Service a Workshop Manual Audi A6 2005 > 6-cylinder TDI engine (2.7 Itr.; 3.0 Itr. 4-valve common fi Edition 10.2014 Service Department. Technical Informationgap 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 26 - Exhaust system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2015 Audi AG, Ingolstadt 40054604720Audi AB 2005 > GOID 00 10 13 6-cylinder TDI engine (2,7 Itr; 3.0 ltr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Auer Contents Technical data 1 1 Engine number 1 2 Engine data 2 3 Safety precautions 4 3.1 Working on the fuel system 4 32 — Working on the cooling system 5 33. Using testers and measuring instruments during a road test 5 3.4 Safety precautions when working on the exhaust system 5 3.5 Working on the subframe 6 4 General repair instructions ....... 7 4.1 Rules for cleanliness when working on fuel surly system, inj turbocharger 7 42 Checking for leaks in the fuel system 7 43° Foreign particles in engine 7 44 Contact corrosion! 8 45 Routing and attachment of pipes, hoses and wiring 8 4.6 Installing radiators, condensers and charge sir coolers 8 4.7 Checking vacuum system 8 Removing and installing engine... 66.6. 6s bee ee cee dese ee eee eee eee s 10 1 Removing and installing engine - vehicles with manual gearbox . 10 1.4 Removing engine TN 10 12 Separating engine from manual garb 28 1.3 Installing engine 32 2 Removing and instaling engine - vehicles with multizonic gearbox 39 21 Removing engine 39 22 Separating engine from multitronic gearbox... 56 2.3 Installing engine 60 3 Removing and instaling engine - vehicles with automatic gearbox 66 3.4. Removing engine..." Coping tt ot amet a 66 32. Separating engine and automatic Gearbox =. «ws.» a4 3.3 Installing engine ot 4 Securing engine to engine and gearbox support 99 5 Assembly mountings 101 5.1. Assembly mountings - exploded view 101 5.2 Removing and installing engine mounting (left-side) 102 5.3. Removing and installing engine mounting (right-side) 106 5.4 Removing and installing torque reaction support 110 Crankshaft group : 112 + Gylinder block (pulley end) 112 14 Poly V-belt drive - exploded view 112 1.2 Removing and installing poly V-belt. 118 1.3. Removing and installing tensioner for poly V-belt 117 1.4 Removing and installing idler roller for poly V-belt 118 1.5 Removing and installing vibration damper with poly V-belt pulley 120 1.6 Removing and installing bracket for ancillaries 120 1.7 Oilseal and sealing flange (pulley end) - exploded view 122 1.8 — Renewing crankshaft oil seal (pulley end) 123 1.8 Removing and installing sealing flange (pulley end) 124 2 Cylinder block (gearbox end) 129 24 Dual-mass flywheel on vehicles with manual gearbox - exploded view 129 contanis iGAD Audi as 2005 > ‘Audr_6-cylinder TDI engine (2.7 ltr; 3.0 ir. 4-valve common rail, EUS), mechanics - Edition 10.2014 15 22 23 24 25 26 27 28 29 3 34 32 33 34 4 44 42 43 44 1 14 12 13 14 2 24 22 23 24 25 26 27 28 29 3 34 32 33 34 35 36 4 44 42 43 44 45 46 47 48 49 4.10 ait 4.12 Removing and installing dual-mass flywheel Extracting and driving in needle bearing for dual-mass flywheel Flywheel anc damper unit on vehicles with muittronic gearbox - exploded view Removing and installing damper unit Removing and installing flywheel : Drive plate on vehicles with automatic gearbox - exoloded view - Removing and installing drive plate. Renewing crankshaft cil seal (gearbox end) Crankshaft Grankshatt - exploded view Crankshaft dimensions Measuring axial clearance of crankshaft Measuring radial clearance of crankshaft Pistons and conrods Pistons and conrods - exploded view Checking piston projection at TDC Piston and cylinder dimensions Measuring radial clearance of conrods Cylinder head, valve gear... 2... eee e eee cece ee eeee es Timing chain covers Timing chain covers - exploded view Removing and installing timing chain cover (left-side) Removing and installing timing chain cover (right-side) Removing and installing timing chain cover (bottom). Chain drive | Gamshatt timing chains - exploded view Removing timing chains from camshafts Removing and installing camshaft timing chains Drive chain for valve gear - exploded view Removing and installing drive chain for valve gear Drive chain for auxiliary drives - exploded view Removing and installing drive chain for auxiliary drives Balance shaft - exoloded view - Removing and installing balance shat... Cylinder head Cylinder head cover - exploded view : Removing and installing cylinder head cover (left-side) Removing and installing cylinder head cover (right-side) Cylinder head - exploded view. Removing and installing cylinder head Checking compression. Valve gear . Valve gear - exploded view Measuring axial clearance of camshafts Measuring radial clearance of camshafts Renewing camshaft cil seal Removing and installing camshafts - cylinder head (left-side) Removing and installing camshafts - cylinder head (right-side) Checking hydraulic valve compensation elements Renewing valve stem cil seals with cylinder head installed Renewing valve stem oil seals with cylinder head removed Valve dimensions. Machining valve seats Checking valve guides 130 132 - 133 1183 . 134 135 . 136 137 140 140 142 142 143 144. 144 147 149 149 150 - 150 150 152 153 . 155 158 1 158 . 160 168 176 178 179 180 183 ol83, = 188 186 187 190 193 195 206 - 209 - 209 244 212 213 215 222 229 231 - 234 - 237 238 - 238 ContentsAudi AB 2005 > GOID 6-cylinder TDI engine (2,7 Itr; 3.0 ltr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Auer 4.43 Checking valves, 239 47 -Lubrication ......2.. 002.02 beet eee eee eteee eee er ees 240 4. Oil pump, sump (btlom section), sump (lop section) 240 1.4 Oil pump, sump (bottom section) - exploded view 240 1.2 Removing and installing cl leve! and oil temperature sender G266 242 13. Removing and installing ump (bottom section) 243 1.4 Removing and installing oil pump 248 1.5 Sump (top section) - exploded view 245 1.6 Removing and installing valve for oil pressure control N428 247 1.7 Removing and installing sump (top section) 248 2 Engine oil cooler, oil filter housing, oil pressure switch 251 21 Engine oil cooler, pressure control valve and oi filter housing - exploded view 25 2.2 Removing and installing engine oil cooler... . ce . ce .. 253 2.3 Removing and installing oil filter housing cee, 254 2.4 Removing and installing pressure control valve for ‘crankcase breather system... 255 2.5 Removing and installing mounting plate for engine oil cooler, pressure control valve for crankcase breather system and oll iter housing 256 2.6 Checking oil pressure switch F2 /oil pressure switeh for reduced oll pressure F278 256 2.7 Removing and installing cil pressure switch F22 257 2.8 Removing and instaling cil pressure switch for reduced oil pressure F378 257 2.9 Checking oll pressure 258 240 Engine oil 259 2.41 Checking oil level 260 19 - Cooling : : 261 1 Cooling system beeen nee eeeeeeeeeneeeeeees 2OF 11 Connection diagram - coolant hoses | 261 12 Draining and filing cooling system 265 13 Checking cooling system for leaks art 2 Coolant pumps and thermostat ...... . 274 2.14 Coolant pump and thermostat - exploded view , - 274 2.2 Removing and installing coolant pump. . . . . 275 2.3. Removing and installing thermostat with hose connection - wee . 276 2.4 — Pump for exhaust gas recirculation cooler V400 - exploded view 278 2.5 — Removing and installing pump for exhaust gas recirculation cooler V400 279 3 Coolant pipes . . . 281 3.1 Coolant pipes - exploded view ..... 281 3.2 Removing and installing coolant temperature ‘sender G62 284 3.3 Removing and installing radiator outlet coolant temperature sender G83 285 3.4 Removing and installing: coolant pipe (left Side) ...°. 235 3.5 Removinig'and' installingrcoolant pipe "(top tefty™. 287 3.6 Removing and installing coolant pipe (right-side) bene . cee 288 3.7 Removing and installing coolant pipe (top right)... oe. 291 3.8 Removing and installing coolant pipe (rear right) ........ seven es 294 39 Removing and installing coolant pipe (top) 293 4 Radiator and radiator fans 208 41 Radiator and radiator fans - exploded view .............0.0005 we ce eee, 204 4.2 Removing and installing radiator beeen ee ee eevee rene. 205 4.3. Removing and installing radiator cowl tenes setae eee 300 4.4 Removing and installing radiator fans V7 / vir7 . ue . wees. 301 21-Turbocharging/supercharging 0.2... .eceeeee eee ees eee eee ee eee sense 1803 1 Turbocharger 303 1.1 Turbocharger - exploded view 303 consents HiiGAD Audi as 2005 > ‘Audr_6-cylinder TDI engine (2.7 ltr; 3.0 ir. 4-valve common rail, EUS), mechanics - Edition 10.2014 12 13 14 2 24 22 23 24 26 1 14 12 13 14 15 16 2 24 22 23 24 25 26 27 3 34 32 33 34 4 4A 42 43 44 45 5 5A 52 53 54 55 6 61 62 63 64 Exhaust system Removing and installing turbocharger Removing and installing intermediate flange Removing and installing turbocharger 1 control unit J724 Charge air cooling Charge air cooler - exploded view . Removing and installing charge air cooler Removing and instaling charge pressure sender G31 - vehicles without aula) heater Removing and installing charge pressure sender G31 - vehicles with auxiliary heater Silencers - vehicles wih front-wheel dive Silencers - exploded view Removing and installing starter catalytic converter - vehicles with manual gearbox Removing and installing starter catalytic converter - vehicles with multitronic gearbox Removing and installing front exhaust pipe. GR Removing and installing particulate fter Separating Y-pioe and rear silencers Silencers - vehicles with four-wheel drive Silencers - exploded view Removing and installing sterter catalytic converter - vehicles with manual gearbox Removing and installing starter catalytic converter - vehicles with automatic gearbox Removing and installing front exhaust pipe - vehicles with manual gearbox Removing and installing front exhaust pipe - vehicles with automatic gearbox Removing and installing particulate fiter ‘Separating Y-pipe and rear silencers Exhaust system Renewing tailpipe WrDtAG AUDI AG cook pees opt oy enay Stress-free alignment of exhaust System™ Aligning tailpipes Checking exhaust system for leaks Exhaust manifolds and intermediate pipes Exhaust manifolds and intermediate pipes - exploded view .. Removing and installing exhaust manifold (left-side) Removing and installing exhaust manifold (right-side) Removing and installing intermediate pioe (left-side) Removing and installing intermediate pipe (right-side) Exhaust gas temperature control Exhaust gas temperature senders - exploded view Removing and installing exhaust gas temperature sender 1 G235 Removing and installing exhaust gas temperature sender 3 G495 Removing and installing exhaust gas temperature sender 4 GO48 - vehicles with manual gearbox and automatic gearbox Removing and installing exhaust gas temperature sender 4 G648 - vehicles with multtronic gearbox Exhaust gas recirculation Exhaust gas recirculation system - exploded view Removing and installing exhaust gas recirculation control motor V338 Removing and installing exhaust gas recirculation cooler Removing and installing exhaust gas recirculation temperature sensor G26 373 374 374 - 375 - 376 379 IV contantsAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer wy} Technical data 1 Engine number (ARL004032; Edition 10.2014) © The engine number ("engine code” and “serial number’) can be found at the front below the toothed belt for the high-pres- sure pump (left-side) -arrovn. © Starting with the letter “C”, the engine codes consist of 4 let- ters. © The first 3 characters of the engine code stand for the engine capacity and the mechanical construction and design. They are stamped an 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 (F) nee ¢ The engine number is concealed by an idler roller for the poly V-belt. Removing ialer roller (left-side) for poly V-belt = page 118 © The 4-character engine code can be found on the type plate (in versions for some countries only), the vehicle data sticker. the engine control unit and on the toothed belt cover for hight: pressure pump. Fitting locations of the type plate (certain countries only) and the vehicle data sticker > Maintenance ; Booklet 405. 1. Engine numbor 1GAD Audi as 2005 > “Auor_6.cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics = Edition 10.2014 2 Engine data [Code tatters ‘CANA CANE GANG (Capacity ir. 2.698 2.698 2.698 Power output kW at rem] 1409/3500 ... 4400 | 120/8500 ... 4400 | 140/3500 ... 4400 Torque Nm at rpm} 380/1400 ... 3500 | 380/140... 3500 | 450/1750 ... 2250 Bore 2 in mm| 83.0 83.0 83.0 Stroke mmn| 83.4 83.4 83.1 ‘Compression ratio 164 164 164 CN atleast 51 51 51 Firing order 1-43-62. 14.36.25 1-4.3-6-2-5 Emission standards cus cus EUS Exhaust ges recirculation yes yes yes Exhaust gas temperature control 2 sensors 2 sensors 2 sensors Turbocharging/supercharging ‘Turbocharger Turbocharger Turbocharger Charge air cooling yes yes yes Lambda control 1 Lambda probe 1 Lambda probe | 1 Lambda probe Particulate fiter yes yes yes \Valves per cylinder 4 4 4 [Code letters CAND CDYA COYB |Capacity ite. 2.688 2.967 2.967 Power output KW at rpm} 120/350 ... 4400 | 176/4000 ... 4400 | 15574000 ... 4400 Torque Nm at rpm} 480/1750 .., 2250 | 00/1500 ... 3000 | 500/150 ... 3000 Bore @inmm| 83.0 83.0 83.0 Stroke mm 83.4 o14 914 |Compression ratio 164 164 16.4 oN atleast 5 5 Firing order 143625 143.625 Emission standards EUS EUS Exhaust gas recirculation yes yes Exhaust gas temperature control 2 sensors 3 sensors Turbocharging/supercharging Turbocharger Turbocharger Turbocharger Charge air cooling. perniessmen msnaranty YR ALD om ro YO yes Lambda control {'Lainbda' probe YUamibda probe | 1 Lambda probe Particulate filter yes yes yes Valves per cylinder 4 4 4 [Code letters ‘oDye (Capacity ir 2.967 Power output KW at rom| 176/400 ... 4400 Torque Nm at rpm] 450/400 ... 3500 Bore 2 in mm| 83.0 Stroke mmn| o14 ‘Compression ratio 164 CN atleast 51 Firing order 1-4-3-6-2-5 2 Rep. 07: 00- Technical data6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail Audi AB 2005 > GOID EUS), mechanics - Edition 10.2014 “Auer [Code letters: oDyc Emission standards EUS Exhaust gas recirculation yes Exhaust gas temperature control 3 sensors Turbocharging/supercherging Turbocharger [Charge air cooling yes Lambda control 1 Lambda probe Particulate fitter yes Valves per cylinder 4 2.Enginedata 3GAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 3 Safety precautions Overview "3.1 Working on the fuel system’, page 4 3°3.2 Working on the cooling system’, page 5 3 Using testers and measuring instruments during a road # 33.4 Safety precautions when working on the exhaust eys- iempage 5 @ >*3.5 Working on the subframe”, e 6 3.1 Working on the fuel system When working on the fuel system note the following warnings: ZA warns Risk of injury - fuel system operates under pressure. ¢ Wrap a cloth around the connection before opening the fue! system. Then release pressure by carefully loosening the connection. The fuel can become extremely hot. This can cause injuries. © Inextreme cases the temperature of the fuel lines and the fuel can be up to 100 °C afer the engine is switched off Allow the fuel to cool down before disconnecting the lines * danger of scalding. + Wear protective gloves. % Wear safety goggles. Observe the following points to prevent personal injuries and damage to the injection and glow plug system: # Always switch off the ignition before connecting or discon- necting tester cables or electrical wiring for the injection or glow plug system. # Always switch off ignition before washing engine. # Faults are stored in the engine control unit if electrical con- nectors were unplugged and the engine was started: “Inter rogate event memory” in “Vehicle self-diagnosis” > Vehicle diagnostic tester. A 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. = Disconnect battery.=..Electrical system;,Rep.at..27, 4 Rp. 07:00- Technical dataAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer 3.2 Working on the cooling system \When working on the cooling system note the following warnings: A WARNING Hot steam/hot coolant can escape - risk of scalding. ¢ [he cooling system is under pressure when the engine is % Toallow pressure to dissipate, cover filler cap on coolant expansion tank with loth and open carefully. 3.3 Using testers and measuring instru- ments during a road test Note the following if testers and measuring instruments have to be used during e road test: A WARNING Accidents can be caussilf the ati 18" Gistabteal By) 76t ‘equipment while road-testing, of 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 oftestequipment while driving causes distraction. + There is an increased risk of injury iftest equipment is not secured. # Test equjoment must always be secured on the rear seat with a strap and operated from the rear seat by a second person. 34 Safety precautions when working on the exhaust system A 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 fo avoid contact with eyes and skin - risk of injury. # Dornot dismantie exhaust gas temperature sender - risk of infuy. BZ canton Avoid damage to flexible joint. Donot bend flexible joint more than 10°. # Install flexible joint so that itis not under tension. ¢ Take care not to damage wire mesh on flexible joint. 58. Safaty precautions 5GAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 3.5 Working on the subframe When working on the subframe note the following warnings: A\ 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. 6 op. o:00- Technical dataAudi AB 2005 > GOID 6-cylinder TDI engine (2,7 Itr; 3.0 ltr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Auer 4 General repair instructions Overview @ "4.1 Rules for cleanliness when working on fuel supply sys- tem. injection system and turbocharger’, page 7 e24, i 7 @ 2°43 Forel es i 7 ¢ ="4.5 Routing and attachment of pipes, hoses and wiring” page 8 © 2°4.6 Installing radi rae air page 8 @ 2°4.7 Checking vacuum system”, page & 44 Rules for cleanliness when working on fuel supply system, injection system and turbocharger Even small amounts of dirt can cause malfunctions. For this rea- son, when working on the fuel supply system, the injection system or the turbocharger, please observe the following basic rules carefully: © Carefully clean connection points ané the surrounding area with engine cleaner or brake cleaner and dry thoroughly before ‘opening - Plug open lines and connections with suitable protective caps immediately. Place parts that have been removed on a clean surface and cover them over. Do not use fluffy cloths. Only install clean components; replacement parts should only be unpacked immediately prior to instalation. Donot use parts, that have been previously unpacked and stored eway loose (@9. in toolboxes, etc.) ‘When the system is open: Do not work with compressed air. Do net move the vehicle unless absolutely necessary. . . . Protect unplugged electrical connectors against dirt and mois- ture and make sure connections are dry when attaching, 4.2 Checking for leaks in the fuel system Allow engine to run for several minutes at moderate rpm. Switch off ignition. Check complete fuel system for leaks. If leaks are found although the connections have been tight- ened to the correct torque, the relevant component must be renewed Road-test vehicle and accelerate with fullthrottle at least once, Then inspect high-pressure section of fuel system again for leaks. 43 Foreign particles in engine ¢ When working on the engine, all open inlet and exhaust ports must be sgeleg with suitable plugs (e.g. rom engine bung set = VAS 6122- ) to prevent foreign particles from entering the engine. 4 Gonaralrepairinsuctions 7GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 4 Inthe event of mechanical damage to one of the cylinder banks, the intake and exhaust systems and combustion cham- bers of the opposite cylinder bank must always be examined to prevent further damage occurring later. 44 Contact corrosion! Contact corrosion can occur if unsuitable fasteners are used (e.g, bolts, nuts, washers, etc.) For this reason, only fasteners with a special surface coating are used. Additionally, all rubber and plastic parts and all adhesives are made of non-conductive materials. Always install new parts if you are not sure whether used parts can be refitted = Electronic parts catalogue Note the following: # We recommend using only genuine replacement parts; these have been tested and are compatible with aluminium. 4 We recommend the use of Audi accessories. Damage caused by contact corrosion is not covered under warranty 45 Routing and attachment of pipes, hoses and wiring Mark hydraulic lines, vacuum lines and electrical wiring before removal so they can be re-installed in the original positions and correctly connected. Make sketches or take photographs if nec- essary. 46 Installing radiators, condensers and charge air coolers 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, charge air cooler or condenser. 47 Checking vacuum system ‘Special tools and workshop equipment required 4 Hand vacuum pump - VAS 6213- Procedure = Check all vacuum lines in the complete vacuum system for: # Cracks % Traces of animal bites 8 Rep. 0: 00- Technical data. . Audi AB 2005 > GOID 6-cylinder TDI engine (2,7 Itr; 3.0 ltr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Auer Kinked or crushed lines Lines porous or leaking Check vacuum line to solenoid valve and from solencid valve to corresponding component. Ia fauitis stored in the memory, check the vacuum lines lead- ing to the corresponding component and also check the re- maining vacuum lines in the system, I itis not possible to build up a vacuum with the hand vacuum pump - VAS 6213. or if the vacuum pressure drops again im- mediately, check the hand vacuum pump and connecting hoses for leaks. 4 Gonararepairinsucions 9GOOD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 10 joving and installing engine 1 Removing and installing engine - ve- hicles with manual gearbox Overview @ 2°11 Removing engine’, page 10 # > "1.2 Separating engine from manual gearbox’, page 28 # "1.3 Installing engine’, page 32 @® Note © The engine is removed trom underneath together with the gearbox and subframe (with lock camer installed) @ Allcable ties which are released or cut open when removing must be fitted in the same position when installing. % Collect drained coolant in a clean container for re-use or dis- posal. 14 Removing engine 10 ep. o.10-Removing and insaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer Special tools and workshop equipment required . . . Used oil collection and extraction unit - V.A.G 1782 Removal lever - 80 - 200- Hose clamps, up to 25 mm 3094. Stepladder - VAS 5085- Engine bung set - VAS 6122. Scissor-type assembly platform - VAS 6131 A- with support set for Audi - VAS 8131/10- Drip tray for workshop hoist = VAS 6208- VAS 5085 vas 6122 Gem 1. Removing and instaling engine - vehicles wth manual gearbox 11GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 4 Hose clip pliers - VAS 6362- # Tensioning strap - T10038- # Counterhold tool - 110172- with -110172/5- for vehicles with four-wheel drive T10172 Procedure A wane 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. A Caution Electronic components are susceptible to damage '# Observe notes on procedure for aisconnecting the battery. = Switch off ignition 12 Rep. o.10-Removing and insaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer = Disconnect earth wire -2- from battery terminal + Electrical system; Rep. gr. 27 = Discharge refrigerant system = Al conditioner with refrigerant Rida — Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unit - V.A.G 1782- — Carefully pull engine cover panel off four retaining pins one after the other -arrows-, ZX wernine Hot steam/hot coolant can escape - risk of scalding. ¢ The cooling system is under pressure wien the engine is ¢ To allow pressure to dissipate, cover filer cap on coolant expansion tank with cloth and open carefully. = Open filer cap on coolant expansion tank. — Remove both front wheels > Wheels and tyres; Rep. gr. 44 — Remove front and rear noise insulation > Rep. gr. 50. ~ Remove cove -t-for dive shaftin wheel housing (eft and Tight). 1. Removing and insaling engine - vehicles wth marual gearbox 13,GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Place drip tray for workshop hoist - VAS 6208- beneath en- gine. Release hose clip -arrow, disconnect coolant hase from cool- ant pipe (left-side) and drain off coolant. Litt retaining clip -arrow- to disconnect coviant hose trom eoel= ant pipe (right-side) and drain off remaining cdolant, Unscrew bolts -arrows- and detach torque reaction support from engine. — Unscrew nut -arrow- on longitudinal member (right-side) and move earth wire clear. 14 ep. o.10-Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2,7 itr: 3.0 Itr 4-valve common rail, EUS), mechanics - Edition 10.2014 “Aver = Disconnect coolant hose -1-. (F) note Disregard -arrow. = Remove bolt -arrov, = Unplug electrical connector for coolant shortage indicator switch - F66- at bottom of expansion tank and move expansion tank to one side with coolant hoses -1- and -2- attached. = Release hose clip -arrow- and detach coolant hose. (Be Disregard -item 1 — Unscrew nut -arrow: on suspension turret (left-side) and move ‘earth wire clear. 1. Removing and instaling engine - vehicles wth manual gearbox 15GAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 = Pull out oil dipstick -1- = Unplug electrical connector -4.. = Remove bolts -2- and detach throttle valve module - J338- item 5. D — Release hose clip -3- and detach air hose. iN SS (F) re Lay a cloth under the hydraulic Ines fo catch escaping hycrautc uid. Clamp off hycraulic hose -arrow: with hose clamp -3094- and detach. ~ Remove bolts -1- and lay hydraulic line aside on top of longi- tudinal member. Prolab opt eae cre =~ Seal off open pipesilines ari connections withclearr'slues from engine bung set - VAS 6122- A Caution Danger of damage to refrigerant lines and hoses. @ DoNOT stretch, kink or bend refrigerant lines and hoses. — Remove bolts -arrows- and disconnect refrigerant lines from AIC compressor. = Seal off open pipesilines and connections with clean plugs from engine bung set - VAS 6122- = Unplug electrical connector -arrow- for charge pressure send- er- G3t- at charge air cooler (left-side) (8) now For illustration purposes, the installation position is shown with the headlight removed. 16 ep. o.10-Removing and instaing engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer Remove bolts -arrows-, detach air ducts -1- and -2- Unplug electrical connector -1- from air mass meter - G70- Remove air hose. To do so, release hose clip -2- and clamps “arrows. Release clamps -arrows- and detach air cleaner (top section). Disconnect vacuum line -1-. Pull pin out of fastener -3.. Detach air cleaner (bottom section) and disconnect electrical connector -2- for ar filter bypass flap valve - N275- on reverse side of air cleaner. 1..Removing and insaling engine - vehicles wth manual gearbox 17GAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Release hose clip -1- and detach coolant hose. Move vacuum hose clear -arrow-. = Lift retaining clip -2- and disconnect coolant hose (top right) from radiator. — Release hose clip -arrow- and detach air hose from air pipe. = Remove nut -1- on remote positive terminal — Remove earth stud -2. ~ Moye clear electical wiring to turbocharger 1 contol motor - A Caution Take care to keep components clean. ¢ Rules for cleanliness when working on the injection sys- tem 2 page 7. = Release hose clips and detach return hose -1- and supply hose -2- from fuel fer. ~ Unserew nuts-arrowe- anc! move bracket wth fuel iter to one side. = Seal off open pipesilines and connections with clean plugs from engine bung set - VAS 6122- 18 ep. o.10-Removing and insaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer = Pull off seal -1- and remove plenum chamber cover -2- = Remove wiper arms > Electrical system; Rep. gr. 92 _- T0980 A Caution Risk of damage to cowi panel trim. # To.avoid cracking the cow panel rim -1. during femoval, appl aamal amount of ap solution othe joi betwen, ite winasoraen an tha cou paral him and olan (ricaly op oul of he wincacrestsncond slaring fore the edge ofthe windscreen. = Unscrew bolts -arrows- and pull cow! panel trim off wind- screen. = If fitted, remove bolts -1- and -3- and detach body brace -2-. 1. Removing and insaling engine - vehicles wth manual gearbox 19GAD Audi as 2005 > ‘Audr_6-cylinder TDI engine (2.7 ltr; 3.0 ir. 4-valve common rail, EUS), mechanics - Edition 10.2014 = Detach vacuum line -arrow- going to brake servo at plenum chamber pertition panel. — Detach vacuum hose -arrow- going to brake servo at plenum chamber partition panel. Remove bolts -arrows- and detach cover for electronics box in ‘engine compartment (left-side). — Release fasteners, pull off fuse holder -1- and then 3-position relay carrier -4- upwards. = Unscrew wiring -3. = Unplug three front electrical connectors -2- at rear of connec- tor console. = Disengage engine wiring harness at electronics box and move clear. fc 20 0p. or.10- Removing and installing engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer A WARNING Risk of burns at the pump valve unit for the heating system (left-side in front of electronics box). ¢ Wearprotectivegloves when working near the pump valve unit for the hesting system. = Remove bolts -arrowvs- and detach cover for electronics box in ‘engine compartment (right-side), = Open cover -1- with screwdriver -arrow- and detach. - Use screwdriver -arrows 1, 2- to carefully lever off retaining strap -3- and remove engine control unit from electronics box. (B) note The engine control unit remains connected to the wiring hamess. Unclio suppressor capacitor -5- and take out of retainer in electronics box. = Unplug electrical connector -4- at rear of connector console. = Unscrew electrical wiring -1- and -2-. = Release catches -arrows- and detach relay carrier from elec tronics box in engine compartment (right-side). 1..Removing and instaling engine - vehicles wih manual gearbox 21GAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 = Use removal lever - 80 - 200- to release electrical wiring up to the alternator. = Place both wiring harnesses on engine and secure engine control unit to prevent it from dropping. = Detach coolant hose -arrow- leading to heat exchanger at rear of engine. L\ casion Risk of injury and risk of damage to brake alscs and’ ith bearings. # When slackening the flange bolt securing the drive shaft, the vehicle must not be stanaing on its wheels. # Secure brake dises by screwing in two whee! bolts. Have a 2nd mechanic press the brake pedal. = Unscrew flange bolt -2- at drive shaft -1- (left and right). = Unscrew nuts -1- on both sides evenly. = Unscrew bolts -2- on both sides and remove anti-roll bar. =I 22 ep. or.10- Removing and installing engineAudi AB 2005 > GOID 6-cylinder TDI engine (2,7 itr: 3.0 Itr 4-valve common rail, EUS), mechanics - Edition 10.2014 “Aver = Unplug electrical connector -2- at front left vehicle level sender Gr = Remove nut-1-and detach coupling rod from track control link L\ caion Danger of damage to the swivel joints of the ypper links: Support whee! bearing housing. - Tie up wheel bearing housing with tensioning strap - T10038- as shown on illustration — Remove bolt -arrow- and detach suspension strut from track control link. = Remove nut -1- for guide link and nut -2- for track control link at subframe, remove bolts, 1. Removing and insaling engine - vehicles with marual gearbox 23GOOD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 = Pivot guide link -1- and track control link -2- outwards. L\ caution Risk of damage if quide link and track control link are allowed {0 drop without support. # Tie up guide link and track control link to wheel bearing housing -arrows- as shown in illustration. — Move clear electrical wiring harness at heat shield for drive shatt (left-side). ~ Remove bolts -arrows- and detach heat shield for drive shaft (left-side). = Detach drive shaft from flange shaft of gearbox. A Caution Danger of damage to brake hose. ¢ Take care when detaching drive shaft. Pivot wheel bearing housing outwards and detach drive shaft. Perform the same work steps on the other side of the vehicle. Remove bolts -arrows- and detach front cross piece. = Detach electrical connector for exhaust gas temperature send- er 4 - G648- -item 2- from bracket and unplug. Move electrical wiring clear. w® Note Ignore items marked -1- and -arrows-. 24 0p. .10- Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2,7 itr: 3.0 Itr 4-valve common rail, EUS), mechanics - Edition 10.2014 “Aver - Remove nuts -arrows- — Unscrew pressure pipe -1- from particulate filter. (CF) ne Disregard -item 2.. — Disconnect exhaust system at clamp -arrow- = Detach particulate filter = Unbolt push rod -1- and connecting rod for selector rod -2.. reece by copy. Copying x prvate of commercial Pp = Remove nut -arrow- and detach gearbox selector lever from selector shaft. 1. Removing and instaling engine - vehicles wth manual gearbox 25GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 ~ Remove bolt -arrow- and tie up clutch slave cylinder at side of ‘engine compartment. L\ casion Avoid damage to clutch slave cylinder. + Do not press clutch pedal after removing slave cylinder. Vehicles with four-wheel drive: = Remove bolts -arrows- and detach heat shield -A- for prop- shaft — Remove bolts connecting propshaft to gearbox (use counter- hold tool -710172- with -T10172/5- ). ~ Slide propshaft towards rear final drive; the constant velocity joints can be moved axially = Tie propshaft up to side of heat shield -arrow. 11017215 26 op. or.10- Removing and installing engineAudi AB 2005 > GOID 6-cylinder TDI engine (2,7 Itr; 3.0 ltr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Auer Set up the scissor-type assembly platform as follows: — Set up scissor-type assembly platform - VAS 6131 A- with support set for Audi - VAS 6131/10- and supplementary set - VAS 6131/11- as follows: Platform | Parts from support set for Audi - VAS 6131/10- vas 6131 coordinates, 83 HOA 10-4 M05 [_i40-14 F3 10-4 10-4 70-5 | 110-14 B10 70-4 10-2 110-5 /10-8 ‘G10 /40-1 110-2 10-5 110-8 EB Lito Os Pos HOS, C15) ost nos | 05 AOS — Initially hand-tighten the support elements on the scissortype assembly platform, ~ Position scissor-type assembly platform - VAS 6131 A- hori- oo zontally, + Take note of spirit level (bubble gauge) — Position scissor-type assembly platform - VAS 6131 A- below engine/gearbox assembly, = Position the support elements from -VAS 6131/10- at front of engine, as shown in illustration. — Make sure that threaded spindles are screwed in completely. — Position the support elements from -VAS 6131/10- at left and Tight of subframe, as shown in illustration, 1..Removing and insaling engine - vehicles wth manual gearbox 27GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Position the support elements fram -VAS 6134/10- at rear of tunnel cross member, as shown in illustration. = Tur all spindles for support elements upwards until ell locat- ing lugs make contact with mounting points. — Tighten base plates for support elements to 20 Nm on scissor- type assembly platform - VAS 6131 A- VAS 6131 — Remove bolts -arrows- for tunnel cross member. - Remove bolts -1- — Mark installation position of subframe and both consoles for ‘engine mountings on longitudinal members with feltetip pen. - Remove bolts -2, 3, 4- in diagonal sequence and in stages. L\ casion Danger of damage to hoses; pipes and wing connections and: f0 engine compartment. Check that ail hases and wiring connections between en- Dom gine, gearbox, subframe and body have been detached. © Carefully guide out engine/gearbox assembly with sub- frame from engine compartment when lowering. — Carefully lower engine/gearbox assembly. ~ Pull out scissor-type assembly platform - VAS 6131 A- with engine/gearbox assembly from underneath vehicle. 12 Separating engine from manual gear- box ‘Special tools and workshop equipment required # Support set for Audi - VAS 6131/10- , supplementary set - VAS 6131/11- and -VAS 6131/12- 28 Roe. or.10- Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2,7 Itr; 3.0 ltr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Auer Procedure + Engine/gearbox assembly removed and secured to scissor- type assembly platform - VAS 6131 A- Screw down spindles of support elements (left and right) at subframe as far as possible, Remove locating lugs from spindles, A second mechanic is required for removing the subframe. Take out subframe to the side. ~ Setup scissortyog assernbly platform - VAS 6134 A. with support set for Audi - VAS 6131/10- and supplementary set - VAS 6131/11- and -VAS 6131/12- as follows: Platform [Parts of support set for Audi - VAS 6134/10- , sup- coordinates) port set -VAS 6131/11- and supplementary Set - VAS 6131/12. 53!) HOA 0-8 M05 [0-14 F3") Hoa 0-4 nos | 10-11 87 0-4 HO-4 HOS 2A FT. HOA Os nos | i042 C10 HOA 0-8 0-5 | 110-10 F10 HOt 0-4 0-5 13 E13) HOA 10-3 10-5 10-6 cis) | 04 0-3 10-5 10-6 + Support elements remain unchanged. ere — Position support elements from -VAS 6131/10- on left side of engine/gearbox assembly, as shown in illustration. VAS 61311 10-10 12 vas 6131/ | |_vas ett 10-4 10-4 1..Removing and insaling engine - vehicles wth marual gearbox 29)GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 ~ Position support elements from -VAS 6131/10- on right side of El vaseiai ‘engine/gearbox assembly, as shown in illustration. ¢ NO-A2 = Turn spindles for support elements upwards unti all locating lugs make contact with mounting points. - Screw spindles on both sides upwards until gearbox support vas arate = VAS 6131/14- makes full contact with gearbox m3 ~ Tighten base plates for support elements to 20Nmonscissor- | as g4g4 VAS 6131 type assembly platform - VAS 6131 A- Moe Nos — Remove bolts -arrows- and detach heat shield for turbocharg- er — Remove electrical connector -arrow- for Lambda probe - G39- from bracket and unplug connector. = Move clear electrical wiring for Lambda probe. = Detach electrical connectors from bracket at front left of gear- box and unplug: - For exhaust gas temperature sender 3 - G495- = For engine speed sender - G28- Move electrical wiring cleer. 30 R09. 9:10- Removing and nsaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer — Remove nuts -arrows- securing starter catalytic converter to turbocharger. — Remove bolt -1- at bracket for starter catalytic converter. (B) Note Disregard -item 2.. A Caution Risk of damage to flexible joints in front silencer. # DoNOT bend the flexible joints in the front silencer more than 10°, ~ Remove bolts -arrows- securing bracket for front exhaust pipe. Detach starter catalytic converter and front exhaust pipe, — Unplug electrical connector -arrow- for reversing light switch - F4- and move electrical wire clear. 1. Removing and instaling engine - vehicles wih manual gearbox 31GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Remove nut -3- for battery positive cable. Unplug electrical connector -2-. Unscrew bolts -1- and -4- and remove starter. — Remove bolts -3.... 10- securing gearbox to engine. — Loosen clamping bolts -1- on sides of scissor-type assembly platform - VAS 6131 A- and pull rear section of platform to- 13 Installing engine Tightening torques (B) noe # Do not use de-greased parts. gether with gearbox towards rear -arrow- % Tolerance for tightening torques: + 15 %. Tightening torques apply only to lightly greased, olled, phosphated or black-finished nuts and boits. # Additional lubricant such as engine oil or gearbox oil may be used, but do not use lubricant containing graphite. [Component Nm Bolts/nuts M6|9 7/15 a]20 M10|40 32. Rop. 9:10- Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer [Component Nm Mig] 65 ‘Assembly mountings > page 101 Positive terminal and earth stud = Tighten nut -1- for positive terminal to 20 Nm. = Tighten earth stud -2- to @ Nm, Earth connection on longitudinal member (right-side) = Tighten nut -1- to 15 Nm. Earth connection to suspension turret ((eft-side) = Tighten nut -arrow- to 9 Nm. Heat shield for drive shaft - — Tighten bolts -arrows- to 23 Nf," Pete rom 1. Removing and instaling engine - vehicles wth manual gearbox 3SGAD Audi as 2005 > ‘Audr_6-cylinder TDI engine (2.7 ltr; 3.0 ir. 4-valve common rail, EUS), mechanics - Edition 10.2014 Engine to manual gearbox Item Bolt Nm 1 M10x60 65!) 2 M10x100 66) 3 M12x100 6 46 M12x110 cy 67 M12x120 6 8.9.10 MA10x60 45 A Dowel sleeves for centralising +) Property class 10.9. Procedure # Renew the bolts tightened with specified tightening angle. + Renew self-locking nuts and bolts as well as seals, gaskets and O-rings. The threaded holes in the flange shaft for the propshaft on the gearbox must be cleaned of remaining locking fuid with @ thread tap before assembling. + Hose connections and air pipes and hoses must be free of oi! and grease before assembly. # Secure all hase connections with the correct type of hose clips (same as original equiment) = Electronic parts catalogue # To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread ofused hase clips before installing. Fit all cable ties in the original positions when installing. — When fitting ¢ new cluteh plate together with a used pressure plate (self-adjusting clutch), the adjuster ring in the pressure plate has to be reset by turning it back as fer as it will go. ifthis is not done, the pressure plate will operate with reduced clamping force, causing clutch slip > Rep. gt. 30 (® Note 4 ifthe clutch plate is not being replaced, it is not necessary to reset the adjuster ring. + New self-adjusting pressure plates are already pre-set ac- cordingly, and do not have to be reset. = Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines - G 000 100- to the splines. Do not lubricate guide sleeve, — Make sure that clutch plate is properly centred (if necessary). = Check clutch release bearing for wear and make sure that plastic ring is securely seated: renew clutch release bearing if necessary = Rep. gr. 30 34 op. 9:10- Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer — Aneedie bearing must be fitted in the crankshaft on vehicles ‘with manual gearbox; install needle bearing if not already fitted = page 132 — Check whether dowel sleeves -A- for centring engine and gearbox are fitted in cylinder block; install missing dowel sleeves. — Press intermediate plate between engine and gearbox onto dowel sleeves. = Bring gearbox into position on engine and tighten bolts 3.10. — Install starter catalytic converter with front exhaust pipe = page 330 = Install starter > Electrical system; Rep. or. 27 — Screw down spindles of support elements on left side of en- gine/gearbox assembly. — Unscrew base plates for support elements (left-side) from scissor-type assembly platform - VAS 6131 Ar S , VAS 61311 VAS 61911 O10 = Screw down spindles of support elements on right side of en- gine/gearbox assembly. — Unscrew base plates for support elements (right-side) from scissor-type assembly platform - VAS 6131 A- (F) ne The mounting points for engine (front), gearbox and tunnel cross ‘member remain unchanged. 1. Removing and insaling engine - vehicles wn manual gearbox 3SGAD Audi as 2005 > ‘Audr_6-cylinder TDI engine (2.7 ltr; 3.0 ir. 4-valve common rail, EUS), mechanics - Edition 10.2014 Set up scissor-type assembly platform - VAS 6131 A- with support set for Audi - VAS 6131/10- as follows: VAS 6131 Platform | Parts from support set for Audi - VAS 6131/10- coordi- nates Bs) | M04 | 04 | 0-5 | 0-11 F30 | Mot | 04 | 05 | M041 B10 wor [ 02 | nos | oe? G10 nor | 02 | 105 | 1082 en” | mo1 | 03 [ mos | 106 cis) | mor [| nos [ mos | 08 +) Support elements remain unchanged. + 2) Secure support elements only after installing the sub- frame. =z] (Fn A second mechanic is required for positioning the subframe on the support elements. =. Fit subframe on both support elements -VAS 6131/10-8- — Screw up spindles of support elements on both sides. = Tighten base plates for support elements to 20 Nm on scissor- type assembly platform - VAS 6131 A- = Guide engine/gearbox assembly together with eubframe into body from below using scissor-type assembly platform - VAS 6131 Ae = Align subframe and consoles for engine mounting on longitu- dinal members according to markings made before removal. ~ Tighten bots for subftame and conscies for engine mountings only to specified torque (do not turn further), the bolts are only fully tightened after performing the wheel alignment check = Rep. gr. 40 Ay wasn Risk of accident because of loose bolt connections. Do NOT drive the vehicle unless the subframe bolts have been tightened to their final torque. 36 R09. 9:10- Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer = Tighten bolts for tunnel cross member = Rep. gr. 34 Remaining installation steps are carried out in reverse sequence; ote the following: — Install clutch slave cylinder > Rep. gr. 30 = Fit selector rod to gearbox = Rep. gr. 34 = Vehicles with four-wheel drive: install propshaft = Rear final drive 01R; Rep. gr. 39, > Rear final drive OAR: Rep. gr. 39 = Rear final drive 08V: Rep. gr. 39 = Install particulete fier > page 330 — Align the exhaust system so it is free of stress = page 359 = Install drive shafts, guide links, track contral links, anti-roll bar coupling rod and suspension struts = Rep. gr. 40 = Install heat shield for drive shaft > page 33. — Install covers for drive shafts + Rep. gr. 68 = Install front cross piece = Rep. gr. 50 = Install refrigerant lines > Rep. gr. 87 = Install hydraulic ine = Rep. gr. 48 Install throttle valve module - J338- and engine control unit = Rep. gr. 23 = Install torque reaction support = page 110 Electrical connections and routing = Current flow diagrams, Electrical fault finding and Fitting locations, > Electrical sys- tem; Rep. gr. 97, > page 33, > page 33, > page 33. Install cover for electronics box in plenum chamber > Elec- trical system; Rep. gr. 97 Install fuel filter > Rep. gr. 20 — Install air cleaner housing = Rep. gr. 23 = Install air hoses with screw-type clips = page 326 = Qbserve notes on procedure for connecting the battery = Electrical system; Rep. gr. 27 A Caution Risk of irreparable damage to control units because of exces- sive voltage. Never use battery charging equipment for boost starting. ~ Install anc acjut wiper arms > Electrical system; Rep. = Install body brace = Rep. gr. 40 = Check oil level > Maintenance ; Booklet 405 = Fill up hydraulic fluid for power steering = Rep. gr. 48 (B) Note The power steering pump must not be run when ary. 1. Removing and instaling engine - vehicles wth marual gearbox 37GAD Audi as 2005 > ‘Audr_6-cylinder TDI engine (2.7 ltr; 3.0 ir. 4-valve common rail, EUS), mechanics - Edition 10.2014 = Connect coolant hoses with plug-in connector > page 295 ~ Charge refrigerant system > Air conditioner with refrigerant Riade — Fill up with coolant = page 266 . ifradiator, heat exchanger, cylinder head, cylinder head gas- ket or cylinder block have been renewed, do not re-use old coolant. Contaminated or dirty coolant must not be used again. = Align subframe and both consoles for engine mountings = Rep. gr. 40 = Fitfront wheels > Wheels and tyres; Rep. gr. 44 — Perform wheel alignment check > Rep. gr. 44 LY wernine Risk of accident because of loose bolt connections. + Tighten bot for subtame te fel setting afer performing iee/ alignment check. = Check fuel system for leaks = page 7 — Install noise insulation panels + Rep. gr. 50. 38 R09. 9:10- Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer 2 Removing and installing engine - ve- hicles with multitronic gearbox Overview ¢ 2°21 Removing engine’, page 39 os mul c page 56 ="2.3 Installing engine’, pace 60 Cm The engine is removed from undemeath together with the * Garbo and subhame (wh ik carton Marod), ¢ Allcable ties which are released or cut open when removing must be fitted in the same position when installing. © Collect drained coolant in a clean container for re-use or dis- posal. 24 Removing engine Special tools and workshop equipment required ¢ Removal lever - 80 - 200- @ Hose clamps, up to 25 mm = 3094- © Stepladder - VAS 5085- @ Engine bung set - VAS 6122. 80-200 Scissor-type assembly platform - VAS 6131 A- with support set for Audi - VAS 6131/10- and supple- mentary set -VAS 6131/11- Drip tray for workshop hoist = VAS 6208- VAS 5085 (wrs005r) 2. Removing and instaling engine - vehicles with mutitoic gearbox BQGAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 # Used cil collection and extraction unit - V.A.G 1782- V.A.G 1782 # Hose clip pliers - VAS 6362- # Tensioning strap - T10038- 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. LX carton Electronic components are susceptible to damage. @ Observe notes on procedure for disconnecting the battery. = Switch off ignition 40 0p. r.10- Removing and installing engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer = Disconnect earth wire -2- from battery terminal + Electrical system; Rep. gr. 27 = Discharge refrigerant system = Al conditioner with refrigerant Rida Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unit - V.A.G 1782. . Carefully pull engine cover panel off four retaining pins one after the other -arrows-, ZX wernine Hot steamv/hot coolant carn escape -/sk of scalding. ¢ The cooling system is under pressure wien the engine is ¢ To allow pressure to dissipate, cover filer cap on coolant expansion tank with cloth and open carefully. = Open filer cap on coolant expansion tank. — Remove both front wheels > Wheels and tyres; Rep. gr. 44 — Remove front and rear noise insulation > Rep. gr. 50. ~ Remove cover -t-for dive shaftin wheel housing (eft and Tight). 2. Removing and instaling engine - vehicles with mutttonic gearbox 41GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 ~ Place drip tray for workshop hoist - VAS 6208- beneath en- gine. = Release hose clip -errow., disconnect coolant hose from cool- ant pipe (left-side) and drain off coolant. — iftretaining clio -arrow- to disconnect coolant hose from cool- ant pipe (right-side) and drain off remaining coolant. = Unscrew bolts -arrows- and detach torque reaction support from engine. — Position used oil collection and extraction unit - V.AG 1782- below connection points. CF noe Observe rules for cleanliness when working on multitronic gear box > Rep. gr. 00 = Disconnect ATF lines -arrows- on right side of engine. = Seal off open pipesilines and connections with clean plugs from engine bung set - VAS 6122- 42 R00. 10 - Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2,7 itr: 3.0 Itr 4-valve common rail, EUS), mechanics - Edition 10.2014 “Aver = Unscrew nut -arrow- on longitudinal member (right-side) and move earth wire clear. Disconnect coolant hose -1-. (B) Note Disregard -arrow. = Remove bolt -arrov. — Unplug electrical connector for coolant shortage indicator ‘switch - F66- at bottom of expansion tank and move expansion tank to one side with coolant hoses -1- and -2- attached, Release hose clip -arrow- and detach coolant hose, (B) note Disregard -item 1-, 2. Removing and instaling engine - vehicles with mutitoic gearbox 43GAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 = Unscrew nut -arrow- on suspension turret (left-side) and move earth wire clear. = Pull out oil dipstick -1-. = Release hose clip -3- and detach air hose. = Unplug electrical connector -4. ~ Remoye bolts -2-and detach throttle vaive module -J836- item 5 (now Lay a cloth under the hychaulc ines to catch escaping hycausle iui = Clamp off hy¢raulic hose -arrow- with hose clamp -3094- and detach. Remove bolts tudinal member. | and lay hydraulic line aside on top of longi- — Seal off open pipesilines and connections with clean plugs from engine bung set - VAS 6122- A Caution i) J =! | Danger of damage to refrigerant lines and hoses. # DONOT stretch, kink or bend refrigerant ines and hoses. = Remove bolts -arrows- and disconnect refrigerant lines from AIC compressor. = Seal off open pipesilines and connections with clean plugs iy i—? from engine bung set - VAS 6122- OTe] 44 0p. r.10- Removing ad instaling engineAudi AB 2005 > 6-cylinder TDI engine (27 Itr: 3.0 ltr. 4-valve common rail, EUS), mechanics - Edition 10.2014 re ~ Unplug sectrcal connector arrow for charge pressure serch er - G31- at charge air cooler (left-side). (B) Note For illustration purposes, the instellation position is shown with the headlight removed. — Remove bolts -arrows-, detach air ducts -1- and -2.. = Unplug electrical connector -1- from air mass meter - G70, — Remove air hose. To do so, release hose clip'“2n.and siamps.. -arrows- Release clamps -arrows- and detach air cleaner (top section) 2. Removing and instaing engine - vehicles with mutttoic gearbox 45GAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 = Disconnect vacuum line -1-. — Pull pin out of fastener -3-. — Detach air cleaner (bottom section) and disconnect electrical connector -2- for air iter bypass flap valve - N275- on reverse side of air cleaner. — Release hose clip -1- and detach coolant hose. = Move vacuum hose clear -arrow. = Lift retaining clip -2- and disconnect coolant hose (top right) from radiator. = Release hose clip -arrow- and detach air hose from air pipe. — Remove nut -1- on remote positive terminal = Remove earth stud -2.. ~ Moye clear electical wiring to turbocharger 1 contol motor - 46 0p, or.10- Removing and installing engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer A Caution Take care to keep components clean. # Rules for cleanliness when working on the injection sys- tem > page 7. Release hose clips and detach return hose -1- and supply. hose -2- from fuel fiter Unscrew nuts -arrows- and move bracket with fuel filter to one side. Seal off open pipaalisas and.cohnachons ith sican. from engine bungeeet VAS 6122-00 snr lugs Pull off seal -1- and remove plenum chamber cover -2-. ~ Remove wiver arms + Electrical system; Rep. gr. 92 L\ caston Risk of damage to cowi panel trim. To avoid cracking the cow! pane! trim -1- during removal, iy ama amount of soap solution tothe ont between the windscreen and the cowl panel trim and pull the trim vertically up out of the windscreen surround, starting from the edge of the windscreen. = Unscrew bolts -arrows- and pull cow panel trim off wind- screen. 2. Removing and instaling engine - vehicles with mutitoic gearbox 47GAD Audi as 2005 > ‘Audr_6-cylinder TDI engine (2.7 ltr; 3.0 ir. 4-valve common rail, EUS), mechanics - Edition 10.2014 = If fitted, remove bolts -1- and -3- and detach body brace -2-. — Detach vacuum line -arrow- going to brake servo at plenum chamber partition panel. ~ Detach vacuum hose -arrow- going to brake servo at plenum chamber partition panel. — Remove bolts -arrows- and detach cover for electronics box in engine compartment (left-side). 4B 0p. or.10- Removing and installing engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer - Release fasteners, pull off fuse holder -1- and then 3-position relay carrier -4- upwards, = Unscrew wiring -3-. — Unplug three front electrical connectors -2- at rear of connec- tor console. Disengage engine wiring harness at electronics box and move clear. ZX waanine Risk of burns at the pump vaive unit for the heating system (left-side in front of electronics box). + Wearprotective gloves when working near the; unt forthe neatng syste = Remove bolts -arrows- and detach cover for electronics box in engine compartment (right-side). = Open cover -1- with screwdriver -arrow- and detach, = Use screwdriver -arrows 1, 2- to carefully lever off retaining strap -3- and remove engine control unit from electronics box. (Bre The engine control unit remains connected to the wiring hamess. — Unclip suppressor capacitor -5- and take out of retainer in electronics box. — Unplug electrical connector -4- at rear of connector console. = Unscrew electrical wiring -1- and -2- 2. Removing and instaling engine - vehicles with matic gearbox 4Q)GAD Audi as 2005 > “Aver _6-cylinder TDI engine (2.7 ltr: 3.0 itr. 4-valve common rail, EUS), mechanics - Edition 10.2014 = Release catches -arrows- and detach relay carrier from elec- tronics box in engine compartment (right-side). eS — Use removal lever - 80 - 200- to release electrical wiring up to the alternator. = Place both wiring hamesses on engine and secure engine control unit to prevent it from dropping — Detach coolant hose -arrow: leading to heat exchanger at rear of engine. A Caution Risk of injury and risk of damage to brake discs and whee! bearings. When slackening the flange bolt securing the drive shaft the vehicle musi not be standing on its wheels. '¢ Secure brake discs by screwing in two wheel bolts. = Have @ 2nd mechanic press the brake pedal — Unscrew flange bolt -2- at drive shaft -1- (left and right). 50 Rep. 9:10- Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer ~ Unscrew nuts -1- on both sides evenly. — Unscrew bolts -2- on both sides and remove anti-roll bar. ~ Unplug electrics! connector2-atfrontif vehicle level ender - Remove nut-1-and detach coupling rod from track control ink. A Caution Danger of damage to the swivel joints of the upper links. Support whee! bearing housing. Tie up wheel bearing housing with tensioning strap - T10038- as shown on illustration. — Remove bolt -arrow- and detach suspension strut from track ‘control link. 2. Removing and instaling engine - vehicles with mattwonic gearbox 51GAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 Remove nut -1- for guide link and nut -2- for track control link at subframe, remove bolts. — Pivot guide link -1- and track control link -2- outwards. A Caution Risk of damage if guide link and track control link are allowed 0 drop without support. ¢ Tie up guide link and track control link to wheel bearing housing -arrows- as shown in illustration. Remove bolts -arrows- and detach heat shield for drive shaft (left-side). = Detach drive shaft from flange shaft of gearbox. A Caution Danger of damage to brake hose, ‘¢ Take care when detaching drive shaft ~ Pivot wheel bearing housing outwards and detach drive shatt. = Perform the same work steps on the other side of the vehicle. Remove Balls “aHtowd: aiid detach trent crags idee: 52. Rop.9:10- Removing and instaling engineAudi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer Unplug electrical connectors -3- for exhaust gas pressure sen- sor 1 ~ G450- and -4. for exhaust gas temperature sender 4 - G648- at rear of gearbox. = Remove bolt -1- and move clear exhaust gas pressure sensor 1. G450- (Fre Disregard -item 2- and -arrow. — Remove nuts -arrows- (Bnet Disregard -items 1, 2. — Disconnect exhaust system at clamp -arrow — Detach particulate filter (CF) ne ‘Mark installation positon of support bracket for selector ever ca- = Remove bolt -1- for cable support bracket. [B) v6 Disregard -item 2-. 2. Removing and instaling engine - vehicles with mutitoic gearbox SSGAD Audi as 2005 > ‘Auor_6-cylinder TDI engine (2.7 itr; 3.0 itr. 4-valve common rail = Pry ball socket -A- of selector lever cable off selector shaft lever in direction of -arrow- using removal lever - 80 - 200- Set up the scissor-type assembly platform as follows: = Set up scissor-type assembly platform - VAS 6131 A- with support set for VAS 6131/11- as follows: idi - VAS 6131/10- and supplementary set - Platform | Parts of support set for Audi - VAS 6131/10- and coordinates supplementary set -VAS 6131/11- 83 110-4 0-4 HOS O11 £3. 110-4 HOA HOS HOA B10 110-4 0-2 HOS 710-8 G10 10-4 110-2. HOS 710-8 Cr 110-4 10-3. HOS 0-12 Faia) [10-4 10-3 0-5 4-2 = Initially hand-tighten the support elements on the scissor-type assembly platform. ~ Position scissor-type assembly platform - VAS 6131 A. hori= zontally. + Take note of spirit level (bubble gauge) — Position scissor-type assembly platform - VAS 6131 A- below ‘engine/gearbox assembly, = Position the support elements from -VAS 6131/10- at front of, engine, as shown in illustration — Make sure that threaded spindles are screwed in completely. EUS), mechanics - Euition 10.2014 VAS 6131 54 op. 9:10- Removing and instaling engine= Position the support elements from -VAS 6131/10- at left and Tight of subframe, as shown in illustration. — Position support elements from -VAS 6131/10- and - VAS 6131/11 t rear of tunnel eross member, e8 shown in ilustration. ‘Tum all spindles for support elements upwards until all locat- ing lugs make contact with mounting points Tighten base plates for support elements to 20 Nm on scissor- type assembly platform - VAS 6131 A = Remove bolts -arrows- for tunnel cross member. — Remove bolts'=4-: n pute oc = Merk installation position of subtrame and both consoles for engine mountings on longitudinal members with felt-tip pen. — Remove bolts -2, 3, 4- in diagonal sequence and in stages. LX casion Danger of damage to hoses, pipes and wiring connections and fo engine compartment. * Check that all hoses and wiring connections between en- gine, gearbox, subframe and body have been detached. Carefully guide out engine/gearbox assembly with sub- frame from engine compartment when lowering. = Carefully lower engine/gearbox assembly. = Pull out scissor-type assembly platform - VAS 6131 A- with engine/gearbox assembly from undemeath vehicie. Audi AB 2005 > GOID 6-cylinder TDI engine (2.7 Ir. 3.0 ltr. 4.valve common rail, EUS), mechanics - Edition 10.2014 Auer Rr 2. Removing and instaling engine - vehicles with mutttoic gearbox SDGAD Audi as 2005 > ‘Aver 6-cylinder TDI engine (2.7 Itr; 3.0 tr. 4-valve common rail, EUS), mechanics - Edition 10.2014 22 Separating engine from multitronic gear- box Special tools and workshop equipment required # Support set for Audi - VAS 6131/10- , supplementary set - VAS 6131/11- and -VAS 6131/12- # Gearbox support - VAS 6131/14- Setting up gearbox support - VAS 6131/14- = Cut foam plastic insert according to the dimensions given 1 + Dimension -a- = 20 mm / + Distance «I = 55 mm. + Distance -c- = 55 mm, Z (F) ne | Order a new foam plastic insert to be kept in stock as a replace- Soe ammeenee Q z I VAS 6131/14 Procedure + Engine/gearbox assembly removed and secured to scissor- type assembly platform - VAS 6131 A- = Screw down spindles of support elements (left and right) at. subframe as far as possible. - Remove locating lugs from spindles, (noe A second mechanic is required for removing the subframe. — Take out subframe to the side. = Remove bolts -arrowst etd detach Reet shield or futbocha or 56 op. or.10- Removing and installing engine