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Audi A6 Quattro 2008, Maintenance Procedures

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Audi A6 Quattro 2008 Maintenance Procedures Download Page 79

Fig. 97: Identifying Ignition Coil Puller T40039 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Puller T40039  

Fig. 98: Removing Rear Engine Cover 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Remove rear engine cover - 2 -.  

Removing cylinder bank 1 (right): 

 

2008 Audi A6 Quattro 

Maintenance Maintenance Procedures

  

FIXYOURCAR 

  

 2:27:41 AM

Page 79 

 

Summary of Contents for A6 Quattro 2008

Page 1: ...Stroke mm 92 8 77 4 92 8 93 0 82 4 92 8 92 8 92 8 Compression ratio 10 3 10 3 12 5 10 5 12 0 11 0 12 5 12 5 Engine code BPJ BDW AUK BBJ BDX BAT BVJ BXA Fuel injection Ignition TFSI MPI FSI MPI FSI MP...

Page 2: ...EU IV EU IV EU IV EU IV No of cylinders 4 4 4 4 4 6 6 6 6 Displacement L 2 0 2 0 2 0 2 0 2 0 2 7 2 7 3 0 3 0 Output kW at RPM 100 4000 103 4000 89 4000 103 4000 100 4000 132 4000 120 4000 165 4000 155...

Page 3: ...hts rear fog lights backup lights brake lights parking lights Interior and reading lights automatic shutoff on interior lights illuminated storage compartment illuminated ashtray luggage compartment l...

Page 4: ...09E ALL WHEEL DRIVE 39 FINAL DRIVE FRONT DIFFERENTIAL for AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE 39 FINAL DRIVE DIFFERENTIAL for CONTINUOUSLY VARIABLE TRANSMISSION CVT 01J 39 FINAL DRIVE DIFFEREN...

Page 5: ...ing or Guided Functions Go to function component selection Service work Energy manager activate deactivate transport mode Now follow guided program BATTERY LEVEL READ OUT WITH GUIDED FAULT FINDING Fol...

Page 6: ...elivery inspection Follow the instructions BATTERY CHECK ELECTROLYTE LEVEL Battery with magic eye Switch ignition off and remove ignition key Sedan Raise luggage compartment floor covering and secure...

Page 7: ...TED STATES INC Avant Remove luggage compartment cargo floor 1 and spare wheel cover 2 Fig 4 Identifying Battery Retaining Band Courtesy of VOLKSWAGEN UNITED STATES INC All If present open battery reta...

Page 8: ...ry charge Three color displays are possible NOTE Shown with formed insert removed in illustration Color display Battery level Green Battery is sufficiently charged Black No charge or charge too low Co...

Page 9: ...display If batteries are equipped with plugs for production reasons these are covered with plastic film Before performing visual check carefully and lightly knock magic eye with handle of a screwdrive...

Page 10: ...ached when the tires have worn down level with the 1 6 mm high tread wear indicators arrows positioned at intervals around the tire If the tread depth is approaching the legal minimum permissible dept...

Page 11: ...ir Kit Courtesy of VOLKSWAGEN UNITED STATES INC On vehicles with a tire repair kit check durability date arrow NOTE Observe that the inflation pressure specifications on the sticker refer to the air p...

Page 12: ...A G 1869 with upgrade kit V A G 1869 4 NOTE Use only new Original VW Audi brake fluid see ETKA WARNING Brake fluid must never come into contact with fluids containing mineral oils oil gas cleaning so...

Page 13: ...id reservoir cap 1 Remove brake fluid reservoir plug arrow from the air Always store brake fluid in air tight containers Wash off brake fluid spillage using plenty of water Observe waste disposal regu...

Page 14: ...A G 1869 or with extractor extract 2 3 of the brake fluid Disconnect suction hose Connect suction hose from VAS 5234 or V A G 1869 to tube 2 of brake fluid reservoir With suction hose from VAS 5234 or...

Page 15: ...l cover cap off clutch slave cylinder bleed screw Fig 15 Connecting Bottle Bleeder Hose Courtesy of VOLKSWAGEN UNITED STATES INC Place extractor bleeder hose 1 on clutch slave cylinder bleeder screw o...

Page 16: ...quence on other side of vehicle at rear Fig 17 Identifying Fluid Level Courtesy of VOLKSWAGEN UNITED STATES INC Connect extractor bleeder hose 1 to front right bleeder screw open bleeder screw and all...

Page 17: ...Install cap to brake fluid reservoir Check pedal pressure and brake pedal free play Free play Max 1 3 of pedal travel BRAKE SYSTEM VISUAL INSPECTION FOR LEAKS AND DAMAGE Check the following components...

Page 18: ...eels in same position after checking Rear disc brake pads WARNING Malfunctions found must be rectified repair measure WARNING At a pad thickness of 11 mm including backing plate the brake pads have re...

Page 19: ...INC NOTE Visual inspection without removing wheels NOTE Use only new Original VW Audi brake fluid see ETKA WARNING Brake fluid is poisonous Due to its caustic nature it must also never be brought int...

Page 20: ...ked individually Mechanically lock and unlock vehicle with keys on drivers door Insert keys in ignition and start engine one after the other If engine switches off by itself after about 3 seconds and...

Page 21: ...lation list Read control module with stored DTC memory Correct relevant malfunctions with customers approval NOISE INSULATION REMOVING Removing Fig 23 Identifying Screws Quick Release Connectors And N...

Page 22: ...ITED STATES INC Exhaust pipe must project below seal and the escape of exhaust from the pipe A must not be impaired FRONT AXLE JOINTS SEAL BOOTS CHECKING PLAY AND ATTACHMENT Tie rod ends Check play by...

Page 23: ...Joint Boots Courtesy of VOLKSWAGEN UNITED STATES INC Check all around ball joint boots arrows for damage and correct seating Use a mirror if necessary Ball joint boots can usually be recognized by le...

Page 24: ...or and exterior drive shaft boot for damage and correct seating Turn wheel if necessary By turning the front wheels tears can be found in their early stages Drive shaft boot damage can usually be reco...

Page 25: ...LT V8 4 2 AND V10 5 2 CHECKING TENSION AND CONDITION Check ribbed belt for NOTE Screw cap fully in to get an accurate fluid level reading Check fluid level Fluid level must be in B range NOTE If fluid...

Page 26: ...TER V8 5V ENGINE MECHANICAL ENGINE CODE BNK V10 5 2L engine RIBBED BELT REPLACING 6 cylinder Engine 13 ENGINE CRANKSHAFT CYLINDER BLOCK 8 cylinder Engine 13 ENGINE CRANKSHAFT CYLINDER BLOCK for 4 2 LI...

Page 27: ...ifying A C System Components Courtesy of VOLKSWAGEN UNITED STATES INC Check all climate control functions Owners manual Carry out temperature setting as follows Set rotary knobs C and D to A Set drive...

Page 28: ...ases the boiling point to 275 F 1 35 C and ensures for a better heat dissipation The coolant portion of the mixture must amount to at least 40 freeze protection to 13 F 25 C and should not exc eed 60...

Page 29: ...protection to about 40 F 40 C otherwise freeze protection and cooling effectiveness will be reduced If freeze protection is insufficient drain off required quantity shown in freeze protection table an...

Page 30: ...ratio 25 35 1 0 1 5 1 5 30 35 0 5 1 0 1 0 35 40 0 5 0 5 0 5 NOTE Determine cause of fluid loss which cannot be attributed to normal use and rectify repair measure Freeze protection to Coolant additive...

Page 31: ...1 and remove air duct upward Unclip lines 2 from retainers Fig 35 Identifying Clamps Air Filter Cover And Screw Especially in countries with tropical climates or when vehicle is driven under heavy lo...

Page 32: ...filter element Assembly is reverse of removal Follow notes See footnote 8 cylinder gasoline engines Remove bolts arrows Fig 36 Removing Air Duct Screws Air Ducts Courtesy of VOLKSWAGEN UNITED STATES...

Page 33: ...Identifying Air Filter Insert Securing Screws Courtesy of VOLKSWAGEN UNITED STATES INC Remove 2 securing screws arrows from air filter insert Remove air filter insert Clean filter housing and install...

Page 34: ...ide Fig 40 Identifying Hose Clamps And Bolts Courtesy of VOLKSWAGEN UNITED STATES INC Loosen hose clamps 1 and remove bolts 2 through 4 Fig 41 Identifying Electrical Connector On Mass Air Flow Sensor...

Page 35: ...ifying Vacuum Hoses And Bolts For Right Air Guide Courtesy of VOLKSWAGEN UNITED STATES INC Remove bolts arrows and remove right air guide Disconnect vacuum hoses 4 and 5 Fig 43 Identifying Hose Clamps...

Page 36: ...iled or soaked dirt particles or moisture can reach the Mass Air Flow Sensor and cause an incorrect air flow reading This causes lack of performance because a lower injection amount is calculated Alwa...

Page 37: ...nsure upper part of air filter housing is not sitting crooked on air filter insert note air filter insert sealing lip Ensure air guide hose is seated firmly on mass air flow sensor Tightening torque N...

Page 38: ...ing upper and lower parts of salt residue dirt or leaves clean with vacuum if necessary Check mass air flow sensor and intake hose clean air side for salt residue dirt and leaves Check intake canal up...

Page 39: ...cover on engine be careful of oil filler tube and oil dipstick Push engine cover first with both hands into position 3 in rubber grommets and then with both hands into position 4 ENGINE OIL DRAIN REPL...

Page 40: ...key 3417 6 cyl 3 2L FSI gasoline engines Fig 49 Identifying Coolant Reservoir And Oil Filter Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove coolant reservoir 1 and lay aside Remove oil filter c...

Page 41: ...A must face upward Smooth side of sealing ring 2 must face toward outside Fig 51 Identifying Oil Filter Housing O Ring Courtesy of VOLKSWAGEN UNITED STATES INC O ring inserting in oil filter housing...

Page 42: ...l filter cover and at oil filter housing Install coolant reservoir Remove noise insulation Noise insulation removing Open oil drain plug on oil pan or extract engine oil Install oil drain plug NOTE Oi...

Page 43: ...ricate lightly Engage new oil filter insert in oil filter cover Install oil filter cover 3 Install coolant reservoir Remove noise insulation Noise insulation removing Open oil drain plug on oil pan or...

Page 44: ...Courtesy of VOLKSWAGEN UNITED STATES INC Remove rear engine cover 2 arrows Remove EVAP valve from bracket and lay aside Fig 55 Securing EVAP Line Courtesy of VOLKSWAGEN UNITED STATES INC Secure EVAP...

Page 45: ...ollowing when first starting the engine As long as the oil pressure warning light in the instrument panel insert flashes the engine is only to run at idle Do not touch the accelerator pedal Bumping th...

Page 46: ...rtesy of VOLKSWAGEN UNITED STATES INC Markings on dipstick NOTE Oil temperature at least 140 F 60 C Vehicle must be in level position After stopping engine wait a few minutes to allow oil to flow back...

Page 47: ...teps in sequential order Fig 59 Connecting Data Link Connector DLC Courtesy of VOLKSWAGEN UNITED STATES INC Connect VAS 5051 5052 Guided functions Go to function component selection Service work NOTE...

Page 48: ...ent upon the vehicle equipment and local conditions urban country The following should be checked by means of a road test Engine Output misfiring idling speed acceleration Clutch Pulling away pedal pr...

Page 49: ...dapter with vehicle tool kit after completing work Correct wheel installation When installing wheels you must observe the following points to ensure wheels fit securely Always tighten wheel bolts to t...

Page 50: ...61 Identifying Adjustment Tool T10127 Equipped With Needle 3125 5 A Courtesy of VOLKSWAGEN UNITED STATES INC Windshield Washer Aiming Tool T10127 equipped with Tip 3125 5A Fig 62 Identifying Dimension...

Page 51: ...ER SYSTEM CHECK SPRAY JET SETTING Headlamp cleaner spray jets are set at the factory and do not need to be adjusted HEADLAMPS CHECK SETTING ADJUST IF NECESSARY NOTE The adjustment dimensions give valu...

Page 52: ...om fuel gauge Calculate additional weight needed using the following table Place extra weight in luggage compartment Tank filling table Example If tank is filled halfway on a front wheel drive vehicle...

Page 53: ...manual headlight range adjuster The headlight range adjuster rotary knob must be in basic setting 0 Vehicles with automatic Headlamp Range Control Fig 64 Connecting Data Link Connector DLC Courtesy o...

Page 54: ...ng Press button Follow the steps of the tester and confirm the entry until the following text appears J 431 Headlamp Range Control Module basic setting Press button Follow test sequence Headlamps chec...

Page 55: ...ew test screen To avoid incorrect settings ignore 15 setting line Headlamps adjusting Fig 67 Identifying Headlight Adjustment Screws Courtesy of VOLKSWAGEN UNITED STATES INC Main headlight left NOTE T...

Page 56: ...431 Headlamp Range Control Module basic setting to end Fog lights in main headlights Fog lights in bumper Inclination figures Fog lights 20 cm Fig 68 Lower Part Of Bumper Cover Retaining Tabs Courtesy...

Page 57: ...nes valid for them WINDSHIELD HEADLAMP WIPER SYSTEM FILLING WITH FLUID Fill washer fluid fully WINDSHIELD WIPER BLADES PARK POSITION AND CHECKING FOR DAMAGE Front windshield work sequence Switch ignit...

Page 58: ...GEN UNITED STATES INC NOTE Every second time it is switched off the wiper motor runs to an under stroke parked position that ensures that the lip of the wiper blade is flipped to the other direction T...

Page 59: ...ver Courtesy of VOLKSWAGEN UNITED STATES INC Carefully spread cover arrows and lift NOTE The dimensions give the distance of the wiper blade point to the black cowl panel grille on lower edge of winds...

Page 60: ...of VOLKSWAGEN UNITED STATES INC Place wiper blade on rear window and adjust as follows Dimension a 27 mm NOTE Dimension gives distance of wiper blade point to lower edge of window Tighten wiper arm n...

Page 61: ...tire pressure to specifications Have a second technician sit in the drivers seat while aligning the headlights Bounce front and rear of vehicle up and down several times to settle vehicle suspension S...

Page 62: ...ight high beam alignment Without moving the Beamsetter slide Broad band sight toward center of vehicle Broad band sight can also be moved up and down for a better position NOTE Try using corners of th...

Page 63: ...on the square target box of the pattern screen If high beam pattern is way out of adjustment Inspect for reflector damage Replace reflector if needed Aligning fog lamp Switch fog lamps ON Align Beamse...

Page 64: ...ame procedures to align the Beamsetter box to the headlamp Align headlight low beam check high beam and align fog lamp WIPER BLADE REPLACING Fig 79 Identifying Wiper Blade Retaining Clips And Wiper Ar...

Page 65: ...KS LOCK BUTTONS AND CHILD SAFETY LOCKS CHECKING Lock and unlock drivers and front passenger doors The lock buttons must move up when unlocking and down when locking each door Press lock buttons down o...

Page 66: ...sed air Remove stubborn dirt with a blunt object SERVICE DISPLAY RESETTING OR ADAPTING Service display resetting Follow these steps in sequential order NOTE If the door locks do not operate freely the...

Page 67: ...am Oil quality adapting Follow these steps in sequential order Connect VAS 5051 5052 Guided Fault Finding or Guided Functions Go to function component selection Service work Combination Processor chan...

Page 68: ...ith rotary button Leave mode with Return button NOTE It is necessary to change oil quality if changed between inspection or LongLife Service Inspection Service Oil quality 1 LongLife Service Oil quali...

Page 69: ...t is installed on vehicles with an operating and display unit Climatronic Control Module J255 base version ETKA No Air Quality Sensors G238 are installed in these vehicles The filter insert with activ...

Page 70: ...es B and remove dust and pollen filter cover A from air conditioning unit NOTE The lid A is held by 4 latches on bottom glove compartment cover B These latches may be difficult to release Therefore be...

Page 71: ...cond part of dust and pollen filter B at tab down and then out of duct NOTE Dust and other contaminants can adhere to the air conditioning unit A brush is attached to the Suction Nozzle VAS 6288 to re...

Page 72: ...Install the rest o the parts removed in reverse order of removal TRANSPORT PROTECTION REMOVING FRONT AND REAR BUMPER TRANSPORTATION PROTECTION DEVICES Removing front axle bumper protection devices Rel...

Page 73: ...Remove protection devices 1 DOOR ARRESTER AND LOCK CYLINDER LUBRICATE Fig 90 Identifying Greasing Points For Door Latches Courtesy of VOLKSWAGEN UNITED STATES INC NOTE It is not necessary to remove t...

Page 74: ...ring pieces TRANSPORT MODE DEACTIVATING WITH VEHICLE DIAGNOSIS TESTING AND INFORMATION SYSTEM VAS 5051 5052 Deactivate air suspension transport mode using guided fault finding or guided functions Foll...

Page 75: ...C Remove plenum chamber cover gasket 1 Remove plenum chamber cover 2 and 3 PLENUM CHAMBER WATER DRAIN CHECKING AND CLEANING 87 AIR CONDITIONING WINTER TIRES FROM FACTORY NOTE Visually inspect plenum c...

Page 76: ...ourtesy of VOLKSWAGEN UNITED STATES INC Spark plug wrench 3122B Fig 94 Placing Ignition Coil Puller T40039 On Topmost Thick Rib Of Ignition Coils Courtesy of VOLKSWAGEN UNITED STATES INC Ignition Coil...

Page 77: ...Install new spark plugs pull this from spark plug Placing on bottom rib can cause damage NOTE Plug designation 28 IGNITION SYSTEM for 3 2 V6 4V FUEL INJECTION IGNITION ENGINE CODE S BKH 28 IGNITION GL...

Page 78: ...plugs with Ignition Coil Puller T40039 Remove spark plugs with Spark Plug Removal Tool 3122 B Install new spark plugs V10 gasoline engines Special tools testers and auxiliary items required NOTE Push...

Page 79: ...OLKSWAGEN UNITED STATES INC Puller T40039 Fig 98 Removing Rear Engine Cover Courtesy of VOLKSWAGEN UNITED STATES INC Remove rear engine cover 2 Removing cylinder bank 1 right 2008 Audi A6 Quattro Main...

Page 80: ...g 100 Identifying Hose Clamps And Electrical Connector Courtesy of VOLKSWAGEN UNITED STATES INC Open hose clamps arrows and remove right air guide hose Disconnect electrical connector 1 on Engine Cool...

Page 81: ...s 1 and 2 Fig 103 Removing Ignition Coils Using Ignition Coil Puller T40039 Courtesy of VOLKSWAGEN UNITED STATES INC Pull ignition coils about 30 mm out of spark plug shaft with Puller T40039 Release...

Page 82: ...eft air duct Fig 105 Identifying Hose Clamps For Left Air Guide Hose Courtesy of VOLKSWAGEN UNITED STATES INC Open hose clamps arrows and remove left air guide hose Fig 106 Identifying Bolts Courtesy...

Page 83: ...to connectors and place all connectors evenly on ignition coils Press ignition coils evenly by hand onto spark plugs do not use a hammer Tightening torque TYPE PLATE VEHICLE IDENTIFICATION NUMBER VIN...

Page 84: ...er contains the following vehicle data Engine code and engine identification Fig 109 Identifying Engine Number On Left Front Of Cylinder Block Courtesy of VOLKSWAGEN UNITED STATES INC V6 gasoline engi...

Page 85: ...OCKS INSTALLING SUSPENSION BLOCKS INSTALLING If pressure is lost in the air suspension shock absorbers the vehicle does not have sufficient ground clearance The vehicle must not be moved in this condi...

Page 86: ...pension block set T40082 The vehicle is not in driveable condition when suspensions blocks are installed The vehicle can only be moved When moving steering wheel from center position do not turn more...

Page 87: ...le On Drive On Ramps T40081 Courtesy of VOLKSWAGEN UNITED STATES INC Drive vehicle front axle backwards on the Drive on ramps T40081 Engage 1st gear or place selector lever in P position and engage ha...

Page 88: ...icle with Onboard vehicle jack Floor jack until wheel is clear of ground Fig 116 Identifying Jack Stand Courtesy of VOLKSWAGEN UNITED STATES INC Stand Remove drive on ramp WARNING Protect vehicle on s...

Page 89: ...using Courtesy of VOLKSWAGEN UNITED STATES INC Ensure writing on rubber block points toward inside of wheel housing and that it is aligned flush with supporting plate Remove stand Let vehicle down slo...

Page 90: ...T40081 Engage 1st gear or place selector lever in P position and engage handbrake Fig 120 Lift Vehicle From Ground With Onboard Vehicle Jack Courtesy of VOLKSWAGEN UNITED STATES INC Lift vehicle with...

Page 91: ...ubber buffer down arrow First insert upper 1 and then lower distance ring 2 until you feel them engage Remove stand Let vehicle down slowly WARNING Protect vehicle on stand from falling down NOTE If t...

Page 92: ...difficult Vehicle lifting mode automatically switches off when vehicle speed exceeds 15 km h When vehicle lifting mode is activated the indicator light in the instrument cluster comes on WARNING Befo...

Page 93: ...urtesy of VOLKSWAGEN UNITED STATES INC Front and rear At plastic recesses on vehicle underbody marked in red TOW STARTING TOWING TOW STARTING TOWING NOTE On vehicles with air suspension vehicle liftin...

Page 94: ...stop and tighten eye with wheel bolt wrench Rear towing eye Sedan Attach tow rope or bar only at following eye example suspension blocks must be installed The vehicle cannot be towed when suspensions...

Page 95: ...mage to both vehicles It is advisable to use synthetic fiber ropes or ropes of similar elastic material only However it is safer to use a tow bar Avoid excessive towing effort and do not jerk During t...

Page 96: ...hen towing vehicles with manual transmission observe the following Before tow starting push in clutch pedal and hold and select gear 2 or 3 Switch ignition on When both vehicles are moving release clu...

Page 97: ...VEHICLE CHECKS WITHIN INSPECTION AND VEHICLE CHECKS WITHIN INSPECTION AND SERVICE FRAMEWORK For vehicle checks we recommend interactive acceptance VAS 5000 and performance test stand V A G 1858 Brake...

Page 98: ...achometer test the vehicle wheels are driven Vehicles with all wheel drive may only be tested on a four wheel test stand Shock absorber check Information on testing shock absorbers can be found in the...

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