Service
Workshop Manual
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ ,
Audi A5 2016 ➤ , Audi A6 2011 ➤ ,
Audi A6 2019 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi A7 Sportback 2018 ➤ ,
Audi A8 2018 ➤ , Audi Q5 2017 ➤ ,
Audi Q7 2016 ➤ , Audi Q8 2018 ➤
Servicing 6-cylinder TDI engine, common rail (EA 897
Gen. I)
Engine ID
Edition 04.2019
CSWBCRTCCVM
CZVCCZVDCZV
CZZA CZZB
D
CZVF
E
CRTDCRTFCRT
CUEACVZACZVACZV
B
E
Service Department. Technical Information
List of Workshop Manual Repair Groups
Re pa ir G ro up
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
Service
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.
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 2
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Safety precautions when working on the glow plug system . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Use of impact wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.8 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.10 Performing adaptions after renewing a component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Exploded view - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.8 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.9 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.7 Checking sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Contents i
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1 Exploded view - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3 Renewing roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.5 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1 Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.1 Exploded view - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 Exploded view - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2 Exploded view - drive chain for high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.3 Exploded view - drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.4 Exploded view - intermediate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.5 Removing camshaft timing chain from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.6 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.7 Removing and installing drive chain for high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . 94
2.8 Installing intermediate drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2 Exploded view - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.5 Removing and installing seals for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3 Measuring radial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.5 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.1 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.4 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 163
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.1 Exploded view - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.3 Removing and installing temperature regulator for engine oil cooler . . . . . . . . . . . . . . . . . . 166
ii Contents
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
3 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1 Exploded view - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.3 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.5 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 172
3.6 Removing and installing oil temperature sender 2 G664 . . . . . . . . . . . . . . . . . . . . . . . . . . 173
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.1 Exploded view - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.3 Exploded view - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.4 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.5 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.7 Removing and installing thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.8 Removing and installing map-controlled engine cooling system thermostat F265 . . . . . . 190
2.9 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 191
2.10 Removing and installing temperature sender for engine temperature regulation G694 . . 192
2.11 Removing and installing coolant temperature sender 2 G802 . . . . . . . . . . . . . . . . . . . . . . 193
2.12 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4 Radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.4 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.1 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.3 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.2 Removing and installing intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.3 Removing and installing intake manifold (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Contents iii
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4.4 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.5 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5 Injectors/high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.3 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.4 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5.5 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5.6 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 236
5.7 Checking pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
5.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5.9 Removing and installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5.10 Removing and installing high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.1 Removing and installing intake air temperature sender G42 . . . . . . . . . . . . . . . . . . . . . . 251
6.2 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.3 Removing and installing fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.4 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
6.5 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 256
6.6 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
6.7 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 257
6.8 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 258
7 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
8.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
8.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
8.3 Removing and installing NOx senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
8.4 Removing and installing particulate sensor G784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.4 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3 SCR (selective catalytic reduction) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3.1 Exploded view - reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3.2 Exploded view - reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3.3 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3.4 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3.5 Removing and installing injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 273
3.6 Removing and installing control unit for reducing agent metering system J880 . . . . . . . . 275
4 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
4.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
4.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 278
4.3 Removing and installing exhaust gas temperature sender 2 G448 . . . . . . . . . . . . . . . . . . 279
4.4 Removing and installing exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . . . 280
4.5 Removing and installing exhaust gas temperature sender 4 G648 . . . . . . . . . . . . . . . . . . 282
iv Contents
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4.6 Removing and installing exhaust gas temperature sender 5 G815 . . . . . . . . . . . . . . . . . . 284
4.7 Removing and installing catalytic converter temperature sensor 1 G20 . . . . . . . . . . . . . . 284
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 291
5.3 Removing and installing exhaust gas recirculation temperature sensor G98 . . . . . . . . . . 296
5.4 Installing repair kit for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
6.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
6.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.1 Exploded view - glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.3 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Contents v
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vi Contents
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00 – Technical data
1 Identification
(ARL006306; Edition 04.2019)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data
Engine number
♦ The engine number (engine code and serial number) can be
found on the front of the cylinder block -arrow-.
♦ There is also a sticker on the intake manifold showing the en‐
gine code and serial number.
♦ In addition, the engine code is listed on the vehicle data stick‐
ers.
For engine data refer to ⇒ Technical data for engines; Rep. gr.
00 ; Overview of engines .
1. Identification 1
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2 Safety precautions
⇒ “2.1 Safety precautions when working on the fuel system”, page
2
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 2
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “2.4 Safety precautions when working on the cooling system”,
page 3
⇒ “2.5 Safety precautions when working on the exhaust system”,
page 3
⇒ “2.6 Safety precautions when working on the SCR system”,
page 4
⇒ “2.7 Safety precautions when working on the glow plug system”,
page 5
2.1 Safety precautions when working on the fuel system
Risk of injury - fuel system operates under high pressure
The fuel system is pressurised. There is a risk of injury as fuel
may spray out.
Before opening the fuel system:
– Put on safety goggles.
– Put on protective gloves.
– Release pressure (wrap a clean cloth around connection and
open connection carefully).
Risk of fire due to escaping fuel
If the battery is connected, the door contact switch activates the
fuel pump when the driver's door is opened. Escaping fuel may
ignite, causing a fire.
– Before opening the fuel system, disconnect power supply to
fuel pump.
2.2 Safety precautions when working on vehicles with start/stop system
Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.
2 Rep. gr.00 - Technical data
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2.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or:
– Have a second mechanic operate test equipment on the rear
seat.
2.4 Safety precautions when working on the cooling system
Risk of scalding as hot coolant can escape
The cooling system is under pressure when the power unit is hot.
Risk of scalding due to hot steam and hot coolant.
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
2.5 Safety precautions when working on the exhaust system
Risk of injury caused by components of the exhaust system
Danger of injury to hands and other parts of the body due to hot
or sharp parts of the exhaust system.
– Allow exhaust system to cool down.
– Put on protective gloves.
Risk to health due to chemical substances in components of ex‐
haust system
Risk to health if components of system for after-treatment of ex‐
haust gases are dismantled.
– Do NOT cut, saw or open components of system for after-
treatment of exhaust gases.
Risk of injury when disconnecting the exhaust system
There is a risk of eye irritation caused by soot particles in the air.
– Put on safety goggles.
2. Safety precautions 3
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2.6 Safety precautions when working on the SCR system
Risk of injury caused by reducing agent
Reducing agent can cause eye and skin irritation, damage to the
respiratory tract and poisoning.
– Put on safety goggles.
– Put on protective gloves.
– Wear protective clothing.
– Ensure that there is sufficient fresh air. In enclosed spaces,
switch on the exhaust extraction system.
Caution
Reducing agent must never be reused. For information re‐
garding storage and disposal see ⇒ ServiceNet → Environ‐
mental protection → Workshop waste management . Contact
Importer for country-specific information regarding storage and
disposal.
When removing and installing components on the SCR system,
please note the following:
♦ The reducing agent tank must be empty when you are working
on the SCR system. Refer to the corresponding work descrip‐
tion to find out when the reducing agent tank must be drained.
Manual drawing back of reducing agent
• The reducing agent line must be drained using a ⇒ Vehicle
diagnostic tester in Guided Functions mode, Drain me-
tering line.
4 Rep. gr.00 - Technical data
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2.7 Safety precautions when working on the
glow plug system
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.
♦ Transport and store only in original packaging or packed
separately in plastic tubes with foam inserts.
♦ 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 ceramic 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).
If necessary, the cylinder head must be removed.
♦ 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.
♦ After removal, the cylinder head must not be put down on
the gasket side with the glow plugs still installed, because
the glow plugs project beyond the gasket surface.
♦ When (re-)installing the glow plug, visually inspect the ce‐
ramic pin to make sure it is not damaged.
2. Safety precautions 5
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3 Repair instructions
⇒ “3.1 Identification plates”, page 6
⇒ “3.2 Use of impact wrenches”, page 6
⇒ “3.3 Rules for cleanliness”, page 7
⇒ “3.4 General notes”, page 7
⇒ “3.5 General repair instructions”, page 9
⇒ “3.6 Foreign particles in engine”, page 10
⇒ “3.7 Contact corrosion”, page 10
⇒ “3.8 Routing and attachment of pipes, hoses and wiring”, page
10
⇒ “3.9 Installing radiators and condensers”, page 11
⇒ “3.10 Performing adaptions after renewing a component”, page
11
3.1 Identification plates
When renewing vehicle components, the identification plates on
the old parts that have a replacement part number (see ⇒ Elec‐
tronic parts catalogue ) must be attached to the new parts due to
approval regulations.
3.2 Use of impact wrenches
In general, it is permitted to use an impact wrench to unscrew
bolts and nuts. An exception to this is when work is performed
inside an open high-voltage battery. For this work, it is not per‐
mitted to use an impact wrench.
An impact wrench may be used to screw in bolts and nuts when
performing repair work if the following requirements are observed.
In general, electric and compressed-air impact wrenches should
be used.
Requirements:
• Only screw in bolts with locking fluid or self-locking nuts at low
speed.
• Use a suitable impact wrench with variable speed and adjust‐
able torque range.
• Use suitable bits when working in the vicinity of sensitive sur‐
faces, e.g. plastic-coated bits for aluminium rims.
• When working in the vicinity of natural gas systems, observe
the information in the Workshop Manual “Natural gas engines
- General information”.
Use:
• Fit bolts/nuts by hand.
• Only use an impact wrench to screw in bolts/nuts until the head
of the bolt/nut makes contact and then continue tightening with
a torque wrench.
• Clean threaded pins before unscrewing the bolt/nut.
6 Rep. gr.00 - Technical data
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
3.3 Rules for cleanliness
Even small quantities of dirt can lead to defects. For this reason,
please observe the following rules when working on the fuel sup‐
ply system, turbocharger and injection system:
♦ 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 plugs (thor‐
oughly cleaned), for example from engine bung set - VAS
6122- .
♦ After removal, place parts on a clean surface and cover them.
Only 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.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
♦ 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.
3.4 General notes
Fuel supply/injection
♦ 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.
♦ 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 .
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.
3. Repair instructions 7
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Exhaust system
Risk of damage to flexible joint
The flexible joint can be damaged or develop leaks if it is handled
incorrectly.
– Do not bend flexible joint more than 10°.
– Install flexible joint so that it is not under tension.
SCR (selective catalytic reduction) system
Risk of damage caused by reducing agent
Reducing agent which has come into contact with trim or body
components can crystallise after some time and damage the af‐
fected surfaces.
– Ensure that no reducing agent makes contact with parts of trim
or body.
– Clean any surfaces which have come into contact with reduc‐
ing agent immediately with water and a cloth.
Glow plug system
♦ The glow plug system is activated via the automatic glow pe‐
riod control unit - J179- . The control unit is self-diagnosis
compatible.
♦ Fitting location of automatic glow period control unit -J179-
⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
♦ A fault is stored in the engine control unit - J623- if a fault oc‐
curs in the glow plug system.
♦ Checking glow plug system ⇒ Vehicle diagnostic tester
♦ For faster starting, the vehicle is equipped with electronically
controlled glow plugs and a separate glow period control unit.
♦ Each glow plug is activated and diagnosed separately.
Note
♦
Wait for 60 seconds each time after performing final control
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.
8 Rep. gr.00 - Technical data
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Running gear, axles, steering
Risk of damage to components
Lowering the vehicle onto its wheels can damage components if
the assembly mountings, steering rack or subframe cross brace
are not fitted as specified.
– Never lower vehicle onto its wheels with suspension compo‐
nents unfastened or detached.
– Never support weight of vehicle on subframe or subframe
cross brace with suspension components unfastened or de‐
tached.
3.5 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:
♦ If components of the fuel system between the fuel tank
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 210 .
♦ 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 reinstalled 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.
3. Repair instructions 9
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♦ 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.
♦ Use correct type of fasteners for electrical wiring (as original
equipment) ⇒ Electronic parts catalogue .
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.
3.6 Foreign particles in engine
♦ When performing assembly work on the engine, all open pas‐
sages in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set - VAS 6122- ) to
prevent foreign particles from entering the engine.
♦ In the event of mechanical damage to one of the cylinder
banks, the intake and exhaust systems and combustion cham‐
bers of the opposite cylinder bank must always be examined
to prevent further damage occurring later.
Note
If the turbocharger has suffered mechanical damage
⇒ page 201
3.7 Contact corrosion
Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.
3.8 Routing and attachment of pipes, hoses and wiring
Risk of damage to pipes/hoses/wiring
Moving or hot components may cause damage to pipes/hoses/
wiring.
– Restore original routing when installing pipes/hoses/wiring.
– Ensure sufficient clearance from all moving or hot compo‐
nents.
10 Rep. gr.00 - Technical data
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3.9 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, charge air cooler or condenser.
3.10 Performing adaptions after renewing a
component
After a component has been renewed, the following programs
must be performed using the ⇒ Vehicle diagnostic tester.
– Select the correct Guided Function in the Guided Fault Finding
routine. The procedure for starting the ⇒ Vehicle diagnostic
tester is always the same.
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and then Start diagnosis.
Procedure - version 1:
– Choose Select own test tab and select following options
one after the other:
♦ Drive train
♦ Select engine code and engine
♦ 0001 - Self-diagnosis compatible systems
♦ 0001 - Engine electronics
♦ 0001 - Engine electronics, functions
After renewing engine control unit:
♦ 0001 - Replace engine control unit
The learnt values must be adapted if components of the engine
or reducing agent system have been renewed or if a reducing
agent line has been opened:
♦ 0001 - Work steps after component replacement
Procedure - version 2:
♦ Systems with diagnostic capability
♦ 0001 - Engine electronics J623
♦ 0001 - Engine electronics, functions
After renewing engine control unit:
♦ 0001 - Replace engine control unit
The learnt values must be adapted if components of the engine
or reducing agent system have been renewed or if a reducing
agent line has been opened:
♦ 0001 - Work steps after component replacement
3. Repair instructions 11
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10 – Removing and installing engine
1 Removing and installing engine
All procedures are described in ⇒ 6-cylinder TDI engine, 3.0 ltr.
4-valve common rail; Rep. gr. 10 ; Removing and installing en‐
gine .
12 Rep. gr.10 - Removing and installing engine
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2 Assembly mountings
All procedures and components are described in ⇒ 6-cylinder TDI
engine, 3.0 ltr. 4-valve common rail; Rep. gr. 10 ; Assembly
mountings .
2. Assembly mountings 13
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3 Engine cover panel
⇒ “3.1 Removing and installing engine cover panel”, page 14
3.1 Removing and installing engine cover
panel
Some models are not fitted with an engine cover panel.
Removing
– Carefully pull engine cover panel off retaining pins one after
another -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– When fitting engine cover panel, take care not to damage oil
filler neck.
– First press engine cover panel onto rear ball studs and then
onto front ball studs with both hands.
14 Rep. gr.10 - Removing and installing engine
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13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 15
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 17
⇒ “1.3 Removing and installing poly V-belt”, page 19
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 20
⇒ “1.5 Removing and installing vibration damper”, page 20
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 22
⇒ “1.7 Removing and installing engine support”, page 24
⇒ “1.8 Renewing crankshaft oil seal (pulley end)”, page 24
⇒ “1.9 Removing and installing sealing flange (pulley end)”, page
26
1.1 Exploded view - cylinder block (pulley end)
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Routing of poly V-belt
⇒ page 17
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
❑ Removing and installing
⇒ page 19
❑ When installing, make
sure it is properly seated
on pulleys
2 - Vibration damper
❑ With poly V-belt pulley
❑ Removing and installing
⇒ page 20
3 - Bolt
❑ Renew after removing
❑ 150 Nm +90°
4 - Idler roller
❑ For poly V-belt
5 - Bolt
❑ 30 Nm
6 - Cover
❑ For idler roller
7 - Cover
❑ For idler roller
8 - Bolt
❑ 30 Nm
1. Cylinder block (pulley end) 15
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9 - Idler roller
❑ For poly V-belt
10 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
11 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
12 - Bracket
❑ For alternator
❑ Removing and installing ⇒ page 23
13 - Bolt
❑ Tightening torque and sequence ⇒ page 17
14 - Bolt
❑ Tightening torque ⇒ Item 2 (page 184)
15 - Pulley
❑ For coolant pump
16 - Bolt
❑ Renew after removing
❑ 50 Nm +90°
17 - Tensioner
❑ For poly V-belt
❑ Removing and installing ⇒ page 20
18 - Gasket
❑ Renew after removing
19 - Bracket
❑ For air conditioner compressor
❑ Removing and installing ⇒ page 22
20 - Bolt
❑ Self-locking
❑ Renew after removing
❑ Tighten in 2 stages and in diagonal sequence:
♦ 5 Nm
♦ 40 Nm
21 - Dowel sleeves
22 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
23 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
16 Rep. gr.13 - Crankshaft group
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Bracket for alternator -1- - tightening torque and sequence
– Tighten bolts in stages as follows (illustration shows vehicle
without high-voltage system):
Stage Bolts Tightening torque
1. -2- 3 Nm
2. -3- 40 Nm
3. -2- 40 Nm
Routing of poly V-belt
1 - Alternator
2 - Idler roller
3 - Idler roller
4 - Coolant pump
5 - Air conditioner compressor
6 - Tensioner for poly V-belt
7 - Vibration damper
1.2 Exploded view - sealing flange (pulley end)
1. Cylinder block (pulley end) 17
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1 - Oil seal
❑ For crankshaft (pulley
end)
❑ Renewing ⇒ page 24
2 - Sealing flange (pulley end)
❑ Removing and installing
⇒ page 26
3 - Bracket
❑ For intake manifold flap
motor - V157-
4 - Bolt
❑ 9 Nm
5 - O-rings
❑ Renew after removing
6 - Oil temperature sender 2 -
G664-
❑ Removing and installing
⇒ page 173
7 - Bolt
❑ 9 Nm
8 - Gasket
❑ Renew after removing
9 - Bolt
❑ Tightening torque and
sequence ⇒ page 184
10 - Thermostat housing
❑ Exploded view
⇒ “2.3 Exploded view thermostat”, page 185
11 - O-ring
❑ Renew after removing
12 - Gasket
❑ Renew after removing
13 - Dowel pin
❑ 2x
14 - Bolt
❑ Renew after removing
❑ Tightening torque and sequence ⇒ page 19
18 Rep. gr.13 - Crankshaft group
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Sealing flange (pulley end) - tightening torque and sequence
– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. - Fit sealing flange with gasket on cyl‐
inder block
2. -1- Tighten for idler roller
⇒ Item 5 (page 15)
3. -2 … 23- Pre-tighten to 3 Nm.
4. -24 … 28-
Pre-tighten to 3 Nm
1)
5. -1- Tighten bolts for idler roller further to
same tightening torque
⇒ Item 5 (page 15)
2)
6. -2 … 23- Tighten to 9 Nm
7. -24 … 28-
1)
♦
These bolts are only relevant if sealing flange is being in‐
Tighten to 9 Nm
1)
stalled together with oil filter and coolant pump.
2)
♦
Final tightening to same tightening torque allows for set‐
tling of gasket.
1.3 Removing and installing poly V-belt
Special tools and workshop equipment required
♦ Socket Torx T60 - T40087-
♦ Locking tool - T40098-
Removing
– If not accessible from above, remove noise insulation (front)
⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Removing and installing noise insulation .
1. Cylinder block (pulley end) 19
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Caution
Running a used poly V-belt in the opposite direction could
cause irreparable damage.
♦ Before removing the poly V-belt, mark the direction of ro‐
tation with chalk or a felt-tip pen for re-installation.
– Slacken poly V-belt by turning tensioner in clockwise direction
-arrow- using socket Torx T 60 - T40087- .
– Detach poly V-belt and lock tensioner with locking tool -
T40098- .
Installing
Installation is carried out in reverse order; note the following:
– Fit poly V-belt ⇒ page 17 .
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
1.4 Removing and installing tensioner for
poly V-belt
Removing
– Detach poly V-belt from tensioner
⇒ “1.3 Removing and installing poly V-belt”, page 19 .
– Remove bolt -2- and detach poly V-belt tensioner -1-.
Installing
Installation is carried out in reverse order; note the following:
– Install poly V-belt ⇒ page 19 .
Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 15
1.5 Removing and installing vibration damp‐
er
Special tools and workshop equipment required
♦ Counterhold tool - T40298- (not illustrated)
Removing
Preparatory work may be necessary depending on model ⇒ 6-
cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 13 ;
Cylinder block (pulley end); Removing and installing vibration
damper .
– Remove poly V-belt ⇒ page 19 .
20 Rep. gr.13 - Crankshaft group
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– Apply counterhold tool - T40298/1- to vibration damper and
secure with bolts -arrows- (tighten to 23 Nm and fit spacer
sleeves - T40298/2- in between).
– To insert the counterhold tool -T40298/1- , the radiator cowl
may need to be pushed forwards slightly.
– Remove bolt -1-.
– Detach counterhold tool - T40298/1- and remove together with
vibration damper.
Installing
Installation is carried out in reverse order; note the following:
Note
♦
After removing, renew bolts tightened with specified tightening
angle.
♦
Before re-installation, check Hirth serration for deformation,
cracks, damage, scores and corrosion.
♦
If the serration is damaged or there is excessive corrosion,
renew vibration damper.
– Position vibration damper -1- on crankshaft -2- and secure
with a new bolt (pay attention to dowel sleeve -arrow-).
– Apply counterhold tool - T40298/1- to vibration damper and
secure with bolts -arrows- (tighten to 23 Nm and fit spacer
sleeves - T40298/2- in between).
– Tighten bolt -1- for vibration damper.
– Remove counterhold tool - T40298/1- .
– Install poly V-belt ⇒ page 19 .
Additional work depending on model ⇒ 6-cylinder TDI engine, 3.0
ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing vibration damper
Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 15
1. Cylinder block (pulley end) 21
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1.6 Removing and installing bracket for an‐
cillaries
⇒ “1.6.1 Removing and installing bracket for air conditioner com‐
pressor”, page 22
⇒ “1.6.2 Removing and installing bracket for alternator”,
page 23
1.6.1 Removing and installing bracket for air
conditioner compressor
Removing
Preparatory work may be necessary depending on model ⇒ 6-
cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 13 ;
Cylinder block (pulley end); Removing and installing bracket for
ancillaries .
– Drain coolant ⇒ page 177 .
– Air conditioner compressor with poly V-belt drive: Remove
poly V-belt ⇒ page 19 .
– Remove air conditioner compressor from bracket and tie up to
left side ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor; Detaching and attaching air conditioner
compressor at bracket .
– Remove bolts -arrows-.
– Detach coolant pipe (left-side) -1- from bracket for air condi‐
tioner compressor, but leave it in installation position (engine
support has been removed in illustration).
22 Rep. gr.13 - Crankshaft group
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Note
Place a cloth underneath to catch escaping coolant.
– Lift retaining clip and disconnect coolant hose -1-.
– Unscrew bolts -arrows- and detach bracket for air conditioner
compressor.
Installing
Installation is carried out in reverse order; note the following:
Note
Renew gasket and O-ring after removal.
– Install poly V-belt ⇒ page 19 .
– Connect coolant hose with plug-in connector ⇒ 6-cylinder TDI
engine, 3.0 ltr. 4-valve common rail; Rep. gr. 19 ; Radiator/
radiator fans; Exploded view - radiator/radiator fans .
Note
Do not reuse coolant.
– Fill up with coolant ⇒ page 177 .
Additional work depending on model ⇒ 6-cylinder TDI engine, 3.0
ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing bracket for ancillaries
Tightening torques
♦ ⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 15
♦ ⇒ 6-cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr.
19 ; Coolant pipes; Exploded view - coolant pipes
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Exploded view - air conditioner compressor drive unit
1.6.2 Removing and installing bracket for al‐
ternator
Removing
Preparatory work may be necessary depending on model ⇒ 6-
cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 13 ;
Cylinder block (pulley end); Removing and installing bracket for
ancillaries .
– Remove poly V-belt ⇒ page 19 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
1. Cylinder block (pulley end) 23
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– Unclip cover -1-.
– If necessary, remove bolt -2- and detach idler roller.
– Remove bolt -1- for air pipe.
– If fitted, remove bolt -2- for coolant pipe (front).
– Move electrical wiring clear.
– Unscrew bolts -2, 3- and remove bracket -1-.
Installing
Installation is carried out in reverse order; note the following:
– Install poly V-belt ⇒ page 19 .
Additional work depending on model ⇒ 6-cylinder TDI engine, 3.0
ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing bracket for ancillaries
Tightening torques
♦ ⇒ Fig. ““Bracket for alternator -1- - tightening torque and se‐
quence”“ , page 17
♦ ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view
- alternator
1.7 Removing and installing engine support
All procedures are described in ⇒ 6-cylinder TDI engine, 3.0 ltr.
4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing engine support .
1.8 Renewing crankshaft oil seal (pulley
end)
Special tools and workshop equipment required
24 Rep. gr.13 - Crankshaft group
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♦ Oil seal extractor - T40019-
♦ Assembly tool - T40320-
Procedure
– Remove vibration damper ⇒ page 20 / remove pulley ⇒ 6-
cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 13 ;
Cylinder block (pulley end); Removing and installing pulley .
– Adjust inner part of oil seal extractor -T40019- so it is flush with
the outer part and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
seal.
– Clean contact surface and sealing surface.
– Fit guide sleeve -T40320/2- on crankshaft and slide oil seal
-1- into sealing flange (pulley end).
Note
Leave guide sleeve -T40320/2- in position on crankshaft for
pressing in oil seal.
1. Cylinder block (pulley end) 25
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– Insert fitting sleeve -T40320/1- and press on oil seal -2- by
hand.
– Screw in fitting sleeve -T40320/1- using bolt -1- for vibration
damper until it makes contact.
– Remove bolt -1- and detach fitting sleeve -T40320/1- and
guide sleeve -T40320/2- .
– Put fitting sleeve -T40320/1- back on and screw it in again
using bolt -1- until it makes contact.
Note
This step is necessary to ensure that the correct installation depth
of the oil seal is attained.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install vibration damper ⇒ page 20 .
1.9 Removing and installing sealing flange
(pulley end)
Special tools and workshop equipment required
♦ Pin wrench - 3212-
♦ Hose clip pliers - VAS 6362-
Removing
Preparatory work may be necessary depending on model ⇒ 6-
cylinder TDI engine, 3.0 ltr. 4-valve common rail (EA 897 Gen. I);
Rep. gr. 13 ; Cylinder block (pulley end); Removing and installing
sealing flange (pulley end) .
– If fitted, remove tensioner for poly V-belt ⇒ page 20 .
26 Rep. gr.13 - Crankshaft group
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Remove vibration damper ⇒ page 20 / remove pulley ⇒ 6-
cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 13 ;
Cylinder block (pulley end); Removing and installing pulley .
– Remove coolant pipe (front) ⇒ 6-cylinder TDI engine, 3.0 ltr.
4-valve common rail; Rep. gr. 19 ; Coolant pipes; Removing
and installing coolant pipes .
– Unplug electrical connectors -1 ... 4- and move electrical wiring
clear.
– Remove bolts -2-, move coolant connection -1- clear and push
to side.
3 - Ignore
– Loosen bolts -arrows- for coolant pump pulley (counterhold
with pin wrench - 3212- ).
– Remove bolts and take off poly V-belt pulley.
– Unplug electrical connector -1- for valve for oil pressure control
- N428- .
1. Cylinder block (pulley end) 27
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Unclip cover for idler roller.
– Slacken and remove bolts in the sequence: -28 ... 1-.
– Drive crankshaft oil seal out of sealing flange after removing
sealing flange.
Installing
Note
♦
Renew bolts after removing.
♦
Renew gasket, O-ring for temperature regulator and crank‐
shaft oil seal after removing.
♦
Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
– Clean surfaces; they must be free of oil and grease.
– Tighten sealing flange bolts (pulley end) ⇒ page 19 .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install crankshaft oil seal (pulley end) ⇒ page 24 .
– Install coolant pipe (front) ⇒ 6-cylinder TDI engine, 3.0 ltr. 4-
valve common rail; Rep. gr. 19 ; Coolant pipes; Removing and
installing coolant pipes .
– Install vibration damper ⇒ page 20 .
– Install poly V-belt tensioner ⇒ page 20 .
Note
Do not reuse coolant.
– Fill up with coolant ⇒ page 180 .
Additional work depending on model ⇒ 6-cylinder TDI engine, 3.0
ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Renewing crankshaft oil seal (pulley end)
Tightening torques
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 17
♦ ⇒ Fig. ““Sealing flange (pulley end) - tightening torque and se‐
quence”“ , page 19
♦ ⇒ “4.1 Exploded view - intake manifold”, page 214
♦ ⇒ “3.1 Exploded view - cylinder head”, page 103
♦ ⇒ “2.1 Exploded view - coolant pump”, page 183
28 Rep. gr.13 - Crankshaft group
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2 Cylinder block (gearbox end)
⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 29
⇒ “2.2 Removing and installing drive plate”, page 30
⇒ “2.3 Renewing crankshaft oil seal (gearbox end)”, page 32
2.1 Exploded view - cylinder block (gearbox end)
Note
Secure engine to engine and gearbox support when performing assembly work ⇒ 6-cylinder TDI engine, 3.0
ltr. 4-valve common rail; Rep. gr. 10 ; Removing and installing engine; Securing engine to engine and gearbox
support .
1 - Bolt
❑ Renew after removing
❑ Clean threads in crank‐
shaft before screwing in
new bolts ⇒ page 30
❑ 60 Nm +90°
2 - Drive plate
❑ Check holes for clutch
module/torque convert‐
er for cracks and scoring
❑ Removing and installing
⇒ page 30
3 - Dowel pin
4 - Crankshaft
5 - Oil seal
❑ For crankshaft (gearbox
end)
❑ Renewing ⇒ page 32
6 - Sender wheel
❑ For engine speed send‐
er - G28-
Caution
Risk of magnetic fields
causing irreparable
damage to sender
wheel.
♦The sender wheel must
be kept away from mag‐
nets (e.g. base of torch,
loudspeaker).
♦If the drive plate/flywheel
or the sender wheel itself
has been removed or re‐
newed, check that the
sender wheel is operat‐
ing correctly before in‐
stallation ⇒ page 39 .
❑ Removing and installing ⇒ page 38
2. Cylinder block (gearbox end) 29
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❑ Checking sender wheel ⇒ page 39
2.2 Removing and installing drive plate
Special tools and workshop equipment required
♦ Counterhold tool - 10-201-
30 Rep. gr.13 - Crankshaft group
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Removing
Caution
Risk of magnetic fields causing irreparable damage to sender
wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation
⇒ “3.7 Checking sender wheel”, page 39 .
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Removing gearbox or ⇒ Gearbox; Rep. gr.
37 ; Removing and installing gearbox; Removing gearbox .
– Insert counterhold tool - 10-201- to slacken bolts for drive plate
-1-.
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 and sender wheel.
Installing
Installation is carried out in reverse order; note the following:
Caution
Risk of magnetic fields causing irreparable damage to sender
wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation ⇒ page 39 .
Note
After removing, renew bolts tightened with specified tightening
angle.
2. Cylinder block (gearbox end) 31
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Threads in crankshaft must be cleaned before any further as‐
sembly work is performed.
– Clean crankshaft flange until all residual adhesive has been
removed completely.
• Ensure you do not damage oil seal when cleaning flange.
• Use a vacuum cleaner to hoover up residual adhesive; do NOT
use compressed air.
– Remove residual adhesive from one of the old bolts -2- for
drive plate using wire brush and remove oil residue using
brake cleaner.
– Screw cleaned bolt into a thread on crankshaft -1- and out
again; repeat this action until no further residual adhesive ap‐
pears.
• Do not screw bolt in too far; otherwise, the camshaft timing
chain located behind it may be damaged.
– When no further residual adhesive appears, repeat the pro‐
cedure for the other crankshaft threads.
• Finally, use a vacuum cleaner to hoover up residual adhesive;
do NOT use compressed air.
– Clean crankshaft flange with a cloth.
• Thread in crankshaft must be free of oil and grease.
– Check sender wheel ⇒ page 39 .
– Install sender wheel -arrow-.
– Pay attention to dowel pin when installing drive plate.
– Fit counterhold tool - 10-201- the other way round to tighten
bolts.
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 29
2.3 Renewing crankshaft oil seal (gearbox
end)
Special tools and workshop equipment required
♦ Fitting tool - T10122B-
32 Rep. gr.13 - Crankshaft group
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♦ Extractor tool - T20143/2-
Procedure
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Removing gearbox or ⇒ Gearbox; Rep. gr.
37 ; Removing and installing gearbox; Removing gearbox .
– Remove drive plate ⇒ page 30 .
– Detach sender wheel -arrow-.
– Pry out oil seal using extractor tool -T20143/2- .
– Clean contact surface and sealing surface.
– Fit assembly aid -T10122/1- onto guide piece - T10122/6- and
slide oil seal -A- onto guide piece.
– Detach assembly aid -T10122/1- .
2. Cylinder block (gearbox end) 33
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– Fit guide piece - T10122/6- onto crankshaft.
– Bolt guide piece to crankshaft through securing points -A- us‐
ing bolts -arrows-.
Caution
Risk of leaks if installed incorrectly.
♦ Slide oil seal onto crankshaft by hand to prevent sealing
lip on oil seal from folding over.
– Slide oil seal over guide piece - T10122/6- onto crankshaft by
hand.
– Press in oil seal evenly all round using thrust piece -
T10122/5- .
– Remove guide piece - T10122/6- .
– Check that oil seal and its sealing lip are correctly seated. If
sealing lip is partially folded over, repeat procedure with a new
oil seal.
– Install drive plate ⇒ page 30 .
34 Rep. gr.13 - Crankshaft group
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3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 35
⇒ “3.2 Crankshaft dimensions”, page 36
⇒ “3.3 Allocation of main bearing shells”, page 37
⇒ “3.4 Measuring axial clearance of crankshaft”, page 37
⇒ “3.5 Measuring radial clearance of crankshaft”, page 38
⇒ “3.6 Removing and installing sender wheel”, page 38
⇒ “3.7 Checking sender wheel”, page 39
3.1 Exploded view - crankshaft
Note
Secure engine to engine and gearbox support when performing assembly work ⇒ 6-cylinder TDI engine, 3.0
ltr. 4-valve common rail; Rep. gr. 10 ; Removing and installing engine; Securing engine to engine and gearbox
support .
1 - Crankshaft
❑ Measuring axial clear‐
ance ⇒ page 37
❑ Measuring radial clear‐
ance ⇒ page 38
❑ Crankshaft dimensions
⇒ page 36
2 - Dowel sleeve
❑ 4x
❑ Insert in cylinder block
3 - Retaining frame
4 - Bolt
❑ Renew after removing
❑ Use old bolts when
measuring radial clear‐
ance
❑ Tightening torque and
sequence ⇒ page 36
5 - Thrust washer
❑ Only fitted on 3rd crank‐
shaft bearing
❑ Installation position: oil
grooves face outwards
❑ Note location
6 - Bearing shell
❑ For retaining frame
(without oil groove)
❑ Renew used bearing
shells
❑ Install new bearing
shells for retaining
frame with correct col‐
oured markings ⇒ page 37
3. Crankshaft 35
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7 - Dowel pin
❑ Check that pin is firmly seated in crankshaft
8 - Thrust washer
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil grooves face outwards
9 - Bearing shell
❑ For cylinder block (with oil groove)
❑ Renew used bearing shells
❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ page 37
Retaining frame - tightening torque and sequence
Note
After removing, renew bolts tightened with specified tightening
angle.
– Insert two dowel sleeves in cylinder block.
– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. -1 … 16- 30 Nm
2. -1 … 16- 50 Nm
3. -1 … 16- Turn 180° further
Position of dowel sleeves
– Check that dowel sleeves -1 ... 4- are inserted in retaining
frame at positions shown in illustration.
• -Arrow-: Pulley end.
3.2 Crankshaft dimensions
Honing di‐
mension
Basic dimen‐
sion
Main bearing journal
∅
mm
65.000 – 0.022
– 0.042
Conrod journal ∅
mm
60.000 – 0.022
– 0.042
36 Rep. gr.13 - Crankshaft group
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3.3 Allocation of main bearing shells
Allocation of crankshaft bearing shells for cylinder block
Bearing shells of the correct thickness are matched to the bear‐
ings in the cylinder block at the factory. Coloured dots on the
bearing shells are used to identify the bearing shell thickness.
• -Arrow-: Pulley end.
The allocation of the bearing shells to the cylinder block is iden‐
tified by a code letter next to the relevant bearing.
Letter on cylinder block Colour coding of bearing
R = Red
G = Yellow
B = Blue
Allocation of crankshaft bearing shells for retaining frame
Bearing shells of the correct thickness are matched to the bear‐
ings in the retaining frame at the factory. Coloured dots on the
side of the bearing shells are used to identify the bearing shell
thickness.
The allocation of the bearing shells to the bearing positions in the
retaining frame is indicated by a sequence of letters on the fly‐
wheel flange on the crankshaft. The first letter in the sequence
stands for bearing “1”, the second letter for bearing “2”, etc.
Letter on crankshaft Colour coding of bearing
R = Red
G = Yellow
B = Blue
3.4 Measuring axial clearance of crankshaft
Special tools and workshop equipment required
♦ Universal dial gauge bracket - VW 387-
3. Crankshaft 37
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♦ Dial gauge - VAS 6079-
Procedure
– Secure dial gauge - VAS 6079- with universal dial gauge
bracket - VW 387- to cylinder block as shown in illustration.
– Apply dial gauge to crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.09 ... 0.25 mm.
3.5 Measuring radial clearance of crank‐
shaft
Special tools and workshop equipment required
♦ Plastigauge
Procedure
– Remove retaining frame and clean bearing journals.
– 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 retaining frame and secure with old bolts ⇒ page 36 without
rotating crankshaft.
– Remove retaining frame again.
– Compare width of Plastigauge with measurement scale.
Radial clearance:
• New: 0.018 ... 0.045 mm.
– When carrying out final assembly, renew bolts.
3.6 Removing and installing sender wheel
Removing
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Removing gearbox or ⇒ Gearbox; Rep. gr.
37 ; Removing and installing gearbox; Removing gearbox .
– Remove drive plate ⇒ page 30 .
38 Rep. gr.13 - Crankshaft group
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Caution
Risk of magnetic fields causing irreparable damage to sender
wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation
⇒ “3.7 Checking sender wheel”, page 39 .
– Detach sender wheel -arrow-.
Installing
Installation is carried out in reverse order; note the following:
– Install drive plate ⇒ page 30 .
3.7 Checking sender wheel
Caution
Risk of magnetic fields causing irreparable damage to sender
wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation.
Special tools and workshop equipment required
♦ Sensor gauge - T10473-
3. Crankshaft 39
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
Procedure
• Sender wheel removed
– Check entire circumference of sender wheel using sensor
gauge - T10473- , as shown in illustration.
Inspection image of sender wheel
A - Sender wheel OK
B - Sender wheel defective
40 Rep. gr.13 - Crankshaft group
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4 Balance shaft
⇒ “4.1 Exploded view - balance shaft”, page 41
⇒ “4.2 Removing and installing balance shaft”, page 41
⇒ “4.3 Renewing roller bearing”, page 48
4.1 Exploded view - balance shaft
1 - Bolt
❑ 23 Nm
2 - Drive chain sprocket
❑ For balance shaft
3 - Balance shaft with balance
weight
❑ Gearbox end
❑ Removing and installing
⇒ page 41
❑ Balance shaft must be
renewed if bolt -item 4has been loosened
4 - Bolt
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
❑ 9 Nm
5 - Bearing plate
6 - Roller bearing
❑ Renewing ⇒ page 48
7 - Thrust washer
8 - Bolt
❑ Use locking pin - 3359-
as counterhold when
loosening and tighten‐
ing
❑ Renew after removing
❑ 20 Nm +45°
9 - Balance weight
❑ Pulley end
10 - Roller bearing
❑ Renewing ⇒ page 48
4.2 Removing and installing balance shaft
Special tools and workshop equipment required
4. Balance shaft 41
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♦ Locking pin - 3359-
♦ Locking pin - T10060A- (2x)
♦ Key - T40049-
♦ Locking pin - T40237-
42 Rep. gr.13 - Crankshaft group
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
♦ Locking pin - T40316-
Removing
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Removing gearbox or ⇒ Gearbox; Rep. gr.
37 ; Removing and installing gearbox; Removing gearbox .
– Remove sealing flange (pulley end) ⇒ page 26 .
– Remove timing chain cover (bottom) ⇒ page 66 .
Caution
Risk of damage to valves and piston crowns.
♦ The crankshaft and camshafts must only be turned with
the chain drive mechanism fully installed.
Caution
Risk of damage to drive chain if thread of bolt exceeds speci‐
fied length.
♦ Use bolts with a maximum thread length -a- of 22 mm to
attach key -T40049- .
♦ If no suitable bolts are available, position suitable washer
(s) under bolt head so that remaining thread length does
not exceed 22 mm.
– Secure special wrench - T40049- onto crankshaft -arrows-.
Caution
Irreparable damage can be caused if the camshaft timing chain
slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– Rotate crankshaft in normal direction of rotation to “TDC”.
• It should be possible to lock camshafts with locking pins T10060A- .
4. Balance shaft 43
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– Lock exhaust camshaft of cylinder bank 1 (right-side) at “TDC”
by inserting locking pin - T10060A- in hole -arrow-.
– Lock inlet camshaft of cylinder bank 2 (left-side) at “TDC” by
inserting locking pin - T10060A- in hole -arrow-.
A4/A5: Remove subframe cross brace ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing sub‐
frame cross brace .
– Unscrew plug -arrow- from sump (top section).
– Screw locking pin - T40237- into hole (20 Nm); if necessary,
turn crankshaft -1- backwards and forwards slightly to fully
centralise locking pin.
44 Rep. gr.13 - Crankshaft group
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– Press tensioning rail of camshaft timing chain tensioner in di‐
rection of -arrow- and lock chain tensioner by inserting locking
pin -T40316- .
– Lock balance shaft with locking pin - 3359- .
– Remove bolts -arrows- and detach drive chain sprocket -1-
from balance shaft.
Note
The camshaft timing chain must not be removed from the cam‐
shaft sprockets or the camshaft.
– Remove bolt -arrow- at pulley end and detach balance weight
-1- and washer -2- from balance shaft.
– Remove locking pin - 3359- at gearbox end and remove bal‐
ance shaft -1- towards rear.
4. Balance shaft 45
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Installing
Installation is carried out in reverse order; note the following:
• Crankshaft locked in “TDC” position with locking pin T40237- .
• Lock exhaust camshaft of cylinder bank 1 (right-side) at “TDC”
using locking pin - T10060A- .
• Lock inlet camshaft of cylinder bank 2 (left-side) at “TDC” using
locking pin - T10060A- .
– Move balance shaft -1- into installation position on gearbox
end and lock in “TDC” position using locking pin - 3359- .
46 Rep. gr.13 - Crankshaft group
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– Place washer -1- to installation position on pulley end and fit
balance weight -2- onto balance shaft.
• Machined surface -arrow- of balance weight must be posi‐
tioned over machined surface of balance shaft.
– Tighten bolt for balance weight.
– Fit drive chain sprocket -1- with camshaft timing chain onto
balance shaft on gearbox end.
• The elongated holes in the drive chain sprocket must be
aligned centrally over the tapped holes in the balance shaft.
– Loosely screw in bolts -arrows-.
• It should just be possible to turn the drive chain sprocket on
the intermediate drive without axial movement.
– Press tensioning rail of camshaft timing chain tensioner in di‐
rection of -arrow- and remove locking pin -T40316- .
– Release chain tensioner.
– Tighten bolts -arrows- at drive chain sprocket -1- for balance
shaft.
– Remove locking pin - T40237- and locking pin - 3359- .
4. Balance shaft 47
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– Remove locking pin - T10060A- (both sides).
Note
If it is difficult to remove one or both locking pins -T10060A- , the
valve timing must be checked ⇒ page 84 .
– Install timing chain cover (bottom) ⇒ page 66 .
– Install sealing flange (pulley end) ⇒ page 26 .
– A4/A5: Install subframe cross brace ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing
subframe cross brace .
Tightening torques
♦ ⇒ “4.1 Exploded view - balance shaft”, page 41
♦ Plug for “TDC” marking ⇒ Item 19 (page 155)
4.3 Renewing roller bearing
Special tools and workshop equipment required
♦ Special tool -T40392-
Pulling out
• Engine secured to engine and gearbox support ⇒ 6-cylinder
TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 10 ; Re‐
moving and installing engine; Securing engine to engine and
gearbox support .
– Remove crankshaft ⇒ page 35 .
– Remove balance shaft ⇒ page 41 .
– Position special tool correctly on roller bearing:
• The chamfer -arrow- faces towards the roller bearing.
48 Rep. gr.13 - Crankshaft group
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Pull roller bearings (front -1- and rear -2-) out inwards using
spindle -T40392/1- and adapters -T40392/2- / -T40392/3- ; to
do so, turn nut -T40392/4- .
– Detach special tool and remove roller bearing.
Installing
– Position adapter correctly on roller bearing:
• Chamfer -arrow- must face roller bearing; chamfer determines
installation depth.
– Pull roller bearings (front -1- and rear -2-) in as far as stop
using spindle -T40392/1- and adapters -T40392/2- / T40392/3- ; to do so, turn nut -T40392/4- .
• The sides of the roller bearings with identification lettering face
outwards.
– Install balance shaft ⇒ page 41 .
– Install crankshaft ⇒ page 35 .
4. Balance shaft 49
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
5 Pistons and conrods
⇒ “5.1 Exploded view - pistons and conrods”, page 50
⇒ “5.2 Removing and installing pistons”, page 52
⇒ “5.3 Measuring piston projection at TDC”, page 53
⇒ “5.4 Checking pistons and cylinder bores”, page 56
⇒ “5.5 Checking radial clearance of conrod bearings”,
page 57
5.1 Exploded view - pistons and conrods
Note
♦
All bearing and running surfaces must be oiled before assembling.
♦
Oil spray jet for piston cooling ⇒ page 51 .
1 - Bolts
❑ Renew after removing
❑ Lubricate threads and
contact surface
❑ 35 Nm +90°
2 - Conrod bearing cap
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod
❑ Mark installation posi‐
tion for re-installation
❑ Mark cylinder allocation
in colour -B-
⇒ page 52
❑ Note when fitting: wide
contact shoulder -Amust face same side on
conrod and conrod
bearing cap
3 - Bearing shells
❑ Note installation posi‐
tion
❑ Renew used bearing
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material; refer to
⇒ Electronic parts cata‐
logue
❑ Ensure that retaining lugs are securely seated.
4 - Conrod
❑ With industrially cracked conrod bearing cap
50 Rep. gr.13 - Crankshaft group
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❑ Mark cylinder allocation in colour -B- ⇒ page 52
❑ Axial clearance for each conrod pair (when new): 0.20 … 0.44 mm
❑ Measuring radial clearance ⇒ page 57
❑ Installation position ⇒ page 52
❑ Only renew as a complete set
❑ Note when fitting: wide contact shoulder -A- must face same side on conrod and conrod bearing cap
5 - Circlip
❑ Renew after removing
6 - Piston pin
❑ Removing and installing ⇒ “5.2 Removing and installing pistons”, page 52
7 - Piston
❑ Measuring piston projection at “TDC” ⇒ page 53
❑ Mark installation position and cylinder number ⇒ page 52
❑ Renew piston if cracking is visible on piston crown or piston skirt
❑ Removing and installing ⇒ page 52
❑ Checking pistons and cylinder bores ⇒ page 56
8 - Circlip
❑ Renew after removing
9 - Piston rings
❑ Measuring ring gap ⇒ page 56
❑ Measuring ring-to-groove clearance ⇒ page 57
❑ Use piston ring pliers (commercially available) to remove and install
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Offset gaps by 120°
Oil spray jet for piston cooling
1 - Bolt, 9 Nm
2 - Oil spray jet with spray nozzle valve for piston cooling
Caution
Risk of damage to oil spray jets.
♦ Do not bend oil spray jets.
♦ Check that oil spray jets have adequate clearance after
re-installing pistons.
♦ Always renew bent oil spray jets.
5. Pistons and conrods 51
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Installation position of pistons
Caution
Risk of damage to piston crown.
♦ If you intend to re-install used pistons, mark the cylinder
number on the piston crown using paint. Do not attempt to
mark the piston crown with a centre punch or by making
a scratch, notch or similar.
• Installation position: Arrow -item 1- on piston crown points to
pulley end.
Marking conrods
– Before removing, mark mating positions of conrods and con‐
rod bearing caps with coloured pen -arrow-.
Note
♦
Only renew conrods as a complete set.
♦
Do not interchange conrod bearings.
Conrod installation position
The larger contact shoulder on the conrod -arrows- faces towards
the adjacent crankshaft bearing.
Note
Illustration shows first conrod pair.
5.2 Removing and installing pistons
Special tools and workshop equipment required
♦ Pin - VW 222A-
♦ Piston ring clamp, commercially available
52 Rep. gr.13 - Crankshaft group
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Removing
• Engine secured to engine and gearbox support ⇒ 6-cylinder
TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 10 ; Re‐
moving and installing engine; Securing engine to engine and
gearbox support .
– Remove cylinder head ⇒ page 109 .
– Remove sump (top section) ⇒ page 158 .
– Mark installation position and matching of conrod bearing caps
to cylinder and to conrods for re-installation ⇒ page 52 .
– Unbolt conrod bearing caps.
– Pull out pistons upwards with conrods.
– Take circlip -2- out of piston pin boss.
– Use drift - VW 222A- to drive out piston pin -3-.
Note
If piston pin is difficult to remove, heat piston to approx. 60 °C.
– Detach piston -1- from conrod -4-.
Installing
Installation is carried out in reverse order; note the following:
Note
After removing, renew bolts tightened with specified tightening
angle.
– Oil running surfaces of bearing shells.
– Install pistons using commercially available piston ring clamp.
Installation position:
• Pistons ⇒ page 52
• Conrods ⇒ page 52
– Install conrod bearing caps according to markings.
– Install sump (upper section) ⇒ page 158 .
– Install cylinder head ⇒ page 109 .
Tightening torques
♦ ⇒ “5.1 Exploded view - pistons and conrods”, page 50
5.3 Measuring piston projection at TDC
Note
Measure piston projection at “TDC” when installing new pistons
or a short engine.
Special tools and workshop equipment required
5. Pistons and conrods 53
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♦ Measuring bridge -VW 382/7- from measuring tool - VW 382-
♦ Measuring plate -VW 385/17- from universal measuring tool -
VW 385-
♦ Dial gauge - VAS 6079-
54 Rep. gr.13 - Crankshaft group
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Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in illustration.
– Measure projection at each piston at both locations marked
with -arrows- (seen in longitudinal direction of engine: at front
and rear of piston).
Note
♦
If the values measured for piston projection are not the same
for all pistons, use the highest value to determine the correct
gasket size.
♦
The cylinder head gasket size must be determined separately
for each cylinder bank.
– Depending on piston projection, install corresponding cylinder
head gasket according to following table:
Piston projection above top sur‐
face of cylinder block
0.81…0.91 mm 1
0.91…0.96 mm 2
0.96…1.07 mm 3
Identification of cylinder head gasket
1 - Part number
2 - Holes
Note
Identification
(no. of holes)
The gaskets for the left and right cylinder heads have different
shapes and cannot be interchanged.
5. Pistons and conrods 55
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5.4 Checking pistons and cylinder bores
Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 10 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.05 mm.
There are different piston sizes specifically matched to the differ‐
ent dimensions of the cylinder block.
Piston ∅ mm
Nominal dimension
Repair oversize
1)
•
Dimensions not including coating (thickness 0.02 mm). The
82.924 … 82.936
82.964 … 82.976
coating will wear down partly in service.
Measuring cylinder bore
– Use a cylinder gauge - VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.08 mm.
1)
1)
Cylinder bore ∅ mm
Nominal dimension
Repair oversize
1)
•
Measure at 50 mm into cylinder bore.
83.006 … 83.014
83.046 … 83.054
1)
1)
Measuring piston ring gap
– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 50 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring new
mm
Wear limit
mm
1st compression ring 0.26 … 0.36 0.60
2nd compression ring 0.70 … 0.90 1.20
Oil scraper ring 0.20 … 0.40 0.70
56 Rep. gr.13 - Crankshaft group
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Measuring ring-to-groove clearance
– Clean groove in piston before checking clearance.
Piston ring new
mm
1st compression ring 0.09 … 0.13 0.160
2nd compression ring 0.05 … 0.09 0.11
Oil scraper ring 0.03 … 0.07 0.10
Wear limit
mm
5.5 Checking radial clearance of conrod
bearings
Special tools and workshop equipment required
♦ 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 1 (page 50) without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigauge with measurement scale.
Radial clearance:
• New: 0.020 ... 0.069 mm.
– Renew conrod bolts.
5. Pistons and conrods 57
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15 – Cylinder head, valve gear
1 Timing chain cover
⇒ “1.1 Exploded view - timing chain cover”, page 58
⇒ “1.2 Removing and installing timing chain cover”, page 61
1.1 Exploded view - timing chain cover
1 - Bolt
❑ Renew after removing
❑ Tightening torque and
sequence ⇒ page 61
2 - Sender wheel
❑ For engine speed send‐
er - G28-
3 - Oil seal
❑ For crankshaft (gearbox
end)
❑ Removing and installing
⇒ page 32
4 - Timing chain cover (bottom)
❑ Removing and installing
⇒ page 66
5 - Dowel sleeve
❑ 2x
6 - Gasket
❑ Renew after removing
7 - Bolt
❑ Renew after removing
❑ Tightening torque and
sequence ⇒ page 60
8 - Timing chain cover (leftside)
❑ Removing and installing
⇒ page 61
9 - Bolt
❑ Renew after removing
❑ Tightening torque and
sequence ⇒ page 60
10 - Reed valve
❑ For crankcase breather
11 - Bolt
❑ 3 Nm
12 - Reed valve
❑ For crankcase breather
13 - Bolt
❑ 3 Nm
58 Rep. gr.15 - Cylinder head, valve gear
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14 - Cover
15 - Bolt
❑ 23 Nm
❑ If insert tool, XZN 10 - V.A.G 1331/15- is used, set torque wrench to 20 Nm
16 - O-ring
❑ Renew after removing
17 - Bolt
❑ 9 Nm
18 - Line
❑ For crankcase breather
19 - O-ring
❑ Renew after removing
20 - Line
❑ For crankcase breather
21 - O-ring
❑ Renew after removing
22 - Line
❑ For crankcase breather
23 - Bolt
❑ 9 Nm
24 - O-ring
❑ Renew after removing
25 - Gasket
❑ Renew after removing
26 - Clamping sleeve
❑ 3x
❑ Prevents ingress of lubricant into threaded hole
27 - Bolt
❑ Renew after removing
❑ Tightening torque and sequence ⇒ page 60
28 - Timing chain cover (right-side)
❑ Removing and installing ⇒ page 61
29 - Bolt
❑ 3 Nm
30 - Reed valve
❑ For crankcase breather
31 - Bolt
❑ Renew after removing
❑ Tightening torque and sequence ⇒ page 60
32 - Gasket
❑ Renew after removing
33 - Bolt
❑ 3 Nm
34 - Reed valve
❑ For crankcase breather
1. Timing chain cover 59
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35 - Dowel sleeve
❑ 2x
36 - Sealing element
❑ 2x
37 - Cover
❑ Not fitted on all versions
38 - Bolt
❑ Tightening torque ⇒ Item 8 (page 302)
39 - Engine speed sender - G28-
❑ Removing and installing ⇒ page 306
Timing chain cover (top left) - tightening torque and tightening
sequence
Note
After removing, renew bolts tightened with specified tightening
angle.
– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. -1 … 9- Screw in by hand until contact is made
2. -1 … 9- 8 Nm
3. -1 … 9- 8 Nm (this step is performed to allow
for settling of timing chain cover)
4. -1 … 9- Turn 90° further
Timing chain cover (top right) - tightening torque and tightening
sequence
Note
After removing, renew bolts tightened with specified tightening
angle.
– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. -1 … 9- Screw in by hand until contact is made
2. -1 … 9- 8 Nm
3. -1 … 9- 8 Nm (this step is performed to allow
for settling of timing chain cover)
4. -1 … 9- Turn 90° further
60 Rep. gr.15 - Cylinder head, valve gear
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Timing chain cover (bottom) - tightening torque and tightening
sequence
Note
After removing, renew bolts tightened with specified tightening
angle.
– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. -1 … 18- 2 Nm
2. -1 … 18- 8 Nm
3. -1 … 18- Turn 90° further
1.2 Removing and installing timing chain
cover
⇒ “1.2.1 Removing and installing timing chain cover (top left)”,
page 61
⇒ “1.2.2 Removing and installing timing chain cover (top right)”,
page 63
⇒ “1.2.3 Removing and installing timing chain cover (bottom)”,
page 66
1.2.1 Removing and installing timing chain
cover (top left)
Special tools and workshop equipment required
♦ Electric drill with plastic brush
♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
– Remove exhaust manifold (left-side) ⇒ 6-cylinder TDI engine,
3.0 ltr. 4-valve common rail; Rep. gr. 26 ; Exhaust manifolds;
Removing and installing exhaust manifolds .
– Unscrew bolts -arrows- and remove engine lifting eye (rear
left) -1-.
– Remove cylinder head cover (left-side) ⇒ page 117 .
1. Timing chain cover 61
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– Loosen bolts in the sequence -9 ... 1-.
– Carefully release timing chain cover (top left) from bonded joint
and remove cover.
Caution
Risk of irreparable damage to engine.
♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine when the timing chain cover (top) is removed.
Installing
– Remove old sealant from sealing surfaces on timing chain
cover.
Caution
Protect lubrication system against contamination.
♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.
♦ Put on safety goggles.
– Remove remaining sealant on timing chain cover -1- and cyl‐
inder head using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
Note
Note expiry date of sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5
mm).
62 Rep. gr.15 - Cylinder head, valve gear
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– Fit gasket -1-.
– Apply sealant at joints between cylinder head and timing chain
cover (bottom) -arrow-, as shown in illustration.
Caution
Make sure lubrication system is not clogged by excess sealant.
♦ The sealant bead must not be thicker than specified.
• The bead of sealant must project 1.5 … 2.0 mm above the
sealing surface.
– Apply sealant beads -1 and 2- onto clean sealing surface of
timing chain cover (left-side), as illustrated.
Note
Install timing chain cover within 5 minutes of applying sealant.
– Fit timing chain cover and tighten bolts ⇒ page 60 .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install cylinder head cover (left-side) ⇒ page 117 .
– Install exhaust manifold (left-side) ⇒ 6-cylinder TDI engine,
3.0 ltr. 4-valve common rail; Rep. gr. 26 ; Exhaust manifolds;
Removing and installing exhaust manifolds .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (top left) - tightening torque and
tightening sequence”“ , page 60
♦ ⇒ “3.1 Exploded view - cylinder head”, page 103
1.2.2 Removing and installing timing chain
cover (top right)
Special tools and workshop equipment required
♦ Insert tool, XZN 10 - V.A.G 1331/15- (not illustrated)
♦ Electric drill with plastic brush
♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
– Remove turbocharger ⇒ page 201 .
– Remove cylinder head cover (right-side) ⇒ page 114 .
1. Timing chain cover 63
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– Remove bolt -3- and press air pipe -2- slightly towards rear.
1, 4 - Ignore
– Unscrew bolts -arrows- and detach bracket -1- for turbocharg‐
er.
Note
Use insert tool, XZN 10 - V.A.G 1331/15- for bolts that are difficult
to access.
– Loosen bolts in the sequence -9 ... 1-.
– Carefully release timing chain cover (top right) from bonded
joint and detach.
Caution
Risk of irreparable damage to engine.
♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine when the timing chain cover (top) is removed.
Installing
– Remove old sealant from sealing surfaces on timing chain
cover.
Caution
Protect lubrication system against contamination.
♦ Cover exposed parts of the engine.
64 Rep. gr.15 - Cylinder head, valve gear
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WARNING
Risk of eye injury.
♦ Put on safety goggles.
– Remove remaining sealant on timing chain cover -1- and cyl‐
inder head using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
Note
Note expiry date of sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5
mm).
– Fit gasket -1-.
– Apply sealant at joints between cylinder head and timing chain
cover (bottom) -arrow-, as shown in illustration.
Caution
Make sure lubrication system is not clogged by excess sealant.
♦ The sealant bead must not be thicker than specified.
• The bead of sealant must project 1.5 … 2.0 mm above the
sealing surface.
1. Timing chain cover 65
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– Apply sealant beads -1 and 2- onto clean sealing surface of
timing chain cover (right-side), as illustrated.
Note
Install timing chain cover within 5 minutes of applying sealant.
– Fit timing chain cover and tighten bolts ⇒ page 60 .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install cylinder head cover (right-side) ⇒ page 114 .
– Install turbocharger ⇒ page 201 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (top right) - tightening torque and
tightening sequence”“ , page 60
♦ ⇒ “1.1 Exploded view - turbocharger”, page 198
♦ ⇒ “2.1 Exploded view - charge air system”, page 206
1.2.3 Removing and installing timing chain
cover (bottom)
Special tools and workshop equipment required
♦ Socket - T10574-
♦ Insert tool, XZN 10 - V.A.G 1331/15- (not illustrated)
♦ Electric drill with plastic brush
♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
Preparatory work may be necessary depending on model ⇒ 6-
cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 15 ;
Timing chain cover; Removing and installing timing chain cover .
– Remove drive plate ⇒ page 30 .
– Remove timing chain covers (top) ⇒ page 61 , ⇒ page 63 .
66 Rep. gr.15 - Cylinder head, valve gear
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– Remove bolt -1-.
– Loosen bolts -arrows- 2 turns using socket - T10574- .
Note
The bolts -arrows- must not be loosened any further than 2 turns.
– Remove bolts -arrows-, lift exhaust gas recirculation cooler
slightly and detach cover -1-.
Note
Use insert tool, XZN 10 - V.A.G 1331/15- for bolts that are difficult
to access.
– Unplug electrical connector -2- for engine speed sender -
G28- . (Shown with gearbox installed.)
1 - Ignore
1. Timing chain cover 67
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– Slacken and remove bolts in the sequence: -18 ... 1-.
– Carefully release timing chain cover (bottom) from bonded
joint and remove cover.
– Press crankshaft oil seal (gearbox end) out of timing chain
cover (bottom).
Installing
– Remove old sealant from grooves on timing chain cover and
from sealing surfaces.
Caution
Protect lubrication system against contamination.
♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.
♦ Put on safety goggles.
– Remove remaining sealant on timing chain cover -1- and cyl‐
inder block using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.
Note
Note expiry date of sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5
mm).
68 Rep. gr.15 - Cylinder head, valve gear
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– Fit sealing elements -arrows-.
Caution
Make sure lubrication system is not clogged by excess sealant.
♦ The sealant bead must not be thicker than specified.
– Apply beads of sealant onto clean sealing surface of timing
chain cover (bottom) as illustrated.
• The beads of sealant -1, 3, 5- must be 1.5 ... 2.0 mm thick.
• The beads of sealant around drillings -2- and -4- must be
1.5 … 2.0 mm thick.
Note
Install timing chain cover within 5 minutes of applying sealant.
– Check whether dowel sleeves -1, 5- are fitted in cylinder block;
install if necessary.
– Check whether clamping sleeves -2, 3, 4- are fitted in cylinder
block; install if necessary.
– Fit timing chain cover (bottom) and tighten bolts ⇒ page 61 .
Remaining installation steps are carried out in reverse sequence;
note the following:
Note
Renew seal and sealing plugs after removing.
– Install crankshaft oil seal (gearbox end) ⇒ page 32 .
– Install exhaust gas recirculation cooler ⇒ page 291 .
– Install timing chain covers (top)
⇒ “1.2.1 Removing and installing timing chain cover (top left)”,
page 61 and
⇒ “1.2.2 Removing and installing timing chain cover (top
right)”, page 63 .
– Install drive plate ⇒ page 30 .
Additional work depending on model ⇒ 6-cylinder TDI engine, 3.0
ltr. 4-valve common rail; Rep. gr. 15 ; Timing chain cover; Re‐
moving and installing timing chain cover
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (bottom) - tightening torque and
tightening sequence”“ , page 61
♦ ⇒ “1.1 Exploded view - timing chain cover”, page 58
1. Timing chain cover 69
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2 Chain drive
⇒ “2.1 Exploded view - camshaft timing chains”, page 70
⇒ “2.2 Exploded view - drive chain for high-pressure pump”, page
72
⇒ “2.3 Exploded view - drive chain for oil pump”, page 73
⇒ “2.4 Exploded view - intermediate drive”, page 74
⇒ “2.5 Removing camshaft timing chain from camshafts”,
page 74
⇒ “2.6 Removing and installing camshaft timing chain”,
page 85
⇒ “2.7 Removing and installing drive chain for high-pressure
pump”, page 94
⇒ “2.8 Installing intermediate drive”, page 96
2.1 Exploded view - camshaft timing chains
1 - Bolt
❑ 23 Nm
2 - Chain slip preventer
3 - Crankshaft
❑ With sprocket for cam‐
shaft timing chain
4 - Guide rail
❑ Note installation posi‐
tion
5 - Guide pin
❑ For guide rail
❑ Renew after removing
❑ 5 Nm +45°
6 - Camshaft timing chain
❑ Removing from cam‐
shafts ⇒ page 74
❑ Before removing, mark
running direction with
paint
❑ Removing and installing
⇒ page 85
7 - Bolt
❑ 23 Nm
8 - Camshaft chain sprocket
❑ Cylinder bank 2 (left-
side)
❑ Installation position:
Side with lettering legi‐
ble from gearbox end
9 - Guide rail
❑ Note installation posi‐
tion
70 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
10 - Guide pin
❑ For guide rail
❑ Renew after removing
❑ 5 Nm +45°
11 - Bolt
❑ Tightening torque ⇒ Item 1 (page 41)
12 - Drive chain sprocket
❑ For balance shaft
13 - Guide rail
❑ Note installation position
14 - Guide pin
❑ For guide rail
❑ Renew after removing
❑ 5 Nm +45°
15 - Camshaft chain sprocket
❑ Cylinder bank 1 (right-side)
❑ Installation position: Side with lettering legible from gearbox end
16 - Bolt
❑ 23 Nm
17 - Guide pin
❑ For tensioning rail
❑ Renew after removing
❑ 5 Nm +45°
18 - Tensioning rail
19 - Chain tensioner
❑ For camshaft timing chain
20 - Bolt
❑ Renew after removing
❑ 5 Nm +90°
2. Chain drive 71
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
2.2 Exploded view - drive chain for high-pressure pump
1 - Drive chain for high-pres‐
sure pump
❑ Removing and installing
⇒ page 94
2 - Bolt
❑ Renew after removing
❑ 5 Nm +90°
3 - Chain tensioner
❑ With guide rail
4 - Drive chain sprocket
❑ For high-pressure pump
❑ Installation position:
Side with lettering legi‐
ble from gearbox end
5 - Guide pin
❑ For guide rail
❑ Renew after removing
❑ 5 Nm +45°
6 - Oil spray jet
❑ For chain lubrication
7 - Bolt
❑ Renew after removing
❑ 5 Nm +45°
8 - Tensioning rail
9 - Crankshaft
❑ With drive chain sprock‐
et for high-pressure
pump
72 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
2.3 Exploded view - drive chain for oil pump
1 - Guide rail
2 - Bolt
❑ Renew after removing
❑ 5 Nm +90°
3 - Bolt
❑ Renew after removing
❑ 5 Nm +90°
4 - Drive chain
❑ For oil pump
5 - Guide pin
❑ Renew after removing
❑ 5 Nm +45°
6 - Guide pin
❑ Renew after removing
❑ 5 Nm +45°
7 - Crankshaft
❑ With drive chain sprock‐
et for oil pump
8 - Tensioning rail
9 - Oil pump
❑ Removing and installing
⇒ page 161
10 - Chain sprocket
❑ For oil pump
11 - Bolt
❑ Tightening torque
⇒ Item 10 (page 153)
2. Chain drive 73
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
2.4 Exploded view - intermediate drive
1 - Camshaft chain sprocket
❑ Installation position:
Side with lettering legi‐
ble from gearbox end
2 - Bolt
❑ Tightening torque
⇒ Item 16 (page 71)
3 - Bolt
❑ Renew after removing
❑ 15 Nm +90°
4 - Intermediate drive
❑ Installing ⇒ page 96
5 - Gear
❑ For backlash compen‐
sation assembly
❑ Do not dismantle back‐
lash compensation as‐
sembly
6 - Gear
❑ For backlash compen‐
sation assembly
❑ Do not dismantle back‐
lash compensation as‐
sembly
7 - Spring element
❑ Do not dismantle back‐
lash compensation as‐
sembly
8 - Spring element
❑ Do not dismantle back‐
lash compensation as‐
sembly
9 - Inlet camshaft
10 - Exhaust camshaft
2.5 Removing camshaft timing chain from
camshafts
Special tools and workshop equipment required
74 Rep. gr.15 - Cylinder head, valve gear
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
♦ Locking pin - T10060A- (2x)
♦ Torque wrench - VAS 6583-
♦ Counterhold tool - T10172 A- with adapters -T10172/7-
♦ Locking pin - T40237-
2. Chain drive 75
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
♦ Wrench, 21 mm - T40263-
♦ Assembly tool - T40309-
♦ Adapter - T40310- (not illustrated)
♦ Adapter - T40314-
Removing
• Engine and gearbox in vehicle
Caution
Risk of damage to valves and piston crowns.
♦ The crankshaft and camshafts must only be turned with
the chain drive mechanism fully installed.
– Remove timing chain cover (top right) ⇒ page 63 .
76 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
Engine with vibration damper:
Caution
Irreparable damage can be caused if the camshaft timing chain
slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– Use wrench, 21 mm - T40263- and adapter - T40314- to turn
crankshaft until vibration damper is at “TDC” position.
• Mark (stuck on) -1- must be vertical and aligned with arrow
marking on coolant pump.
Engine with pulley:
Caution
Irreparable damage can be caused if the camshaft timing chain
slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– Use wrench, 21 mm - T40263- and adapter - T40314- to turn
crankshaft until pulley is at “TDC” position.
• Notch -1- should align with arrow marking on coolant pump.
2. Chain drive 77
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
All engine versions (continued):
• It should be possible to lock camshafts with locking pins T10060A- . If not, turn crankshaft 360° further in direction of
engine rotation.
– Lock exhaust camshaft of cylinder bank 1 (right-side) at “TDC”
by inserting locking pin - T10060A- in hole -arrow-.
– Lock inlet camshaft of cylinder bank 2 (left-side) at “TDC” by
inserting locking pin - T10060A- in hole -arrow-.
A4/A5: Remove subframe cross brace ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing sub‐
frame cross brace .
– Unscrew plug -arrow- from sump (top section).
– Screw locking pin - T40237- into hole (20 Nm); if necessary,
turn crankshaft -1- backwards and forwards slightly to fully
centralise locking pin.
78 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Remove bolts -arrows- for camshaft chain sprocket for cylin‐
der bank 1 (right-side).
– Slacken bolts -arrows- by a half turn.
– With the help of a second mechanic, apply torque evenly to
camshaft chain sprocket for cylinder bank 1 (right-side) by
turning adapter - T40310- anti-clockwise -arrow- and maintain
this torque.
• This will press the chain tensioner back.
Note
The chain tensioner is oil-damped and can therefore only be
pressed back slowly by applying constant pressure.
– Fit retainer -T40309/1- into tensioning rail -1- and tighten bolts
-2, 3-, as shown in illustration.
Stage Bolts Tightening torque
1. -2- Screw in by hand until contact is made
2. -3- Screw in by hand until contact is made
3. -2- 8 Nm
4. -3- 8 Nm
– Release tension on camshaft chain sprocket for cylinder
bank 1 (right-side) and remove adapter - T40310- .
2. Chain drive 79
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Unscrew bolts -arrows- completely and detach camshaft chain
sprocket for cylinder bank 1 (right-side).
Note
Do not loosen bolt -arrow- for intermediate drive -1- for cylinder
bank 1 (right-side). If bolt for intermediate drive has been loos‐
ened, backlash must be re-adjusted ⇒ page 96 .
– Remove timing chain cover (top left) ⇒ page 61 .
• Inlet camshaft of cylinder bank 2 (left-side) locked at “TDC” by
inserting locking pin - T10060A- in hole -arrow-.
– Apply counterhold tool - T10172 A- with adapter -T10172/7- to
head of bolts for camshaft chain sprocket for cylinder bank 2
(left-side) and remove bolts (re-apply counterhold tool several
times as necessary).
– Detach camshaft chain sprocket for cylinder bank 2 (left-side)
and secure camshaft timing chain with a piece of wire to pre‐
vent it from falling into chain case.
80 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
Note
Do not loosen bolt -arrow- for intermediate drive -1- for cylinder
bank 2 (left-side). If bolt for intermediate drive has been loosened,
backlash must be re-adjusted ⇒ page 99 .
Installing
• Crankshaft locked in “TDC” position with locking pin T40237- .
• Lock exhaust camshaft of cylinder bank 1 (right-side) at “TDC”
using locking pin - T10060A- .
• Lock inlet camshaft of cylinder bank 2 (left-side) at “TDC” using
locking pin - T10060A- .
Note
Locking pins -T10060A- must not be tensioned; it should be pos‐
sible to move them easily. If necessary, turn intermediate drive
slightly to align camshafts (fit two bolts and turn using counterhold
tool - T10172 A- and adapter -T10172/7- ).
2. Chain drive 81
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Position camshaft chain sprocket for cylinder bank 2 (left-side)
with timing chain on intermediate drive.
• The side of the chain sprocket with lettering faces the gearbox.
• The elongated holes in the camshaft chain sprocket must be
aligned centrally over the threaded holes in the intermediate
drive.
– Loosely screw in bolts -arrows-.
• It should just be possible to turn the camshaft chain sprocket
on the intermediate drive without axial movement.
– Position camshaft chain sprocket for cylinder bank 1 (right-
side) with timing chain on intermediate drive.
• The side of the chain sprocket with lettering faces the gearbox.
• The elongated holes in the camshaft chain sprocket must be
aligned centrally over the threaded holes in the intermediate
drive.
– Screw in bolts -arrows- loosely for camshaft chain sprocket for
cylinder bank 1 (right-side).
• It should just be possible to turn the camshaft chain sprocket
on the intermediate drive without axial movement.
– Check that camshaft timing chain is positioned correctly on
guide rail and tensioning rail.
– With the help of a second mechanic, apply torque evenly to
camshaft chain sprocket for cylinder bank 1 (right-side) by
turning adapter - T40310- anti-clockwise -arrow- and maintain
this torque.
– Remove retainer -T40309/1- .
– Release camshaft chain sprocket.
– Remove bolts -2, 3-.
82 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Apply an initial torque of 10 Nm to camshaft chain sprocket for
cylinder bank 1 (right-side) in clockwise direction -arrow- using
adapter - T40310- and torque wrench - VAS 6583- .
– Detach torque wrench and adapter - T40310- from camshaft
chain sprocket.
– Pre-tighten bolts -1, 2- for camshaft chain sprocket for cylinder
bank 1 (right-side) to 10 Nm.
– Screw in bolts -arrows- for camshaft chain sprocket for cylin‐
der bank 1 (right-side) and pre-tighten to 10 Nm.
– Pre-tighten bolts -arrows- for camshaft chain sprocket for cyl‐
inder bank 2 (left-side) to 10 Nm.
– Tighten bolts for camshaft chain sprocket for cylinder bank 1
(right-side) to final torque.
– Tighten bolts for camshaft chain sprocket for cylinder bank 2
(left-side) to final torque.
– Remove locking pin - T40237- and locking pin -T10060A- .
2. Chain drive 83
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
Checking valve timing
Caution
Irreparable damage can be caused if the camshaft timing chain
slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– Turn crankshaft two rotations until vibration damper/pulley
reaches “TDC” again (illustration shows engine with vibration
damper).
– While turning in this direction, lock crankshaft -1- with locking
pin - T40237- . Tighten locking pin to 20 Nm.
Caution
The crankshaft must be exactly in “TDC” position to ensure
accurate valve timing adjustment.
♦ If crankshaft has been turned past “TDC” position, turn
crankshaft two further rotations until it is again positioned
just before “TDC”. Then turn further in the same direction
and lock crankshaft with locking pin - T40237- .
– Check that camshafts on both cylinder heads are positioned
at “TDC”.
• It should be possible to lock camshafts with locking pins T10060A- .
– Lock exhaust camshaft of cylinder bank 1 (right-side) at “TDC”
by inserting locking pin - T10060A- in hole -arrow-.
84 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Lock inlet camshaft of cylinder bank 2 (left-side) at “TDC” by
inserting locking pin - T10060A- in hole -arrow-.
Note
♦
The adjustment is OK even if the locking pins -T10060A- are
difficult to insert.
♦
If it is not possible to insert the locking pins -T10060A- , repeat
the adjustment procedure ⇒ page 81 .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Remove locking pin - T40237- and locking pin -T10060A- .
– Install timing chain covers (top)
⇒ “1.2.1 Removing and installing timing chain cover (top left)”,
page 61 and
⇒ “1.2.2 Removing and installing timing chain cover (top
right)”, page 63 .
– A4/A5: Install subframe cross brace ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing
subframe cross brace .
Tightening torques
♦ ⇒ “2.1 Exploded view - camshaft timing chains”, page 70
♦ Plug for “TDC” marking ⇒ Item 19 (page 155)
2.6 Removing and installing camshaft tim‐
ing chain
Special tools and workshop equipment required
♦ Locking pin - 3359-
♦ Torque wrench - VAS 6583-
2. Chain drive 85
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
♦ Locking pin - T10060A- (2x)
♦ Counterhold tool - T10172A-
♦ Key - T40049-
♦ Locking pin - T40237-
86 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
♦ Locking pin - T40316-
Removing
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Removing gearbox or ⇒ Gearbox; Rep. gr.
37 ; Removing and installing gearbox; Removing gearbox .
– Remove timing chain cover (bottom) ⇒ page 66 .
Caution
Risk of damage to valves and piston crowns.
♦ The crankshaft and camshafts must only be turned with
the chain drive mechanism fully installed.
Caution
Risk of damage to drive chain if thread of bolt exceeds speci‐
fied length.
♦ Use bolts with a maximum thread length -a- of 22 mm to
attach key -T40049- .
♦ If no suitable bolts are available, position suitable washer
(s) under bolt head so that remaining thread length does
not exceed 22 mm.
– Secure key - T40049- onto rear of crankshaft -arrows-.
Caution
Irreparable damage can be caused if the camshaft timing chain
slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– Rotate crankshaft to “TDC”.
• It should be possible to lock camshafts with locking pins -
T10060A- .
2. Chain drive 87
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Lock exhaust camshaft of cylinder bank 1 (right-side) at “TDC”
by inserting locking pin - T10060A- in hole -arrow-.
– Lock inlet camshaft of cylinder bank 2 (left-side) at “TDC” by
inserting locking pin - T10060A- in hole -arrow-.
A4/A5: Remove subframe cross brace ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing sub‐
frame cross brace .
– Unscrew plug -arrow- from sump (top section).
– Screw locking pin - T40237- into hole (20 Nm); if necessary,
turn crankshaft -1- backwards and forwards slightly to fully
centralise locking pin.
88 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Press tensioning rail of camshaft timing chain tensioner in di‐
rection of -arrow- and lock chain tensioner by inserting locking
pin -T40316- .
– Remove bolt -arrow- for chain slip preventer.
Caution
If a used timing chain rotates in the opposite direction when it
is refitted, this can cause breakage.
♦ Mark running direction of timing chain with coloured ar‐
rows for re-installation.
– Apply counterhold tool - T10172A- with adapter -T10172/7- to
head of bolts for camshaft chain sprocket for cylinder bank 2
(left-side).
– Remove bolts -arrows- (apply counterhold tool for each one).
– Perform the same work step on the other side of the vehicle.
– Detach camshaft timing chain with camshaft chain sprockets.
2. Chain drive 89
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
Note
Do not loosen bolt -arrow- for intermediate drive -1-. If bolt for
intermediate drive has been loosened, backlash must be re-ad‐
justed ⇒ page 96 .
Installing
• Crankshaft locked in “TDC” position with locking pin T40237- .
90 Rep. gr.15 - Cylinder head, valve gear
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2011 ➤ ...
Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
• Lock exhaust camshaft of cylinder bank 1 (right-side) at “TDC”
using locking pin - T10060A- .
• Lock inlet camshaft of cylinder bank 2 (left-side) at “TDC” using
locking pin - T10060A- .
• Balance shaft locked in “TDC” position with locking pin 3359- .
Note
♦
Locking pins -T10060A- must not be tensioned; it should be
possible to move them easily. If necessary, turn intermediate
drive slightly to align camshafts (fit two bolts and turn using
counterhold tool - T10172A- and adapter -T10172/7- ).
♦
After removing, renew bolts tightened with specified tightening
angle.
– Position camshaft chain sprocket for cylinder bank 2 (left-side)
with timing chain on intermediate drive.
• The side of the chain sprocket with lettering faces the gearbox.
• The elongated holes in the camshaft chain sprocket must be
aligned centrally over the threaded holes in the intermediate
drive.
– Loosely screw in bolts -arrows-.
• It should just be possible to turn the camshaft chain sprocket
on the intermediate drive without axial movement.
– Position camshaft chain sprocket for cylinder bank 1 (right-
side) with timing chain on intermediate drive.
• The side of the chain sprocket with lettering faces the gearbox.
• The elongated holes in the camshaft chain sprocket must be
aligned centrally over the threaded holes in the intermediate
drive.
– Screw in bolts -arrows- loosely for camshaft chain sprocket for
cylinder bank 1 (right-side).
• It should just be possible to turn the camshaft chain sprocket
on the intermediate drive without axial movement.
– Check that camshaft timing chain is positioned correctly on
guide rail and tensioning rail.
– Press tensioning rail of camshaft timing chain tensioner in di‐
rection of -arrow- and remove locking pin -T40316- .
– Release chain tensioner.
2. Chain drive 91
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Servicing 6-cylinder TDI engine, common rail (EA 897 Gen. I) - Edition 04.2019
– Loosen bolts -arrows- at drive chain sprocket -1- for balance
shaft.
– Lock balance shaft with locking pin - 3359- , as shown in illus‐
tration.
Note
If necessary, remove bolts and bring drive chain sprocket for bal‐
ance shaft into position.
– Loosely screw in bolts -arrows-.
• The elongated holes in the drive chain sprocket must be
aligned centrally over the tapped holes in the balance shaft.
• It should just be possible to turn the drive chain sprocket on
the balance shaft without axial movement.
– Apply an initial torque of 10 Nm to camshaft chain sprocket for
cylinder bank 1 (right-side) in clockwise direction -arrow- using
adapter - T40310- and torque wrench - VAS 6583- .
– Detach torque wrench and adapter - T40310- from camshaft
chain sprocket.
– Pre-tighten bolts -1, 2- for camshaft chain sprocket for cylinder
bank 1 (right-side) to 10 Nm.
– Screw in bolts -arrows- for camshaft chain sprocket for cylin‐
der bank 1 (right-side) and pre-tighten to 10 Nm.
92 Rep. gr.15 - Cylinder head, valve gear
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