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Audi Q7 2007

6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006

4 Dismantling and assembling pistons and conrods

Conrod installation position

The larger contact shoulder on the conrod -arrows- faces to-

wards the adjacent main bearing.

Illustration shows front pair of conrods.

4.2

Checking piston projection at “TDC”

♦

Piston projection at “TDC” must be measured when install-

ing new pistons or a short engine. Depending upon piston

projection, install the corresponding cylinder head gasket

according to the table below:

♦

If the measured values for piston projection are not the

same for all pistons, use the highest value to determine the

correct gasket size.

♦

The cylinder head gasket must be determined separately

for each cylinder bank.

Special tools and workshop

equipment required

♦

-VW 382/7- from meas-

uring tool -VW 382-

♦

-VW 385/17- from uni-

versal measuring tool

-VW 385-

♦

Dial gauge -VAS 6079-

Note

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Содержание Q7 2007

Страница 1: ...ervice Department Technical Information Workshop Manual Audi Q7 2007 6 cylinder TDI engine 3 0 ltr 4 valve common rail mechanics Edition 01 2006 Engine code BUN BUG http shenduauto com QQ 1398556747 1...

Страница 2: ...looking for 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 worthine...

Страница 3: ...er pump exploded view of components 1 10 Removing and installing exhauster pump 2 Servicing work on timing chain end 2 1 Drive plate exploded view of components 2 2 Removing and installing drive plate...

Страница 4: ...lling parts of lubrication system 1 1 Oil pump sump bottom section exploded view of components 1 2 Removing and installing sump bottom section 1 3 Removing and installing oil pump 1 4 Sump top section...

Страница 5: ...and installing charge air pressure sender G31 26 Exhaust system 1 Removing and installing parts of exhaust system 1 1 Exhaust system exploded view of components 1 2 Renewing tailpipes 1 3 Removing and...

Страница 6: ...Audi Q7 2007 6 cylinder TDI engine 3 0 ltr 4 valve common rail mechanics 01 2006 Contents 6 vi http shenduauto com QQ 1398556747 18218750259...

Страница 7: ...f four retaining pins one after the other arrows Before removing mark direction of rotation of poly V belt with chalk or felt tipped pen If the belt runs in the opposite direc tion when it is refitted...

Страница 8: ...g on the injection system Even small amounts of dirt can cause faults in the injection system When working on the fuel supply injection system pay careful attention to the following basic rules Code l...

Страница 9: ...diately prior to installation Do not use parts that have been previously unpacked and stored away loose e g in toolboxes etc When the system is open Do not work with compressed air Do not move the veh...

Страница 10: ...re released or cut open when remov ing must be fitted in the same position when installing Collect drained coolant in a clean container for re use or disposal 1 1 Removing engine Special tools and wor...

Страница 11: ...t and release retaining clips on rear side of cover 1 in direction of arrow A Then detach cover from driver s seat console in direction of arrow B Use removal lever 80 200 to pry out cover 1 from floo...

Страница 12: ...sing liners right and left Rep Gr 66 Disconnect air intake hoses 1 and 4 Unscrew bolts 2 and 3 and remove air pipe bottom Place drip tray for workshop hoist VAS 6208 under en gine Disconnect coolant h...

Страница 13: ...nect coolant hoses from coolant pipes arrows and drain off coolant Disconnect coolant hose from coolant pipe right side ar row and drain off remaining coolant Carefully pull engine cover panel off fou...

Страница 14: ...filter Detach fuel hose going to fuel cooler at the connections marked 3 and 5 Remove bolts 1 and 2 and nut 4 Move fuel lines at bulkhead clear and lay aside fuel filter with fuel hoses connected Remo...

Страница 15: ...ulic hose for power steering pump using a hose clamp 3094 Disconnect hydraulic hose 1 from power steering pump Disregard item 2 To prevent damage to the refrigerant lines ensure that the pipes and hos...

Страница 16: ...1 Ignore arrows Detach air intake hose top at the connections marked 1 and 2 Detach air intake hose bottom 3 Unclip differential breather hose 1 from air cleaner hous ing top section Unplug electrica...

Страница 17: ...fuel return pipe 2 at bulkhead Remove fuel filter together with fuel hoses fuel hoses re main connected to filter Detach electrical connectors 1 and 2 for exhaust gas temperature sender 1 G235 and Lam...

Страница 18: ...d take off wiper arms Use puller commercially available to remove wiper arm if necessary Pull off rubber seal 5 on plenum chamber covers Detach plenum chamber covers 2 and 4 Remove cover for electroni...

Страница 19: ...ulkhead plate at rear right of engine compartment Remove grommets from drillings above suspension struts Secure suspension struts left and right using spring ten sioner VW 552 Securing the suspension...

Страница 20: ...etach retaining clips 2 for brake lines Plug brake lines with suitable bleeder valve cap Unplug electrical connectors arrow at speed sensors for left and right front wheels Move wiring clear Release e...

Страница 21: ...dual pressure holding valve Plug both connections Make sure that no dirt particles get into the connections All models Unscrew bolts arrows connecting transfer box to rear propshaft Slide rear propsha...

Страница 22: ...w bracket for exhaust system from longitudinal member arrows Unscrew temperature sender before particulate filter G506 arrow Detach connecting hoses arrows going to exhaust gas pressure sensor 1 G450...

Страница 23: ...steering at left of lock carrier Disregard item 2 Unscrew bolt arrow and move coolant pump for contin ued circulation V51 clear to one side Observe rules for cleanliness when working on automatic gear...

Страница 24: ...ssor type assembly platform VAS 6131 with support set for Audi VAS 6131 10 supplementary set VAS 6131 11 and VAS 6131 13 as follows Platform coordi nates Parts from support set for Audi VAS 6131 10 su...

Страница 25: ...rm under engine gear box assembly Position the support elements from VAS 6131 10 or VAS 6131 11 at front of subframe as shown in the illus tration Make sure that threaded spindles are screwed in compl...

Страница 26: ...s VW 552 from drillings in wheel housing Mark the installation position of the subframe the engine cross member and the gearbox carrier on longitudinal members with felt tip pen Unscrew bolts 1 4 in d...

Страница 27: ...end or kink selector lever cable Lower engine gearbox assembly Pull out scissor type assembly platform VAS 6131 with engine gearbox assembly from beneath vehicle 1 2 Separating engine and gearbox Spec...

Страница 28: ...n unchanged Fit support VAS 6131 13 7 into drillings at front of en gine and secure with bolt M10x45 item 1 and nut 2 Secure support VAS 6131 13 7 to scissor type assembly platform Place support eleme...

Страница 29: ...upport elements from VAS 6131 10 VAS 6131 12 and VAS 6131 13 in position to support propshaft as shown in illustration Remove bolts arrows on bracket for particulate filter Unscrew bolt arrow at brack...

Страница 30: ...nuts arrows Detach starter catalytic converter with particulate filter Detach coolant hoses 1 and 2 at right of engine Remove bolts 1 and 2 Detach both coolant pipes rear left together with coolant h...

Страница 31: ...tic gearbox Rep Gr 37 Unscrew bolts 1 and 2 and detach ATF pipes from gear box Unscrew bolt arrow and detach ATF pipes Before removing mark direction of rotation of poly V belt with chalk or felt tipp...

Страница 32: ...ve bolts arrows at alternator If alternator sticks in its bracket screw bolt back in again down to the last 2 turns Tap carefully on bolt heads with flat side of hammer to re lease bushes of alternato...

Страница 33: ...n arrow 2 faces the adapter When loosening torque converter bolts counterhold crank shaft using adapter T40058 Ignore arrow Unscrew 3 bolts arrow for torque converter working through opening of remove...

Страница 34: ...neously detach torque converter from drive plate arrow Loosen clamping bolts 1 on sides of scissor type assem bly platform VAS 6131 and pull rear section of platform together with gearbox slightly tow...

Страница 35: ...Lifting tackle 3033 Engine and gearbox sup port VAS 6095 with support bracket for V6 TDI engine VAS 6095 1 4 Workshop hoist VAS 6100 Lift arm extension workshop hoist VAS 6101 Procedure Engine gearbox...

Страница 36: ...the separating point to catch escaping hy draulic fluid Unscrew banjo bolt arrow for power steering pressure pipe Unbolt bracket for wiring harness from air conditioner com pressor arrow Remove bolts...

Страница 37: ...hop hoist VAS 6100 with lift arm extension work shop hoist VAS 6101 as shown in the illustration Use workshop hoist to take up some of the weight of the engine do not lift Remove support VAS 6131 13 7...

Страница 38: ...d angle as well as oil seals and gaskets Hose connections and hoses for charge air system must be free of oil and grease before assembly Secure all hose connections with the correct type of hose clips...

Страница 39: ...bolts of the correct type same as original equip ment as specified in Parts catalogue Bolt gearbox to engine Tightening torques apply only to lightly greased oiled phosphated or black finished nuts a...

Страница 40: ...mber and gearbox carrier according to the markings made on the longitudinal members during removal Tighten bolts for subframe engine cross member and gear box carrier only to the specified torque do n...

Страница 41: ...original cylinder head and cylinder block are re installed Contaminated or dirty coolant must not be used again Charge the refrigerant system Air conditioner system with refrigerant R134a Adjust subf...

Страница 42: ...gine mounting to engine cross member 60 Drive plate to torque converter 85 1 Engine cross member to longitudinal mem ber 120 180 1 2 Bracket for continued circulation coolant pump V51 to longitudinal...

Страница 43: ...it is prop erly seated on pul leys 2 27 Nm Bolt strength rating 10 9 3 Cover for idler roller 4 Alternator Removing and in stalling Rep Gr 27 To facilitate attach ment of alternator knock back thread...

Страница 44: ...pin wrench 3212 when loosening and tightening Fig Installation position marking vorne front faces in direction of travel 25 22 Nm 26 Seal Renew 27 Bracket for ancillaries 28 40 Nm 29 25 Nm 30 Air con...

Страница 45: ...chalk or felt tipped pen If the belt runs in the opposite direc tion when it is refitted this can cause breakage Slacken poly V belt by swivelling tensioner in direction of arrow using a lever with T...

Страница 46: ...t is refitted this can cause breakage Slacken poly V belt by swivelling tensioner in direction of arrow using a lever with TORX 60 bit Remove poly V belt from tensioning roller Unscrew bolts arrows an...

Страница 47: ...of arrow using a lever with TORX 60 bit Remove poly V belt from tensioning roller Mark position of vibration damper for re installation Unscrew bolts 1 and remove vibration damper Installing Installat...

Страница 48: ...t into oil seal as far as possible applying firm pressure Loosen knurled screw and turn inner part against crank shaft until the oil seal is pulled out Clamp flats of oil seal extractor in vice Remove...

Страница 49: ...40 Install poly V belt page 39 1 6 Removing and installing sealing flange front Special tools and workshop equipment required Electric drill with plastic brush attachment Safety goggles Sealant Parts...

Страница 50: ...e bolts Pull off front sealing flange right side first arrows 1 then left side arrows 2 Drive out oil seal with sealing flange removed Installing Renew gaskets seals and O rings Remove old sealant fro...

Страница 51: ...strainer in the oil pump The front sealing flange must be installed within 5 minutes after applying sealant Tighten bolts securing front sealing flange arrow in diag onal sequence and in stages Remain...

Страница 52: ...cket for high pressure pump Remove using puller T40064 Fig on page 47 6 Toothed belt tension ing roller 7 9 Nm 8 Toothed belt cover rear 9 Toothed belt drive sprocket Use counterhold tool 3036 when lo...

Страница 53: ...hten ing central nut 1 Pulling off toothed belt sprocket for high pressure pump Use puller T40064 to pull off belt sprocket for high pres sure pump Loosening and tightening central bolt for toothed be...

Страница 54: ...high pressure pump Special tools and workshop equipment required Counterhold tool 3036 Adapter T40058 Removing Carefully pull engine cover panel off four retaining pins one after the other arrows Loo...

Страница 55: ...shaft using counterhold tool 3036 Detach damper weight and toothed belt Installing Check installation position of toothed belt tensioning roller Retaining lug arrow must engage in slot on front brack...

Страница 56: ...elow the notch Then release toothed belt tensioning roller until lug 1 and notch 2 are exactly in line Hold toothed belt tensioning roller in this position and tight en securing bolt arrow Turn cranks...

Страница 57: ...ection arrow Check toothed belt tension Lug 1 should align with notch 2 If specification is not obtained Adjust the toothed belt tension again Tightening torques Caution Do not rotate crankshaft in op...

Страница 58: ...pump Removing and in stalling page 52 3 Vacuum hose Secure with correct type of hose clips as original equip ment Parts cata logue 4 5 Nm 5 O ring Renew 6 Inlet camshaft 7 O ring Renew 8 O ring Renew...

Страница 59: ...on Remove bolts arrows and detach exhauster pump Installing Installation is carried out in the reverse order note the follow ing Renew O rings Set drive lugs of exhauster pump so they engage in slots...

Страница 60: ...plate Removing and in stalling page 54 2 Washer Thickness 3 4 mm 3 30 Nm 90 1 4 turn further Renew 4 Dowel sleeve 5 Centring sleeve for torque converter 6 Crankshaft oil seal on timing chain end Remov...

Страница 61: ...Installing Installation is carried out in the reverse order note the follow ing Fit shim 1 5 mm onto crankshaft Install drive plate with washer 3 4 mm Use new bolts for securing Reverse position of c...

Страница 62: ...4 Pry out the oil seal using the oil seal extractor lever T20143 2 Modify assembly sleeve T10122 2 by drilling an 8 mm hole arrow 2 for the dowel sleeve Use hole arrow 1 in washer as a drilling templa...

Страница 63: ...chanics 01 2006 2 Servicing work on timing chain end 57 6 Fit assembly sleeve T10122 2 with oil seal onto crank shaft Press in the oil seal with press tool T10122 3 evenly so that it is flush Install...

Страница 64: ...tight ening page 62 4 Timing chain cover left side 5 9 Nm Note correct se quence when tight ening page 62 6 Gasket Renew 7 9 Nm Note correct se quence when tight ening page 62 8 9 Nm 9 Sealing cap 10...

Страница 65: ...ttachment Safety goggles Sealant Parts catalogue Removing Remove automatic gearbox Rep Gr 37 Remove drive plate page 54 Remove coolant pipe rear right page 181 Remove turbocharger page 195 Remove inte...

Страница 66: ...m sealing surfaces Remove remaining sealant on timing chain covers and cyl inder block cylinder head using rotating plastic brush or similar Clean sealing surfaces they must be free of oil and grease...

Страница 67: ...whether the two dowel sleeves are fitted in the cyl inder block install if necessary Fit timing chain cover bottom and tighten bolts as fol lows Apply bead of sealant onto clean sealing surface of tim...

Страница 68: ...n steps are carried out in reverse se quence note the following Install crankshaft oil seal timing chain end page 55 Install drive plate page 54 Install intermediate pipe left side page 213 right side...

Страница 69: ...ive sprocket for tim ing chain left side 4 5 Nm 90 1 4 turn further Renew 5 Chain tensioner for tim ing chain left side 6 Chain sprocket for inlet camshaft Side with lettering faces towards gear box 7...

Страница 70: ...rive sprocket 3 Timing chain right side Before removing mark running direc tion with paint 4 Chain sprocket for inlet camshaft Side with lettering faces towards gear box 5 24 Nm 6 Chain tensioner for...

Страница 71: ...equipment required Locking pin 3242 Adapter T40049 Locking pin T40060 2x Adapter T40061 Adapter T40062 Drill bit 3 3 mm 2x Removing The crankshaft and camshafts must only be turned with the chain driv...

Страница 72: ...pendicular to the imaginary line between the locking pin and the centre of the camshaft To obtain the correct TDC position the side pin 1 must then be turned 90 arrow so it is in line with the imagina...

Страница 73: ...ensioner for timing chain left side in direction of arrow and lock chain tensioner by in serting a 3 3 mm drill bit item 1 Mark running direction of timing chain left side with paint Remove locking pi...

Страница 74: ...g Crankshaft 1 locked in TDC position with locking pin 3242 Drive chain for valve gear installed page 83 Renew seal Renew the bolts tightened with specified tightening angle Check that camshafts on bo...

Страница 75: ...he sprocket on the cam shaft without axial movement Lock camshaft left side with locking pin T40060 The side pin arrow on the locking pin T40060 must be in line with the imaginary line between the loc...

Страница 76: ...r the fol lowing step Tighten bolts 1 and 2 Take off adapter T40062 and pull out locking pin T40060 Tighten remaining bolts for sprocket right side Using a torque wrench and adapter T40062 apply a tor...

Страница 77: ...T40060 must be in line with the imaginary line between the locking pin and the centre of the camshaft Cylinder bank 1 right side Cylinder bank 2 left side Adjusting valve timing If the locking pin ca...

Страница 78: ...sition tighten bolts on sprocket to approx 5 Nm Remove locking pin T40060 and adapter T40061 Tighten bolts on sprocket to final torque Repeat this procedure on the other cylinder bank if neces sary Re...

Страница 79: ...t is not neces sary to remove the timing chain cover on the opposite cyl inder head as well In this case it is only necessary to remove the exhauster pump or the sealing cap because the timing chain o...

Страница 80: ...removed Remove bolts 1 4 and detach timing chain cover left side Remove bolts 1 4 and detach timing chain cover right side Insert guide pin of adapter T40058 with the larger diam eter section arrow 1...

Страница 81: ...he correct TDC position the side pin 1 must then be turned 90 arrow so it is in line with the imaginary line between the locking pin and the centre of the cam shaft Check that camshafts on both cylind...

Страница 82: ...by in serting a 3 3 mm drill bit item 1 Unscrew bolts 1 from chain tensioner and 2 from cam shaft sprocket Remove camshaft sprocket and chain tensioner left side Cover chain tensioner opening with a...

Страница 83: ...ew the bolts tightened with specified tightening angle Check that camshafts on both cylinder heads are posi tioned at TDC It should be possible to lock camshafts with locking pins T40060 The side pin...

Страница 84: ...inary line between the locking pin and the centre of the camshaft Pull drill bit 3 from locating hole this releases the chain tensioner left side Install timing chain right side with camshaft sprocket...

Страница 85: ...r sprocket right side Using a torque wrench and adapter T40062 apply a torque of 15 Nm to camshaft sprocket left side in the di rection indicated arrow Maintain this torque for the fol lowing step Tig...

Страница 86: ...40060 must be in line with the imaginary line between the locking pin and the centre of the camshaft Cylinder bank 1 right side Cylinder bank 2 left side Adjusting valve timing If the locking pin cann...

Страница 87: ...60 and adapter T40061 Tighten bolts on sprocket to final torque Repeat this procedure on the other cylinder bank if neces sary Remove locking pin 3242 Check valve timing once again page 79 Remaining i...

Страница 88: ...fluid for locking flu id refer to Parts catalogue 8 Drive chain for valve gear Before removing mark running direc tion with paint Removing and in stalling page 83 9 Guide rail 10 Mounting pin 12 Nm I...

Страница 89: ...ction of chain with paint Remove bolts 2 and 3 and detach chain sprockets to gether with drive chain and guide rail 1 Installing Installation is carried out in the reverse order note the follow ing Cr...

Страница 90: ...oil pump and balance shaft Before removing mark running direc tion with paint Removing and in stalling page 85 8 Crankshaft 9 Chain sprocket for oil pump Installation position Side with lettering face...

Страница 91: ...or oil pump and balance shaft Special tools and workshop equipment required Locking pin 3242 Diesel injection pump locking pin 3359 Adapter T40049 Drill bit 3 3 mm Removing Remove timing chain covers...

Страница 92: ...in for oil pump and balance shaft with paint Lock balance shaft with diesel injection pump locking pin 3359 and loosen bolts arrows for balance shaft sprock et Press guide rail of chain tensioner in d...

Страница 93: ...n pump lock ing pin 3359 Install chain tensioner with chain and balance shaft sprock et The elongated holes in the sprocket 3 must be aligned centrally over the tapped holes in the balance shaft Tight...

Страница 94: ...reverse se quence note the following Install timing chain covers page 60 Tightening torques 2 13 Balance shaft exploded view of components 1 Sleeve bearing 2 60 Nm Counterhold with diesel injection p...

Страница 95: ...insulation 2 Place used oil collection and extraction unit V A G 1782 under engine Drain off engine oil Remove engine page 4 Separate engine from gearbox page 21 Secure engine to engine stand page 29...

Страница 96: ...centralise locking pin Lock balance shaft at front of engine with diesel injection pump locking pin 3359 Unscrew bolt and detach balance weight from balance shaft Lock balance shaft at rear of engine...

Страница 97: ...arried out in the reverse order note the follow ing Crankshaft 1 locked in TDC position with locking pin 3242 Install chain for oil pump and balance shaft page 85 Install timing chain covers page 60 I...

Страница 98: ...ling Fig on page 93 4 Bolt Renew Tightening se quence Fig on page 93 5 Thrust washer Only fitted on 3rd crankshaft bearing Oil grooves face outwards Note location Measuring axial clearance of crank sh...

Страница 99: ...bolts in the sequence 1 16 as follows 1 Tighten bolts to 30 Nm using torque wrench 2 Tighten bolts to 50 Nm using torque wrench 3 Turn bolts 90 1 4 turn further using a rigid wrench Matching cranksha...

Страница 100: ...t webs The number 1 arrow preceding the sequence of letters indicates the colour code for No 1 bearing Bearing bush for torque converter On vehicles with automatic gearbox check that bearing bush arro...

Страница 101: ...earance Special tools and workshop equipment required Plastigage Procedure Do not interchange used bearings Bearing shells worn down to nickel layer must be renewed Remove retaining frame and clean be...

Страница 102: ...of lugs on casting A 3 Bearing shells Note installation po sition Do not interchange used bearing shells mark positions Bearing shells worn down to nickel layer must be renewed Measuring radial clear...

Страница 103: ...il spray jet for piston cooling 1 Bolt 9 Nm 2 Oil spray jet with spray nozzle valve for piston cooling Checking piston ring gap Insert ring at right angle to cylinder wall from above and push down int...

Страница 104: ...on B Maximum deviation from nominal dimension 0 08 mm Nominal dimension 4 3 Piston and cylinder dimensions on page 100 Installation position of pistons Installation position Arrow item 1 on piston cro...

Страница 105: ...hen install ing new pistons or a short engine Depending upon piston projection install the corresponding cylinder head gasket according to the table below If the measured values for piston projection...

Страница 106: ...move conrod bearing cap Clean bearing cap and bearing journal Place a length of Plastigage corresponding to the width of the bearing on the bearing journal or bearing shell Fit conrod bearing cap and...

Страница 107: ...3 0 ltr 4 valve common rail mechanics 01 2006 4 Dismantling and assembling pistons and conrods 101 6 Radial clearance New 0 015 0 062 mm Wear limit 0 12 mm Renew bolts for conrod bearings http shendu...

Страница 108: ...ace cylinder head on a soft foam surface after remov al Removing page 112 Checking for distor tion Fig on page 104 Cylinder heads must not be machined on diesel engines Installing page 114 If renewed...

Страница 109: ...t sequence when tightening page 116 13 Oil retention valve Tighten to 25 Nm 14 Lifting eye 15 M6 9 Nm M8 22 Nm 16 Intermediate pipe left side Removing and installing page 213 17 25 Nm Coat with high t...

Страница 110: ...l off toothed belt drive sprocket Checking cylinder head for distortion Use straight edge and feeler gauge to measure for distor tion at several points Max permissible distortion 0 1 mm Cylinder head...

Страница 111: ...pipe Observe rules for cleanliness page 2 Mark high pressure pipes to ensure they are re connected to the same injectors Do not attempt to bend high pressure pipes to a different shape Tightening hig...

Страница 112: ...Tighten union nuts on high pressure pipes finger tight ini tially Ensure that high pressure pipes are not under tension To tighten unions of high pressure pipes use torque wrench V A G 1331 and tool...

Страница 113: ...ch V A G 1331 Ratchet V A G 1331 1 Tool insert AF 19 V A G 1331 5 Puller T10055 with adapter T10055 1 Socket 17 mm T40055 Removing The following description shows the removal and installation of the l...

Страница 114: ...lay aside fuel filter with fuel hoses connected Detach air intake hose 5 from throttle valve module J338 Unplug electrical connector 6 at throttle valve module J338 Remove bolts 1 4 and remove intake...

Страница 115: ...iring harness clear Pull release pins upwards arrow and pull return line con nections off injectors Mark high pressure pipes to ensure they are re connected to the same injectors Loosen union nuts for...

Страница 116: ...charge air system must be free of oil and grease before assembly Secure all hose connections with the correct type of hose clips same as original equipment Parts catalogue Tighten cylinder head cover...

Страница 117: ...Ensure that high pressure pipes are not under tension To tighten unions of high pressure pipes at rail elements use torque wrench V A G 1331 with tool insert AF 19 V A G 1331 5 To tighten unions of h...

Страница 118: ...workshop equipment required Counterhold tool 3036 for cylinder head left side Puller T10320 for cyl inder head left side Puller T40064 for cyl inder head left side Removing Drain off coolant page 161...

Страница 119: ...ed belt drive sprocket Take off toothed belt drive sprocket together with toothed belt Remove bolts arrows and detach toothed belt cover rear Cylinder head right side Disconnect fuel supply line 2 and...

Страница 120: ...ead cover left or right page 107 Loosen cylinder head bolts in the sequence shown Remove bolts and carefully detach cylinder head Audi Q7 models with a 3 0 ltr TDI engine are always equipped with stee...

Страница 121: ...is ready to be fitted When installing an exchange cylinder head with fitted cam shafts oil the contact surfaces between the roller rocker fingers and cams After working on the valve gear turn the engi...

Страница 122: ...the Part No should face towards the cylinder head Fit the cylinder head Insert new cylinder head bolts and tighten finger tight Tighten cylinder head bolts as follows in the sequence 1 8 1 Tighten wit...

Страница 123: ...rox 30 minutes be fore starting engine Hydraulic valve compensation ele ments have to settle otherwise valves will strike pistons After working on the valve gear turn the engine carefully at least 2 r...

Страница 124: ...m Observe correct tightening sequence page 127 9 9 Nm Observe correct tightening sequence page 127 10 Retaining frame With integrated camshaft bearings Removing and installing 2 4 Removing and install...

Страница 125: ...installation position with a coloured pen Checking page 128 Lubricate contact surfaces before installing 15 Pressure limiting valve 1 0 bar 25 Nm For lubricating points in cylinder head 2 2 Checking...

Страница 126: ...learance exhaust camshaft Specification 0 03 0 08 mm Wear limit 0 12 mm 2 3 Renewing camshaft oil seal Special tools and workshop equipment required Oil seal extractor 2085 Counterhold tool 3036 Assem...

Страница 127: ...retaining pins one after the other arrows Loosen clamps arrows Pivot toothed belt cover forward and disengage retaining pegs on bottom side of toothed belt cover Loosen bolt arrow for tensioning roll...

Страница 128: ...r place it in po sition and screw it into oil seal as far as possible applying firm pressure Loosen knurled screw and turn inner part against crank shaft until the oil seal is pulled out Clamp flats o...

Страница 129: ...l 3036 Puller T10320 Camshaft insert tool T40094 Bracket T40095 Tensioner T40096 Electric drill with plastic brush attachment Safety goggles Sealant Parts cata logue Removing Remove timing chain from...

Страница 130: ...t damage roller rocker fingers and com pensation elements when removing camshafts Carefully remove retaining frame and camshafts Installing Remove sealant residue from cylinder head and retaining fram...

Страница 131: ...on for both sides In the following the procedure is described for the left cyl inder head The procedure for the right cylinder head is similar and is performed in the same sequence Place exhaust camsh...

Страница 132: ...am shaft Slide exhaust camshaft 1 towards inlet camshaft until gear teeth engage Fit retaining frame 1 onto camshafts All camshaft bearings must be seated on the camshafts Attach bracket T40095 to cam...

Страница 133: ...95 onto cylinder head After installing the retaining frame wait about 30 minutes for the sealant to dry Tighten retaining frame bolts in the sequence 1 18 evenly initially only hand tight The retainin...

Страница 134: ...uge Procedure Start engine and run until coolant temperature reaches ap prox 80 C Increase engine speed to approx 2500 rpm for 2 minutes perform road test if necessary If the irregular valve noise sto...

Страница 135: ...m between camshaft and roller rocker finger Renew hydraulic compensation element 2 4 Removing and installing camshafts on page 123 2 6 Renewing valve stem oil seals Special tools and workshop equipmen...

Страница 136: ...1 11 hand tight into the glow plug hole of the relevant cylinder Screw snap in device VAS 5161 6 with engaging fork VAS 5161 5 into guide plate Slide knurled spacer ring VAS 5161 23 1 onto assembly ca...

Страница 137: ...valve stem oil seal Secure puller with a punch 1 or other suitable tool as shown in the illustration Apply a suitable tool to puller and pull out valve stem oil seal arrow A plastic sleeve A is includ...

Страница 138: ...knurled screw still in pulled position Installation is carried out in the reverse order note the follow ing Install glow plugs Rep Gr 28 Install camshafts page 123 Audi Q7 models with a 3 0 ltr TDI en...

Страница 139: ...ING Care must be taken when disposing of old sodium cooled exhaust valves The valves must be sawn in two with a metal saw be tween the centre of the stem and valve head When do ing so the valves must...

Страница 140: ...meters are different Determine amount of sideways play Wear limit 1 0 mm If the wear limit is exceeded repeat the measurement with new valves Renew cylinder head if wear limit is still ex ceeded Valve...

Страница 141: ...g the engine the oil passag es must be cleaned carefully and the oil cooler must be re newed in order to prevent further damage occurring later The oil level must not be above max mark on dipstick dan...

Страница 142: ...t dismantle With pressure relief valve for cold condi tion 11 bar and pressure control valve 3 5 bar Removing and in stalling page 142 6 23 Nm 7 Dowel sleeves 8 Oil pump drive shaft 9 Coupling 10 Comp...

Страница 143: ...ng Oil retention valves The oil retention valves are located at the rear end of the cyl inder heads left and right arrow They are accessible after removing the timing chains from the camshafts left or...

Страница 144: ...nd installing sump bottom section Special tools and workshop equipment required Support bracket 10 222 A Spindle 10 222 A 10 Support 10 222 A 19 Lifting tackle 2024 A with extension 2024 A 1 Engine an...

Страница 145: ...ir cleaner housing Rep Gr 23 Remove nuts for engine mountings arrow on both sides Remove front left wheel housing liner Rep Gr 66 Unscrew nuts and bolts arrows for retaining clips for re frigerant lin...

Страница 146: ...e of lifting tackle and secure with split pin Hang pin of lifting tackle onto front spindle of support bracket Fit extension 2024 A 1 to left side of lifting tackle Engage lifting tackle 2024 A in fro...

Страница 147: ...el and oil temperature sender G266 item 1 Place used oil collection and extraction unit V A G 1782 under engine Drain off engine oil Unbolt bottom section of sump arrow There will still be some oil in...

Страница 148: ...tially to 5 Nm in diagonal sequence Tighten bolts on sump bottom section in diagonal se quence Install subframe Rep Gr 40 Install air cleaner housing Rep Gr 23 Install coolant pipe left side page 174...

Страница 149: ...t back against spring pres sure Take out oil pump Oil pump drive shaft remains in position Installing Installation is carried out in the reverse order note the follow ing Renew seals and O rings Check...

Страница 150: ...roller 5 22 Nm 6 Idler roller for poly V belt Note installation po sition 7 Sealing flange front Removing and in stalling page 43 8 O ring Renew 9 Sealing element 2 x 10 O ring Renew 11 9 Nm 12 9 Nm 1...

Страница 151: ...bolts and take off front noise insulation 1 and rear noise insulation 2 Place used oil collection and extraction unit V A G 1782 under engine Drain off engine oil Remove engine page 4 Separate engine...

Страница 152: ...ont marking nozzle approx 1 5 mm Install seals 1 and 2 in top section of sump Apply beads of sealant arrows onto clean sealing surface of sump top section as illustrated The grooves arrows on the seal...

Страница 153: ...re carried out in reverse se quence note the following Install oil pump page 143 Install sump bottom section page 141 Install sealing flange front page 44 Install chain for oil pump and balance shaft...

Страница 154: ...new 6 Seal Renew 7 O ring Renew 8 9 Nm 9 Oil supply pipe To turbocharger 10 O ring Renew 11 Oil filter element When removing pull out of sealing cap item 13 When installing fit connection at bottom of...

Страница 155: ...on Rep Gr 23 Remove bottom section of intake manifold left and right Rep Gr 23 Remove toothed belt for high pressure pump page 48 Remove high pressure pump Rep Gr 23 Remove exhaust gas recirculation c...

Страница 156: ...57 Fill cooling system page 162 Tightening torques 1 8 Removing and installing oil filter housing Special tools and workshop equipment required Torque wrench V A G 1331 Ratchet V A G 1331 1 Tool inser...

Страница 157: ...ff four retaining pins one after the other arrows Unscrew union nuts 1 4 and detach high pressure pipes Remove intake manifold top section Rep Gr 23 Loosen sealing cap arrow using 32 mm socket Take of...

Страница 158: ...rail elements use torque wrench V A G 1331 with ratchet V A G 1331 1 and tool insert AF 19 V A G 1331 5 To tighten unions of high pressure pipe at high pressure pump use torque wrench V A G 1331 with...

Страница 159: ...n cooler page 221 Install coolant pipe rear page 181 Install bottom section of intake manifold left and right Rep Gr 23 Install intake manifold top section Rep Gr 23 Fill cooling system page 162 Tight...

Страница 160: ...s recirculation cooler page 221 Install high pressure pump Rep Gr 23 Install toothed belt for high pressure pump page 48 Install coolant pipe rear page 181 Install bottom section of intake manifold le...

Страница 161: ...5 6 Detach exhaust gas recirculation valve N18 arrow from retainer Unplug electrical connector arrow Unscrew oil pressure switch F1 Installing Installation is carried out in the reverse order note the...

Страница 162: ...ls and workshop equipment required Oil pressure tester V A G 1342 Voltage tester V A G 1527 B Auxiliary measuring set V A G 1594 C Procedure Oil level OK Engine oil temperature approx 80 C Remove oil...

Страница 163: ...when starting Test lamp should light up at 0 7 1 1 bar If LED does not light up Renew oil pressure switch Checking oil pressure Start engine Minimum oil pressure at idling speed 1 8 bar Minimum oil p...

Страница 164: ...read off the oil level Markings on oil dipstick a Do not top up oil b Oil may be topped up c Oil must be topped up It is sufficient if the oil level is somewhere in area b grooved area on dipstick aft...

Страница 165: ...necessary relieve pressure before commencing re pair work Renew gaskets seals and O rings Secure all hose connections with the correct type of hose clips same as original equipment Parts catalogue Th...

Страница 166: ...For fuel cooling sys tem Removing and in stalling page 169 3 Expansion tank 4 Filler cap Checking pressure relief valve in filler cap page 189 5 From heat exchanger 6 To heat exchanger 7 Cylinder hea...

Страница 167: ...for workshop hoist VAS 6208 Hose clip pliers V A G 1921 Cooling system charge unit VAS 6096 Refractometer T10007 Draining Collect drained coolant in a clean container for re use or dis posal Open fill...

Страница 168: ...t Filling The cooling system is filled all year round with a mixture of water and radiator antifreeze anti corrosion agent It is important to use only coolant additive Plus G 012 A8F A1 also designate...

Страница 169: ...t be at least 40 If greater frost protection is required in very cold climates the amount of G 12 can be increased but only up to 60 this gives frost protection to about 40 C If the antifreeze percent...

Страница 170: ...protection to 25 C G12 50 and water 50 for frost protection to 35 C G12 60 and water 40 for frost protection to 40 C Screw adapter V A G 1274 8 onto coolant expansion tank Attach cooling system charge...

Страница 171: ...a vacuum in the cooling system The needle on the gauge should remain in the green zone Close valve B The needle on the gauge should stop in the green zone The vacuum level in the cooling system is the...

Страница 172: ...ansion tank Start engine Set heater air conditioner front and rear to HI Run the engine for 3 minutes at 2000 rpm Allow the engine to run at idling speed until the two large coolant hoses at main radi...

Страница 173: ...To radiator bottom right 4 Hose connection with thermostat Removing and in stalling page 171 5 Seal Renew 6 Coolant pump Removing and in stalling page 167 7 9 Nm 8 Poly V belt pulley for coolant pump...

Страница 174: ...efore removing mark direction of rotation of poly V belt with chalk or felt tipped pen If the belt runs in the opposite direc tion when it is refitted this can cause breakage Slacken poly V belt by sw...

Страница 175: ...e order note the follow ing Clean sealing surface Install poly V belt page 39 Fill cooling system page 162 Tightening torques 1 5 Removing and installing continued coolant circulation pump V51 Special...

Страница 176: ...detach from continued coolant circulation pump V51 Unscrew bolt 2 and remove continued coolant circulation pump V51 Installing Installation is carried out in the reverse order note the follow ing Sec...

Страница 177: ...f poly V belt with chalk or felt tipped pen If the belt runs in the opposite direc tion when it is refitted this can cause breakage Slacken poly V belt by swivelling tensioner in direction of arrow us...

Страница 178: ...ng pins one after the other arrows Remove air intake hose arrows Unplug electrical connector 1 at coolant temperature sender G62 Detach retaining clip 2 and remove coolant temperature sender G62 Insta...

Страница 179: ...ew bolt 1 and pull coolant pipe top out of cylinder block Installing Installation is carried out in the reverse order note the follow ing Renew O ring Secure all hose connections with the correct type...

Страница 180: ...ve power steering pump Rep Gr 48 Remove air conditioner compressor Rep Gr 87 Unplug electrical connector 3 Remove bolts 1 and 2 and detach throttle valve module J338 from intake connecting pipe Remove...

Страница 181: ...eft side from bracket for ancillaries Installing Installation is carried out in the reverse order note the follow ing Renew seal and O ring Secure all hose connections with the correct type of hose cl...

Страница 182: ...verse order note the follow ing Secure all hose connections with the correct type of hose clips same as original equipment Parts catalogue Install starter catalytic converter page 204 Fill cooling sys...

Страница 183: ...tools and workshop equipment required Support bracket 10 222 A Adapter 10 222 A 22 2 hole pin wrench 3212 Puller T10320 Puller T40064 Removing Disconnect earth wire at battery with ignition switched...

Страница 184: ...arrows Detach air intake hose top at the connections marked 1 and 2 Detach air intake hose bottom 3 Unclip differential breather hose 1 from air cleaner hous ing top section Unplug electrical connect...

Страница 185: ...front Attach spindle of support bracket 10 222 A to rear right engine lifting eye Take up weight of engine using spindle of support bracket Unbolt earth connection 1 at longitudinal member right side...

Страница 186: ...40064 to pull off belt sprocket for high pres sure pump Remove bolts arrows and detach toothed belt cover rear Unbolt poly V belt pulley from coolant pump arrows counterhold with 2 hole pin wrench 321...

Страница 187: ...te new O ring with G12 and slide onto coolant pipe Install toothed belt for high pressure pump page 48 Remove alternator Rep Gr 27 Install poly V belt page 39 Observe notes on procedures required afte...

Страница 188: ...ver panel off four retaining pins one after the other arrows Unclip differential breather hose 1 from air cleaner hous ing top section Unplug electrical connector 3 at air mass meter G70 Detach air in...

Страница 189: ...ge to the intake manifold flap motor V157 the connecting rod 1 is not detached Unplug electrical connector 1 at coolant temperature sender G62 Remove bolt 2 Disconnect coolant hoses arrows and take ou...

Страница 190: ...ne after the other arrows Unclip differential breather hose 1 from air cleaner hous ing top section Unplug electrical connector 3 at air mass meter G70 Detach air intake hose 4 from turbocharger Relea...

Страница 191: ...or Remove locking elements for radiator on left and right press latch from below arrow Unscrew bolts 2 on left and right of lock carrier Disengage radiator and swivel to rear Disregard item 1 Unscrew...

Страница 192: ...e refrigerant lines ensure that the pipes and hoses are not stretched kinked or bent Lift out radiator from above Installing Installation is carried out in the reverse order note the follow ing Hose c...

Страница 193: ...r from coolant hoses 1 and 6 Installing Installation is carried out in the reverse order note the follow ing Secure all hose connections with the correct type of hose clips same as original equipment...

Страница 194: ...ment required Cooling system tester V A G 1274 Adapter for cooling sys tem tester V A G 1274 8 Adapter for cooling sys tem tester V A G 1274 9 Procedure Engine must be warm Open filler cap on coolant...

Страница 195: ...re relief valve in filler cap Attach cooling system tester V A G 1274 with adapter V A G 1274 9 to filler cap Use hand pump on cooling system tester to create pres sure The pressure relief valve shoul...

Страница 196: ...90 Unscrew bolts and remove front noise insulation 1 Disconnect air intake hoses 1 and 4 Unscrew bolts 2 and 3 and remove air pipe bottom Remove bolts 2 and 3 Detach air pipe from air intake hoses 1 a...

Страница 197: ...compartment Installing Installation is carried out in the reverse order note the follow ing Hose connections and hoses for charge air system must be free of oil and grease before assembly Secure all...

Страница 198: ...e wiring clear Remove bolts 1 2 3 4 8 and remove radiator fan 2 V177 with radiator fan control unit 2 J671 Remove bolts 5 6 7 and remove radiator fan V7 with radiator fan control unit J293 Installing...

Страница 199: ...have been removed on a clean surface and cover them over Use only lint free cloths Carefully cover or seal open components if repairs cannot be carried out immediately Only install clean components re...

Страница 200: ...tem perature lubricant for high tempera ture lubricant refer to Parts cata logue 7 Connecting pipe to changeover flap for ex haust gas recirculation cooler 8 9 Nm 9 O ring Renew 10 Gasket Renew 11 Ex...

Страница 201: ...Nm Coat with high temperature lubricant for high temperature lubricant refer to Parts catalogue 29 22 Nm 30 O ring Renew 31 Oil return pipe To cylinder block 32 Gasket Renew 33 30 Nm 90 1 4 turn furth...

Страница 202: ...olant pipe rear page 181 Unscrew bolts arrows and detach turbocharger from in termediate flange Installing Installation is carried out in the reverse order note the follow ing Renew gaskets seals and...

Страница 203: ...ighten with torque wrench initially to 10 Nm 2 Tighten with torque wrench to 30 Nm 3 Turn 90 1 4 turn further using a rigid wrench Install turbocharger page 195 Install starter catalytic converter pag...

Страница 204: ...ose To turbocharger Must be free of oil and grease when in stalling 4 9 Nm 5 9 Nm 6 Air intake hose To charge air cooler right side Must be free of oil and grease when in stalling 7 Connection 8 9 Nm...

Страница 205: ...description shows the removal and installation of the left side charge air cooler Unscrew bolts and remove front noise insulation 1 Remove bumper cover front Rep Gr 63 Detach cover above radiator arro...

Страница 206: ...sembly Secure all hose connections with the correct type of hose clips same as original equipment Parts catalogue Install bumper cover front Rep Gr 63 Tightening torques 1 7 Removing and installing ch...

Страница 207: ...TDI engine 3 0 ltr 4 valve common rail mechanics 01 2006 1 Servicing charge air system with turbocharger 201 6 Component Nm Charge air pressure sender G31 to charge air cooler 5 http shenduauto com QQ...

Страница 208: ...Nm Renew 2 Mounting Renew if damaged Check preload 1 10 Stress free alignment of exhaust system on page 217 3 Clamp Before tightening align exhaust sys tem so it is free of stress page 217 Installati...

Страница 209: ...ticulate filter G506 Tighten to 45 Nm Coat thread with high temperature paste refer to Parts catalogue 16 Particulate filter Removing and installing page 207 After renewing particulate filter perform...

Страница 210: ...ailpipe onto rear silencer and align Check clearance between tailpipes and bumper on both sides Dimension x left side dimension x right side 1 3 Removing and installing starter catalytic converter Rem...

Страница 211: ...tem 205 6 Unbolt bracket for noise insulation arrows Unscrew temperature sender before particulate filter G506 arrow Unscrew nuts 1 3 Unscrew bolt arrow at bracket for starter catalytic con verter Car...

Страница 212: ...tion is carried out in the reverse order note the follow ing Renew gaskets and self locking nuts Fit all cable ties in the original positions when installing Install exhauster pump page 52 Install tem...

Страница 213: ...ving Unscrew bolts and take off front noise insulation 1 and rear noise insulation 2 Unbolt bracket for noise insulation arrows To avoid any damage the flexible joint at the starter catalytic converte...

Страница 214: ...enew gaskets and self locking nuts Secure all hose connections with the correct type of hose clips same as original equipment Parts catalogue Install temperature sender before particulate filter G506...

Страница 215: ...manifold Removing and in stalling left side page 210 right side page 211 3 Gasket Renew 4 Gasket Renew 5 25 Nm Coat with high tem perature lubricant for high tempera ture lubricant refer to Parts cat...

Страница 216: ...Removing Carefully pull engine cover panel off four retaining pins one after the other arrows Remove air intake hose arrows Lay a cloth under the separating point to catch escaping hy draulic fluid C...

Страница 217: ...o 10 Nm 2 Tighten with torque wrench to 30 Nm 3 Turn 90 1 4 turn further using a rigid wrench Align exhaust system so it is free of stress page 217 Check hydraulic fluid level of power steering Rep Gr...

Страница 218: ...s meter G70 Detach air intake hose 4 from turbocharger Release retaining clips 2 and detach top section of air cleaner housing Take electrical connector arrow out of bracket and un plug it Unbolt brac...

Страница 219: ...g intermediate pipe to exhaust mani fold as follows 1 Tighten with torque wrench initially to 10 Nm 2 Tighten with torque wrench to 30 Nm 3 Turn 90 1 4 turn further using a rigid wrench Tightening tor...

Страница 220: ...ermediate pipe detached Unbolt intermediate pipe arrows Installing Installation is carried out in the reverse order note the follow ing Renew gaskets seals and O rings Tighten bolts securing intermedi...

Страница 221: ...take hose 4 from turbocharger Release retaining clips 2 and detach top section of air cleaner housing Take electrical connector arrow out of bracket and un plug it Unbolt bracket for electrical connec...

Страница 222: ...ve intermediate pipe Shown in illustration with engine removed Installing Installation is carried out in the reverse order note the follow ing Renew seals and gaskets Tighten bolts securing intermedia...

Страница 223: ...ensions is not attained remove rel evant brackets from body and adjust as required Align tailpipes page 204 1 11 Checking exhaust system for leaks Start engine and run at idling speed Seal off tailpip...

Страница 224: ...g pins one after the other arrows Take electrical connector 1 for exhaust gas temperature sender 1 G235 out of bracket Unplug electrical connector and move wiring clear Disregard items 2 4 Remove heat...

Страница 225: ...out of bracket Unplug electrical connector and move wiring towards bot tom of vehicle Disregard items 1 3 Unscrew temperature sender before particulate filter G506 arrow Installing Install in reverse...

Страница 226: ...9 9 Nm 10 Exhaust gas recircula tion cooler Removing and in stalling page 221 11 Coolant hose 12 Coolant hose 13 Gasket Renew 14 Vacuum hose From change over valve for exhaust gas recirculation cooler...

Страница 227: ...exhaust gas recirculation valve with connecting pipe Installing Installation is carried out in the reverse order note the follow ing Renew seals and gaskets Install intake manifold top section Rep Gr...

Страница 228: ...e follow ing Renew gaskets seals and O rings Secure all hose connections with the correct type of hose clips same as original equipment Parts catalogue Install mechanical exhaust gas recirculation val...

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