector -1- for Lambda probe - G39- .

– Unscrew Lambda probe - G39- -5- using tool from Lambda
probe open ring spanner set - 3337- .
Installing
When installing, note the following:
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Parts catalogue .
♦ When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
• Tightening torques: refer to Exploded view - Lambda probe

⇒ page 244

9 Engine control unit

⇒ “9.1 Wiring and component check with test box V.A.G 1598/42
”, page 247
⇒ “9.2 Removing and installing engine control unit J623 ”,
page 248
9.1 Wiring and component check with test

box - V.A.G 1598/42-
♦ Adapter cable - V.A.G 1598/39-1-
♦ Adapter cable - V.A.G 1598/39-2-
♦ Test box - V.A.G 1598/42-
9. Engine control unit 247

Note
♦ The test box has 105 sockets. The connecting cable can be
disconnected from the test box. This means that only the cable
(and not the test box) has to be purchased for future engine
control units with different types of connectors.
♦ The smaller of the two connectors on the engine control unit
has the contacts 1 to 60. The larger of the two connectors has
the contacts 1 to 94.
♦ To carry out tests on the 60-pin wiring harness connector, the
adapter cable - V.A.G 1598/39-1- is connected to connector
“A” on the test box. For components connected to 60-pin wiring
harness connector ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
♦ To carry out tests on the 94-pin wiring harness connector, the
adapter cable - V.A.G 1598/39-2- must be connected to con‐
nectors “A” and “B” on the test box. For components connec‐
ted to 94-pin wiring harness connector ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
♦ The test box - V.A.G 1598/42- is designed so it can be con‐
nected both to the wiring harness for the engine control unit
and to the engine control unit itself at the same time.
♦ The advantage of this is that the electronic engine control sys‐
tem remains fully functional when the test box is connected
(for example, for measuring signals when the engine is run‐
ning).
♦ The relevant test procedure will state whether it is necessary
to also connect the engine control unit to the test box.
WARNING
To prevent irreparable damage to the electronic components,

select appropriate measuring range before connecting the
measuring cables and observe the test requirements.
– Remove engine control unit ⇒ page 248 .

– Connect the test box - V.A.G 1598/42- to wiring harness with
adapter cable - V.A.G 1598/39-1- or adapter cable - V.A.G
1598/39-2- . Connect earth clip of test box to negative terminal
of battery. The instructions for performing the individual tests
indicate whether or not the engine control unit itself also needs
to be connected to the test box.
– Carry out test as described in appropriate repair procedures.
Installing engine control unit
Installation is performed in the reverse sequence; the engine con‐
trol unit must be installed with the protective housing. New shear
bolts must be used.
Perform the following after reconnecting engine control unit:
9.2 Removing and installing engine control

unit - J623-

♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐

ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small, commercially available mole grips -3-
Removing
– Before removing the engine control unit - J623- , the adaption
values of the injectors and the ash deposit mass must be read
out. Use ⇒ Vehicle diagnostic tester.
Note
If the adaption values of the injectors cannot be read out of the

old (defective) engine control unit, the adaption values must be
entered into the new engine control unit manually and the adap‐
tion procedure must be performed accordingly.
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
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 the protective housing
-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 protective housing has to be removed before the connec‐
tors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).
– Slightly pull off rubber seal in front of nut -1- on plenum cham‐
ber cover.
– Unscrew nut -1-.
– Unhook wiring harness -2- from retainers -A-.
– Pull filler neck -3- with filler pipe out of washer fluid reservoir
and through opening in body.

– Unscrew bolts -arrows- and take off lid for electronics box.
– Release retainers -arrows A- and pull out engine control unit

- J623- -arrow B-.
To help prevent unauthorised access to the connectors on the

engine control unit, the engine control unit -1- is bolted on by
means of locking plates -2 and 5- and shear bolts -3 and 4-.
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 as shown in illustration, i.e.

set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.
WARNING
Heating the thread of the locking plate also heats up the shear
bolts and parts of the metal housing. Take care to avoid burns.
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 the hot air blower and heat the bolt for approximately
20 ... 30 seconds.
– Unscrew shear bolts using mole grips (see arrow in illustra‐
tion).
– 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 connectors on engine control unit and unplug con‐
nectors.
– Take out old engine control unit - J623- and install new engine
control unit - J623- .
Installing
Installation is performed in the reverse sequence.
– After installation, the protective housing must be re-fitted on
the engine control unit - J623- .
– Clean threaded holes for shear bolts to remove any residue
from locking fluid. This can be done using a thread tap.
– Always use new shear bolts.
• Tightening torque for bolts securing lid of electronics box: 3.5
Nm.
The procedure required after connecting the new engine control
unit is described in the Guided Fault Finding or Guided Functions.
Use ⇒ Vehicle diagnostic tester.
– The injector delivery calibration and the injector voltage cali‐
bration must additionally be re-adapted in the engine control
unit - J623- after the control unit has been renewed (these
functions influence engine power and exhaust emissions).
– On vehicles with particulate filter the current mileage (km)
reading must be stored in the engine control unit via an adap‐
tion procedure.

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 252
⇒ “1.2 Removing and installing front exhaust pipe”, page 254
⇒ “1.3 Separating exhaust pipes/silencers”, page 255
⇒ “1.4 Renewing tailpipes”, page 256
⇒ “1.5 Stress-free alignment of exhaust system”, page 257
⇒ “1.6 Checking exhaust system for leaks”, page 258
1.1 Exploded view - silencers
1 - Gasket
❑ Renew
❑ With catalytic converter
❑ With pressure line for
exhaust gas pressure
sensor 1 - G450-
⇒ page 259
❑ Mounting components
⇒ page 254
❑ After renewing, perform
adaption in “Guided
Functions” mode ⇒ Ve‐
hicle diagnostic tester
3 - Gasket
❑ Renew
4 - Nut
❑ Renew
❑ 23 Nm
5 - Front exhaust pipe
❑ With flexible joint; do not
bend flexible joint more
than 10° – otherwise it
can be damaged
❑ Protect against knocks
and impact
⇒ page 254
❑ Align exhaust system so
it is free of stress
⇒ page 257
6 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 257
❑ Tighten bolted connections evenly
7 - Nut
❑ 23 Nm
252 Rep. gr.26 - Exhaust system

8 - Rear silencer
❑ Combined in one unit with centre silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point: centre silencer / rear silencer ⇒ page 255
❑ Renewing tailpipe ⇒ page 256
❑ Align exhaust system so it is free of stress ⇒ page 257
9 - Mounting
❑ Check preload ⇒ “1.5 Stress-free alignment of exhaust system”, page 257
10 - Bolt
❑ 20 Nm
11 - Rubber mounting
12 - Bracket
13 - Bolt
❑ 23 Nm
14 - Tailpipe
❑ Can be renewed separately for repair purposes ⇒ page 256
❑ Cutting point between rear silencer and tailpipe ⇒ page 256
15 - Clamp
16 - Nut
❑ 23 Nm
17 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 257
❑ Tighten bolted connections evenly
18 - Centre silencer
❑ Combined in one unit with rear silencers as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point: centre silencer / rear silencer ⇒ page 255
❑ Align exhaust system so it is free of stress ⇒ page 257
19 - Mounting
❑ Check preload ⇒ “1.5 Stress-free alignment of exhaust system”, page 257
20 - Bolt
❑ 23 Nm
21 - Nut
❑ 23 Nm
22 - Bracket
23 - Bolt
24 - Nut
❑ Renew
❑ 23 Nm
1. Exhaust pipes/silencers 253

Installation position of front clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolt connection faces to right.
Installation position of rear clamps

– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp.
• Bolted connection faces to left.
Components of mountings for particulate filter

1- Spacer sleeve
2- Compression spring
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Buffer
8- Bracket
9- Bolt, 23 Nm
10 - Bracket
11 - Nut
1.2 Removing and installing front exhaust

pipe
Removing
WARNING

system
system”, page 5 .


tion .
– Remove nuts -arrows- for front exhaust pipe.
Caution
Risk of damage to flexible joints in front exhaust pipe

♦ Do not bend flexible joints in front exhaust pipe more than
10°.
– Loosen bolts -arrows-, push back clamp and detach front ex‐
haust pipe.
Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - silencers”, page 252
Note
Renew seals, gaskets and self-locking nuts.

– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .
1.3 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.

♦ Chain pipe cutter - VAS 6254-
Procedure
– Cut through exhaust pipe at right angles at the position marked
-arrow- using chain pipe cutter - VAS 6254-
– Position centre of clamp -arrow- over cutting location.
– Install clamps so that the bolt ends do not protrude beyond

bottom of clamp.
• Bolted connection faces to left.
1.4 Renewing tailpipes

♦ The tailpipes can be cut through at the point marked so that
the tailpipes can be renewed separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.

– Cut through exhaust pipe at right angle at the position marked

by -arrows- using chain pipe cutter - VAS 6254- .
– Fit tailpipe.
– Check clearance between tailpipe and bumper:

• Dimension -x- (left-side) = dimension -x- (right-side)
– Tighten bolt connections on clamps.
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‐
er
– Loosen bolted connections on front clamp.
– Push exhaust system towards front of vehicle -arrow- so that
rear mountings for rear silencer are preloaded by -a- =
11 ... 15 mm.
– Align rear silencer so it is horizontal.
– Check clearance between tailpipes and bumper:

– Tighten bolt connections on clamp evenly.
Vehicles with clamps between centre silencer and rear silencer
– Loosen bolted connections on front and rear clamps.

– Push centre silencer towards front of vehicle -arrow- until

mounting for centre silencer is preloaded by -a- = 6 ... 10 mm.
– Tighten bolt connections on front clamp evenly.
– Push rear silencer towards front of vehicle -arrow- so that rear

mounting for rear silencer is preloaded by -a- = 11 ... 15 mm.
– Align rear silencer so it is horizontal.
– Check clearance between tailpipes and bumper:

– Tighten bolted connections on rear clamps evenly.
1.6 Checking exhaust system for leaks

– Start the engine and run at idling speed.
– Plug tailpipe during leak test (e.g. with cloth or plugs).
– Listen for leaks at connection points between cylinder head/
exhaust manifold, exhaust manifold/intermediate pipe and tur‐
bocharger/intermediate flange etc.
– Rectify any leaks that are found.

2 Emission control system

⇒ “2.1 Removing and installing particulate filter”, page 259
2.1 Removing and installing particulate filter

♦ Tool set, 17 mm - T10395-
Removing
Note

♦ On vehicles with a multitronic gearbox the turbocharger must
be removed to remove the particulate filter
⇒ “1.2 Removing and installing turbocharger”, page 171 .
WARNING

system
system”, page 5 .
Vehicles with multitronic gearbox

All vehicles (continued)
– Unfasten connection -1-, remove bolt -2- and take out mount‐
ing for particulate filter.
2. Emission control system 259

– Remove exhaust gas temperature sender 4 - G648- -1-.

– Unplug electrical connectors -1- for Lambda probe - G39- and

-2- for exhaust gas temperature sender 3 - G495- and move
clear.
– Unplug electrical connector -3- for exhaust gas pressure sen‐
sor 1 - G450- .
– Remove bolt -4-, unclip air hoses for exhaust gas pressure
sensor 1 and remove from particulate filter.



cooler.
Note
– Unfasten bolts -arrows- and remove bracket for exhaust gas

recirculation.
– Remove nut -3- for exhaust gas recirculation pipe.

– Remove bolts -1 and 2- and -4 and 5-, move exhaust gas re‐
circulation pipe aside.
Note
It is not possible to remove exhaust gas recirculation pipe.
Note
♦ On vehicles with auxiliary heater

♦ Using hose clamps up to 25 mm - 3094- clamp off coolant
hoses at plenum chamber partition panel and detach from
metal pipe.
♦ Unfasten coolant line from suspension turret and longitudinal
member and swivel to side.
– Remove nuts -1, 2 and 3- on turbocharger.
Note
Nut -1- is accessible from below on vehicles with auxiliary heater.
2. Emission control system 261

– Guide out particulate filter upwards -arrow-.

Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - silencers”, page 252
♦ ⇒ “3.1 Exploded view - exhaust gas temperature control”, page
263
♦ ⇒ “4.1 Exploded view - exhaust gas recirculation system”,
page 270
Note
Renew seals, gaskets and self-locking nuts.
– After renewing particulate filter, perform "Adaption" in “Guided

Functions” mode ⇒ Vehicle diagnostic tester.

3 Exhaust gas temperature control

⇒ “3.1 Exploded view - exhaust gas temperature control”,
page 263
⇒ “3.2 Removing and installing exhaust gas temperature sender”,
page 264
3.1 Exploded view - exhaust gas temperature control
1 - Turbocharger
⇒ page 245
sender 3 - G495-
❑ 45 Nm
⇒ page 266
❑ Coat with high-tempera‐
ture paste; for high-tem‐
perature paste refer to
⇒ Electronic parts cata‐
logue
sor 1 - G450-
⇒ page 242
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
⇒ Electronic parts cata‐
logue
sender 4 - G648-
❑ 45 Nm
⇒ page 264
⇒ Electronic parts catalogue
❑ 45 Nm
3. Exhaust gas temperature control 263

3.2 Removing and installing exhaust gas

temperature sender
⇒ “3.2.1 Removing and installing exhaust gas temperature send‐
er 1 G235 ”, page 264
er 3 G495 ”, page 266
er 4 G648 ”, page 267
3.2.1 Removing and installing exhaust gas

temperature sender 1 - G235-
♦ Tool set, 17 mm - T10395-
Removing
WARNING

system
system”, page 5 .

tion .

– Unplug electrical connector -3- for exhaust gas temperature

sender 1 - G235- and unclip from bottom of cylinder block.

Note

cooler.

– Remove union nut -1-.
– Remove exhaust gas temperature sender 1 - G235- -1- and

unclip electrical wiring on cylinder block -arrow-.
Installing
Tightening torques
page 263
Tightening torques
⇒ “4.1 Exploded view - exhaust gas recirculation system”,
page 270

♦ Tool set, 17 mm - T10395-
Removing
Note
WARNING

system
system”, page 5 .

– Unplug electrical connector -2- at exhaust gas temperature

sender 3 - G495- and move clear.

Installing
Tightening torques
page 263

♦ Tool set, 17 mm - T10395-

Removing
WARNING

system
system”, page 5 .

tion .
– Support gearbox using engine and gearbox jack - V.A.G 1383
A- with gearbox support - T10337- attached.
– Remove bolts -arrows- for tunnel cross member.
– Lower gearbox using engine and gearbox jack - V.A.G 1383

A- as far as distance -a-.
• Dimension -a- = 80 mm (maximum).

– Unclip electrical wiring -A- from gearbox and unplug electrical

connector -C-.
– Unclip bracket -B- for exhaust gas temperature sender 4 -
G648- from gearbox.

Installing
Tightening torques
page 263
Tightening torques ⇒ “1.1 Exploded view - silencers”, page 252
Tightening torques for tunnel cross member ⇒ Rep. gr. 34 ; As‐
sembly mountings; Exploded view - assembly mountings

4 Exhaust gas recirculation

page 270
⇒ “4.2 Exploded view - exhaust gas recirculation valve N18 with
exhaust gas recirculation potentiometer G212 ”, page 271
⇒ “4.3 Removing and installing exhaust gas recirculation valve
N18 ”, page 272
⇒ “4.4 Removing and installing exhaust gas recirculation cooler”,
page 273
⇒ “4.5 Removing and installing vacuum unit for exhaust gas re‐
circulation cooler”, page 274
4.1 Exploded view - exhaust gas recirculation system
1 - Gasket
❑ Renew
2 - Bolt
❑ Tightening torque and
sequence ⇒ page 271
3 - Connecting pipe for exhaust
gas recirculation
4 - Coolant hoses
5 - Spring-type clip
cooler
⇒ page 273
7 - Bracket
8 - Bolt
❑ 9 Nm
9 - Bolt
❑ 9 Nm
10 - Gasket
11 - Vacuum unit
12 - Vacuum hose
❑ From exhaust gas recir‐
culation cooler change-
over valve - N345-
13 - Bolt
❑ 7 Nm
14 - Gasket
❑ Renew
15 - Bolt
❑ 25 Nm
❑ Renew

Tightening torque and sequence

1- Position bolts -4- and-5-.
2- Position bolts -1- and-2-.
3- Fit nut -3-.
4- Tighten bolts -1- and -2- to 20 Nm.
5- Tighten bolts -4- and -5- to 20 Nm.
6- Tighten bolt -3- to 8 Nm.
4.2 Exploded view - exhaust gas recirculation valve - N18- with exhaust gas
recirculation potentiometer - G212-
1 - Intake manifold
⇒ page 207
2 - Bolt
3 - Gasket
❑ Renew
4 - Seal
❑ Renew
5 - Pipe
❑ To exhaust gas recircu‐
lation cooler
6 - Bolt
7 - Gasket
❑ Renew
8 - Bolt
❑ 10 Nm
9 - Intake manifold flap motor -
V157-
10 - Bolt
11 - Bolt
❑ 10 Nm
12 - Guide tube for oil dipstick
13 - Exhaust gas recirculation valve - N18- with exhaust gas recirculation potentiometer - G212-
4. Exhaust gas recirculation 271

4.3 Removing and installing exhaust gas re‐

circulation valve - N18-
Removing
– Open hose clip -arrow- securing air hose and disconnect hose
downwards from intake manifold flap motor - V157- .
– Remove intake manifold flap motor - V157- .


– Remove bolts -2- and -3- and detach exhaust gas recirculation
valve - N18- with exhaust gas recirculation potentiometer -
G212- .
Note
Disregard -item 4-.
Installing
Tightening torques
page 270
Note
Renew seals.
– Install intake manifold flap motor - V157-

⇒ “4.1 Exploded view - intake manifold”, page 207 .
4.4 Removing and installing exhaust gas re‐

circulation cooler
Removing


– Clamp off coolant hoses -1- and -2- using hose clamps up to
25 mm - 3094- and disconnect hoses.
– Remove bolts -arrows- and detach exhaust gas recirculation
cooler.
Installing
Tightening torques
page 270
Note
♦ Renew gaskets and O-rings.

– Top up coolant.
4.5 Removing and installing vacuum unit for

exhaust gas recirculation cooler

Removing

Note
– Remove bolts -arrows- and move exhaust gas recirculation

cooler to one side.

– Remove bolts -1- to -4- and detach vacuum unit with gasket.
Note
Disregard hand vacuum pump - VAS 6213- .
Installing
Tightening torques
page 270
Note
♦ Renew gaskets and self-locking nuts.

– Set sliding ring -1- to position -A- for vacuum function.
– Set change-over flap -1- as shown in illustration using hand

vacuum pump - VAS 6213- .
– Install vacuum unit with gasket and secure in position.

5 Exhaust manifold
⇒ “5.1 Exploded view - exhaust manifold”, page 277
⇒ “5.2 Removing and installing exhaust manifold”, page 277
5.1 Exploded view - exhaust manifold
1 - Gasket
❑ Renew
2 - Exhaust manifold
⇒ page 277
3 - Nut
❑ 25 Nm
❑ Renew
ture lubricant; for high-
temperature lubricant
refer to ⇒ Parts cata‐
logue
4 - Heat shield
5 - Nut
❑ 25 Nm
5.2 Removing and installing exhaust mani‐

fold
Removing
5. Exhaust manifold 277

– Remove heat shield at exhaust manifold -arrows-.
– Remove nuts -arrows- for exhaust manifold.

– Remove exhaust manifold.
Installing
Tightening torques
⇒ “5.1 Exploded view - exhaust manifold”, page 277
Tightening torques
Note
Renew gaskets and self-locking nuts.
– Install turbocharger ⇒ page 171 .

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Checking glow plug system”, page 279
⇒ “1.2 Removing and installing glow plug”, page 279
⇒ “1.3 Different types of glow plugs”, page 281
⇒ “1.4 Handling ceramic glow plugs”, page 282
⇒ “1.5 Removing and installing Hall sender G40 ”, page 282
⇒ “1.6 Removing and installing engine speed sender G28 ”, page
283
1.1 Checking glow plug system

Automatic glow period control unit - J179- is located in relay and
fuse holder in electronics box in plenum chamber.
A - Automatic glow period control unit - J179-
The glow plug system is activated via the automatic glow period
control unit - J179- . The automatic glow period control unit - J179-
is capable of self-diagnosis.
A fault is stored in the engine control unit if a fault occurs in the
glow plug system.
The procedure for checking the glow plug system is described in
the Guided Fault Finding.
For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.
Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Wait for 60 seconds each time after performing final control
with respect to the correctness of information in this document. Copyright by AUDI AG.
diagnosis of the glow period control unit. The ignition must re‐
main switched on.
♦ If you do not wait for 60 seconds (if ignition is switched off and
immediately switched on again), the glow plugs can be dam‐
aged (due to repeated pre-heating).
♦ The activation of the glow plugs is controlled according to
coolant temperature.
1.2 Removing and installing glow plug

1. Glow plug system 279

♦ U/J extension and socket, 10 mm - 3220-
♦ Pliers - 3314-
Removing
– Detach glow plug connectors from glow plugs.
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
openings, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
Caution
Make sure that no wire connection is damaged when unplug‐

ging the glow plug connectors; otherwise the entire wiring
harness must be renewed. When unplugging the glow plug
connectors, do not compress the pliers - 3314- with too much
force so that the support sleeve is not damaged.
280 Rep. gr.28 - Glow plug system

– Apply groove -arrow A- of pliers - 3314- to collar of support

sleeve -arrow B- and pull glow plug connectors off glow plugs.
Note
♦ Glow plug 1 - Q10- -5-

♦ Glow plug 2 - Q11- -6-
♦ Glow plug 3 - Q12- -7-
♦ Glow plug 4 - Q13- -8-
– To slacken the glow plugs use special tool U/J extension and
socket, 10 mm - 3220- .
Installing
– To tighten the glow plugs use special tool U/J extension and
socket, 10 mm - 3220- with a suitable torque wrench.
– Then tighten glow plugs to specified torque.
• Tightening torque: 17 Nm
– Attach glow plug connectors correctly and make sure they are
securely fitted.
– Install engine cover panel ⇒ page 36 .
1.3 Different types of glow plugs

♦ These engines can be fitted with either metal or ceramic glow
plugs.
A - Bosch ceramic glow plugs are colour-coded with a “white seal”
-arrow- and have a chamfered shoulder (-detail view-) at the tip.
A - NGK ceramic glow plugs are colour-coded with a “white seal
(on some versions painted over in silver)” -arrow- but do not have
a chamfered shoulder at the tip.
B - Metal glow plugs are colour-coded with a “red seal” -arrow-.
Caution
It is very important that you observe the handling procedures

for ceramic glow plugs. The metal glow plugs do not require
any special handling procedures.

1.4 Handling ceramic glow plugs

It is important to note the following points regarding ceramic glow
plugs:
Caution
♦ Due to the special properties of the material used, ceramic

glow plugs are easily damaged and require extra care
when handling and removing/installing. Always observe
the special instructions when removing and installing ce‐
ramic glow plugs ⇒ page 279 .
♦ Transport and store only in original packaging or packed
separately in bubble wrap.
♦ Do not remove new ceramic glow plugs from packaging
until they are ready to be fitted.
♦ Ceramic glow plugs are sensitive to knocks and bending.
For this reason, ceramic glow plugs which have been
dropped (even from a height of only about 2 cm) must not
be installed, even if no damage is apparent (hair-line
cracks may not be visible).
♦ Always install a new ceramic glow plug if you are not sure
the old one is in perfect condition.
♦ Damaged glow plugs (e.g. heater pin of the glow plug is
damaged) will invariably cause engine damage.
♦ If the heater pin of the glow plug is damaged, the frag‐
ments must be removed from the combustion chamber
before starting the engine for the first time; otherwise this
will invariably cause mechanical damage (piston seizure).
♦ To check compression, select function “Self-diagnosis
compatible systems” in “Guided Fault Finding” ⇒ Vehicle
diagnostic tester.
♦ The ceramic glow plugs must not be removed when
checking cylinder compression.
♦ The software of the engine control unit is specifically adap‐
ted to either the ceramic or the metal glow plugs, so it is
important to install the correct type.
♦ Mixed installation of ceramic glow plugs and metal glow
plugs on the same engine is not permissible.
1.5 Removing and installing Hall sender -

G40-
– Remove vibration damper ⇒ page 43 .

– Unplug electrical connector for Hall sender - G40- -arrow-.

– Release connector from its retainer.
– Unbolt Hall sender - G40- -arrow-.
– Using a screwdriver, remove projections and take out cover

for repair opening -arrows-.
– Take Hall sender - G40- off cylinder head and guide its con‐
nector through repair opening in toothed belt cover.
Installing
Install in reverse sequence. Note the following:
♦ Seal repair opening in toothed belt cover with rubber plug; for
rubber plug refer to ⇒ ETKA (Electronic parts catalogue) .
– Fit toothed belt and adjust valve timing ⇒ page 87 .
1.6 Removing and installing engine speed

sender - G28-
♦ Socket (4 mm) - T10370-

Removing
– Remove oil filter bracket ⇒ page 131 .
– Unplug electrical connector at engine speed sender - G28-
-arrow- using assembly tool - T10118- .
Note
To release electrical connector without assembly tool - T10118- ,

press connector on engine speed sender in with a screwdriver
and at the same time lift release tab with a thin wire hook.
– Move wiring clear.
– Unscrew securing bolt -2- for engine speed sender - G28-

-item 1-.
Installing
– Install oil filter bracket ⇒ page 131 .
• Tightening torque: refer to overview of fitting locations
⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 51 .

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Service

4-cylinder TDI engine (2.0 ltr. 4-valve common rail)

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 159

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

1.1 Engine identification number/engine da‐

♦ The four-letter engine code is found on the type plate (country

For engine data refer to:

2.1 Safety precautions when working on the

Fuel under pressure - risk of injuries!

The high-pressure pump has very close tolerances and must

2 Rep. gr.00 - Technical data

Observe the following points to prevent personal injuries and

To prevent irreparable damage to the electronic components

Escaping fuel can cause a risk.

2.2 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

2.3 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

2.4 Safety precautions when working on the

Risk of damage to running gear components.

2.5 Safety precautions when working on the

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

4 Rep. gr.00 - Technical data

Overheating can occur if the filler cap is not fitted properly.

2.6 Safety precautions when working on the

Please note the following warnings when working on all parts

Risk of damage to flexible joint.

3.1 Rules for cleanliness

3.2 General notes

6 Rep. gr.00 - Technical data

♦ The vehicles are fitted with a crash/fuel shut-off system. This

3.3 General repair instructions

The high-pressure pump has very close tolerances and must

♦ Clean tools and workbench etc. before working on the injection

♦ Fuel hoses in engine compartment must only be secured with

3.4 Foreign particles in engine

3.5 Contact corrosion

3.6 Routing and attachment of pipes, hoses

3.7 Installing radiators and condensers

8 Rep. gr.00 - Technical data

10 – Removing and installing engine

♦ Removal lever - 80 - 200-

♦ Hose clip pliers - V.A.G 1921-

♦ Drip tray for workshop hoist - VAS 6208-

1. Removing and installing engine 9

♦ Locking tool - T40098-

♦ Support bracket - 10 - 222 A-

♦ Shackle - 10-222 A/12-

♦ Workshop hoist - VAS 6100-

10 Rep. gr.10 - Removing and installing engine

♦ Lifting tackle - 2024 A-

♦ Lift out engine without gearbox.