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Audi A3 Workshop Manual

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3K views235 pages

Audi A3 Workshop Manual

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LeeGeddes

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Service

Workshop Manual
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve
turbo), mechanics
CDL CDL
Engine ID AXX BPY BWA BHZ BZC A C
Edition 03.2017

Service Department. Technical Information

Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
26 - Exhaust system

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2017 Audi AG, Ingolstadt A0050438920

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Procedure before opening high-pressure section of injection system . . . . . . . . . . . . . . . . 3
3.3 Working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Using testers and measuring instruments during a road test . . . . . . . . . . . . . . . . . . . . . . . . 4
3.5 Working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Rules for cleanliness when working on fuel supply system, injection system and
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.6 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6
4.7 Installing radiators,
permitted condensers
unless authorised andAG
by AUDI AG. AUDI charge
does notair coolers
guarantee or accept. .any
. . liability
........................ 7
with respect to the correctness of information in this document. Copyright by AUDI AG.

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing and installing engine, detaching from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Checking adjustment of assembly mountings (engine/gearbox mountings) . . . . . . . . . . . . 27
2.3 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.1 Exploded view - poly V-belt, bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.4 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.5 Front sealing flange - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.6 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.7 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Rear sealing flange and dual-mass flywheel - exploded view . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Removing and installing sealing flange (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.5 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.6 Removing and installing chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Contents i
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.1 Toothed belt drive - exploded view (vehicles without separate toothed belt covers) . . . . . . 61
1.2 Removing and installing toothed belt (vehicles without separate toothed belt covers) . . . . 64
1.3 Toothed belt drive - exploded view (vehicles with separate toothed belt covers) . . . . . . . . 72
1.4 Removing and installing toothed belt (vehicles with separate toothed belt covers) . . . . . . 75
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.2 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.4 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.5 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 113
3.6 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 118
3.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.8 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Oil pump and sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Sump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 127
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.4 Balance shaft assembly with oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.5 Removing and installing balance shaft assembly with oil pump . . . . . . . . . . . . . . . . . . . . . . 133
2 Oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Exploded view - oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Draining oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.3 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2.4 Removing and installing oil filter bracket . .Protected. . . . .by. copyright.
. . . . . Copying
. . . . .for. private
. . . . or. .commercial
. . . . . .purposes,
. . . . .in. part
. 142
or in whole, is not
2.5 Checking oil pressure and oil pressure switch . . .unless
permitted . . . authorised
. . . . . .by. AUDI
. . . AG.
. . .AUDI
. . .AG . .does
. . .not. guarantee
. . . . . .or 145
accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2.6 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.7 Checking oil pressure and oil pressure switch (1-pin oil pressure switch) . . . . . . . . . . . . . . 148
2.8 Checking oil pressure and oil pressure switch (2-pin oil pressure switch) . . . . . . . . . . . . . . 150
2.9 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1 Parts of cooling system (on engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.1 Cooling system components (on engine) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.2 Exploded view - continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.3 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.4 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.5 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.6 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.7 Removing and installing coolant distributor housing with map-controlled engine cooling
thermostat F265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2 Parts of cooling system (on body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 Exploded view - radiator and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

ii Contents
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

2.4 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 172

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1 Turbocharger with charge air system, engine codes AXX, BPY, BWA . . . . . . . . . . . . . . . . 173
1.1 Fitting hose connections with plug-in connectors - vehicles with engine codes AXX, BPY,
BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.2 Turbocharger - exploded view, vehicles with engine codes AXX, BPY, BWA . . . . . . . . . . 174
1.3 Removing and installing turbocharger, vehicles with engine codes AXX, BPY, BWA . . . . 178
1.4 Checking vacuum unit for turbocharger, engines with code letters AXX, BPY, BWA . . . . 185
1.5 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.6 Adjusting vacuum unit for turbocharger, engines with code letters AXX, BPY, BWA . . . . 187
1.7 Charge air cooler - exploded view, engine codes AXX, BPY, BWA . . . . . . . . . . . . . . . . . . 192
1.8 Diagram of turbocharger system, engines with code letters AXX, BPY, BWA . . . . . . . . . . 193
1.9 Removing and installing charge air cooler - vehicles with engine codes AXX, BPY and
BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.10 Checking charge air system for leaks, vehicles with engine codes AXX, BPY, BWA . . . . 195
2 Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC
........................................................................ 198
2.1 Turbocharger - exploded view, engines with code letters BHZ, BZC, CDLA, CDLC . . . . . . 198
2.2 Removing and installing turbocharger, engines with code letters BHZ, BZC, CDLA, CDLC
........................................................................ 202
2.3 Charge air system - exploded view, engines with code letters BHZ, BZC, CDLA, CDLC . . 208
2.4 Diagram of turbocharger system, engines with code letters BHZ, BZC, CDLA, CDLC . . . . 211
2.5 Removing and installing charge air cooler, engines with code letters BHZ, BZC, CDLA,
CDLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.6 Checking charge air system for leaks, engines with code letters BHZ, BZC, CDLA, CDLC
........................................................................ 213

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 Exhaust
permittedsystem, engines
unless authorised with
by AUDI codeAGletters
AG. AUDI does not AXX, BPY,
guarantee BWA
or accept ........................
any liability 216
1.1 Exhaust system - exploded view, engines with code letters AXX, BPY, BWA . . . . . . . . . .
with respect to the correctness of information in this document. Copyright by AUDI AG.
216
1.2 Removing and installing front exhaust pipe with catalytic converters and front silencer,
engines with code letters AXX, BPY, BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.3 Separating centre and rear silencers, engines with code letters AXX, BPY, BWA . . . . . . 221
1.4 Stress-free alignment of exhaust system, vehicles with engine codes AXX, BPY, BWA . . 221
1.5 Checking exhaust system for leaks, vehicles with engine codes AXX, BPY, BWA . . . . . . 222
2 Exhaust system, engines with code letters BHZ, BZC, CDLA, CDLC . . . . . . . . . . . . . . . . 223
2.1 Exhaust system - exploded view, engines with code letters BHZ, BZC, CDLA, CDLC . . . . 223
2.2 Removing and installing front exhaust pipe with catalytic converter and front silencer, engines
with code letters BHZ, BZC, CDLA, CDLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2.3 Stress-free alignment of exhaust system, engines with code letters BHZ, BZC, CDLA,
CDLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2.4 Checking exhaust system for leaks, engines with code letters BHZ, BZC, CDLA, CDLC . . 228
3 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Contents iii
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

iv Contents
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

00 – Technical data
1 Engine number
(ARL005179; Edition 03.2017)
The engine number (“engine code” and “serial number”) can be
found at the front of the joint between engine and gearbox.
There is also a sticker with “engine code” and “serial number”
attached to the toothed belt cover.
In addition, the engine code is listed on the vehicle data stickers.

1. Engine number 1
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2 Engine data
Code let‐ AXX BPY BWA BHZ CDL CDL BZC
ters A C
Ca‐ ltr. 1.984 1.984 1.984 1.984 1.984 1.984 1.984
pac‐
ity
Pow kW 147/5 147/5 147/5 195/6 188/6 195/6 188/6
er at 700 700 100 000 000 000 000
out‐ rpm
put
Tor‐ Nm 280/2 280/2 280/1 350/2 330/2 350/2 330/2
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
que at 000 000 800with respect
500 to the400 500
correctness 400 in this document. Copyright by AUDI AG.
of information
rpm
Bore ∅ 82.5 82.5 82.5 82.5 82.5 82.5 82.5
mm
Stro mm 92.8 92.8 92.8 92.8 92.8 92.8 92.8
ke
Compres‐ 10.5 10.5 10.3 9.8 9.8 9.8 9.8
sion ratio
RON 98 1) 98 1) 98 1) 98 1) 98 1) 98 1) 98 1)
Injection/ FSI FSI FSI FSI FSI FSI FSI
ignition
system
Fir‐ 1-3-4 1-3-4 1-3-4 1-3-4 1-3-4 1-3-4 1-3-4
ing -2 -2 -2 -2 -2 -2 -2
or‐
der
Knock yes yes yes yes yes yes yes
control
Turbo‐ yes yes yes yes yes yes yes
charging/
super‐
charging
Exhaust no no no no no no no
gas recir‐
culation
Intake no no no no no no no
manifold
change-
over
Variable yes yes yes yes yes yes yes
valve tim‐
ing
Secon‐ no no no no no no no
dary air
system
• 1) Unleaded petrol RON 95 can also be used, but results
in reduced power

2 Rep. gr.00 - Technical data

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

3 Safety precautions

3.1 Working on the fuel system

When working on the fuel system note the following warnings:

WARNING

The fuel system operates at extremely high pressure. This can

cause injury.
♦ The fuel pressure in the high-pressure section of the in‐
jection system must be reduced to a residual pressure
prior to opening the system.
♦ Wrap a clean cloth around the connection and carefully
loosen the connection to allow the residual pressure to
dissipate.

– Procedure before opening high-pressure section of injection

system ⇒ Rep. gr. 24
Observe the following to prevent injuries to persons and damage
to the injection and ignition system:
♦ Always switch off the ignition before connecting or discon‐
necting electrical wiring for the injection or ignition system or
tester cables.
♦ Always switch off ignition before washing engine.
♦ Faults are stored in engine control units if electrical connectors
were unplugged and engine was started: “Generate readiness
code” in “Guided Functions” ⇒ Vehicle diagnostic tester .

Caution

To prevent irreparable damage to the electronic components

when disconnecting the battery:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Observe
permittednotes on procedure
unless authorised forAUDI
by AUDI AG. disconnecting the battery.
AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Always switch off the ignition before disconnecting the
battery.

– Disconnect battery ⇒ Rep. gr. 27 .

3.2 Procedure before opening high-pres‐

sure section of injection system

WARNING

♦ The injection system consists of a high-pressure section

(maximum approx. 120 bar) and a low-pressure section
(approx. 6 bar).
♦ The fuel pressure in the high-pressure section must be
reduced to a residual pressure of approx. 6 bar prior to
opening the system. For details of procedure, refer to ⇒
Rep. gr. 24 .

3. Safety precautions 3
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

3.3 Working on the cooling system

When working on the cooling system note the following warnings:

WARNING

Hot steam/hot coolant can escape - risk of scalding.

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

Caution

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

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

3.4 Using testers and measuring instru‐

ments during a road test
Note the following if testers and measuring instruments have to
be used during a road test: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING

Accidents can be caused if the driver is distracted by test

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

3.5 Working on the exhaust system

When working on the exhaust system please note the following:

Caution

Risk of damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.

4 Rep. gr.00 - Technical data

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

4 General repair instructions

4.1 Rules for cleanliness when working on

fuel supply system, injection system and
turbocharger
Even small quantities of dirt can lead to defects. For this reason,
please observe the following rules when working on the fuel sup‐
ply system, injection system and turbocharger:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connectionsProtected
immediately with
by copyright. Copying for private or commercial purposes, in part or in whole, is not

clean plugs, e.g. from engine bung set - VAS 6122- .

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Place removed parts on a clean surface and cover them. Use

only 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 their packing (e.g. in tool boxes
etc.).
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.

4.2 Checking fuel system for leaks

– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section of fuel system again for
leaks.

4.3 Foreign particles in engine

♦ When working on the engine, all open inlet and exhaust ports
must be sealed with suitable plugs (e.g. from engine bung set
- VAS 6122- ) to prevent foreign particles from entering the
engine.

4.4 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.

4. General repair instructions 5

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.

4.5 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.
♦ To avoid damaging pipes, hoses and wiring, ensure sufficient
clearance from all moving or hot components in engine com‐
partment (limited space in engine compartment).

4.6 Checking vacuum system

Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-

Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Porous or leaking lines
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the memory, check the vacuum lines lead‐
ing to the corresponding component andProtected
also check theCopying
by copyright. re‐ for private or commercial purposes, in part or in whole, is not
maining vacuum lines in the system. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– If it is not possible to build up pressure with the hand vacuum
pump - VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.

6 Rep. gr.00 - Technical data

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

4.7 Installing radiators, condensers and

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

4. General repair instructions 7

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

10 – Removing and installing engine

1 Removing and installing engine, de‐
taching from gearbox

1.1 Removing engine

Special tools and workshop

equipment required
♦ Drip tray for workshopProtected
hoist by copyright. Copying for private or commercial purposes, in part or in whole, is not
- VAS 6208- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring type clip pliers - VAS
5024A-
♦ Stepladder - VAS 5085-
♦ Engine bracket - T10012-
♦ Socket (8 mm) - 3247-

8 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Engine bung set - VAS 6122-

Note

♦ The engine is removed from underneath together with the

gearbox.
♦ Renew all cable ties which are released or cut open when re‐
moving the engine. Refit in the same position when installing
the engine.
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.

– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

– Remove electrical connector -arrow- for Lambda probe (be‐

fore catalytic converter) from bracket, unplug and move clear.

WARNING

Hot steam/hot coolant can escape - risk of scalding.

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

– Open filler cap on coolant expansion tank.

– Remove cover -1- over battery. To do so, press release tab

-arrow-.

Caution

To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– With ignitionwith
switched off,correctness
respect to the disconnect battery
of information earth
in this cable
document. Copyright by AUDI AG.
-arrow-.
– Remove battery. ⇒ Electrical system; Rep. gr. 27 .

1. Removing and installing engine, detaching from gearbox 9

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove battery tray -arrows-.

– Use screwdriver to pry off cover caps on wiper arms and un‐
screw hexagon nuts.
– Pull wiper arms off wiper shafts and remove.

– Unclip washer jets -arrow-.

– Push washer jets through assembly opening back into plenum
chamber, leaving hoses connected.

– Detach rubber seal -1- from plenum chamber cover.

– Detach plenum chamber cover -2-.
– Detach engine wiring harness at rear plenum chamber panel.

– Remove plenum chamber intermediate plate -arrows-.

– Remove engine control unit ⇒ Rep. gr. 24 .

10 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unplug engine wiring harness connector -1-.

– Release wiring protector for engine wiring harness -arrow- and

lift off.

– Open wiring duct brackets -arrows-.

– Move electrical connector -1- clear and unplug connector.

– Open wiring duct bracket located below -2-.
– Open wiring duct bracket -3-.
– Remove engine control unit wiring harness from wiring duct.

1. Removing and installing engine, detaching from gearbox 11

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unplug electrical connector -1- for reversing light switch.

– Disconnect earth cable -2-.
– Slide cover -3- to rear.

– Detach wires -1 and 2- at starter and move clear.

– Remove the cover above the fuse box (press release tabs
-arrows-).

– Unscrew the electrical wire -arrow- and move clear up to al‐

ternator.
– Remove both front wheels.
– Remove noise insulation ⇒ Rep. gr. 50 .

12 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove noise insulation (left and right) - fasteners -1 ... 3-.

– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.

– To drain off coolant, detach bottom coolant hose -arrow-.

– Detach top coolant hose from radiator -2-.

– Detach coolant hoses going to heat exchanger -arrows-.

Note

Shown in illustration from rear with engine removed.

1. Removing and installing engine, detaching from gearbox 13

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew securing bolts -arrows- for front exhaust pipe/turbo‐

charger accessible from above.

– Disconnect vacuum hose -arrow- leading to brake servo.

– Unclip securing clips -1- and -2- on both selector cables.

– Pull off selector cable end-pieces from gearbox selector lever
and relay lever. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach cable support bracket from gearbox -arrows- and
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
place to one side.

WARNING

Do not press clutch pedal after disconnecting hose leading to

slave cylinder.

– Pull out clip -2- as far a stop in -direction of arrow- and detach
hose -1-.

WARNING

Fuel supply line is pressurised. Wear safety goggles and pro‐

tective clothing to avoid possible injury and skin contact. Before
opening hose connections wrap a cloth around the connection.
Then release pressure by carefully pulling hose off connection.

14 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Mark fuel line -2- and line going to ACF -1-.

– Disconnect fuel line -2- and move clear.
– Disconnect ACF line -1- and move clear.
– Disconnect vacuum line -3- going to activated charcoal filter
(press release tabs).
– Lift out ACF.

– Detach coolant hoses -1 and 2-.

– Discharge air conditioner ⇒ Rep. gr. 87 ; Air conditioner with
refrigerant R134a .

– Disconnect air conditioner pipe -arrow- from compressor.

– Loosen bolts -arrows- of assembly mounting for engine ap‐

prox. 2 turns.

1. Removing and installing engine, detaching from gearbox 15

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Loosen bolts -arrows- of assembly mounting for gearbox ap‐

prox. 2 turns.

– Unplug electrical connector -1-.

– Release cable retainers -2 and 3- and move electrical wiring
clear.

– Unscrew bolts -1- from above.

– Remove air pipe -1 and 2- for charge air cooler.

16 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unplug electrical connector -2-.

– Unscrew the bolts -3- and remove radiator cowl from below.

– Detach electrical connector -1- from longitudinal member (left-

side) and move wire clear.

– Detach air pipe -arrow- from charge air cooler.

– Detach air conditioner pipe from condenser -arrow-.

– Unplug connector from charge pressure sender - G31- ⇒ Rep.
gr. 24 ; Overview of fitting locations .

1. Removing and installing engine, detaching from gearbox 17

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unplug electrical connector at oil level sender -1-.

– Unclip bracket -2-.
– Unplug electrical connector at continued coolant circulation
pump -3- and move wiring clear.
– Remove propshaft (front) ⇒ Rep. gr. 39 .

– Remove heat shield above drive shaft using hexagon key ex‐
tension, 8 mm - 3247- .
– Remove drive shafts (left and right) ⇒ Rep. gr. 40 .

– Remove underbody cover (right-side) -arrows-.

– Unplug electrical connector -arrow- for Lambda probe after

catalytic converter and move wiring clear.

18 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew remaining securing nuts -arrows- for front exhaust

pipe/turbocharger from below.
– Remove support for front exhaust pipe with catalytic converter
(unscrew bolts -1 and 2-).

Note

To avoid damage, the flexible joints in the front exhaust pipe must
not be bent more than 10 °.

– Separate exhaust system at clamp -arrows-.

– Remove front cross-piece for underbody -arrows-.

– Unbolt bracket for exhaust system -arrows-.

– Detach catalytic converter with front exhaust pipe.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Removing and installing engine, detaching from gearbox 19

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew bolts -1 ... 3- and remove pendulum support.

– Remove additional coolant pump -arrows-.

– Bolt engine bracket - T10012- with securing bolt -1- and nut
-2- to cylinder block (tightening torque: approx. 20 Nm).
– Insert engine and gearbox jack - V.A.G 1383 A- in engine
bracket - T10012- and raise engine slightly.

Note

To unscrew bolts for assembly mounting use stepladder - VAS

5085- .

– Remove bolts -arrows- of assembly mounting on engine.

20 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove bolts -arrows- of assembly mounting for gearbox.

Note

♦ Check that all hoses, pipes and wiring connections between

engine, gearbox and body have been detached.
♦ Carefully guide engine/gearbox assembly when lowering to
avoid damage.

– Pull engine/gearbox assembly as far forward as possible, and

lower gradually.

1.2 Separating engine and gearbox

• Engine/gearbox assembly removed and attached to engine
bracket - T10012- .
– Unscrew bolt -1- with gearbox installed.
– Pull up cover plate -2- and remove.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

Shown in illustration with gearbox removed.

– Remove bolts -1 ... 8- on engine/gearbox flange.

– Detach starter.

Note

The manual gearbox can be detached from the engine without a

workshop hoist, a 2nd mechanic is required for this purpose.

– Separate gearbox from engine.

1.3 Securing engine to assembly stand

1. Removing and installing engine, detaching from gearbox 21

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Lifting tackle - 2024 A-
♦ Workshop hoist - VAS
6100-
♦ Engine and gearbox sup‐
port - VAS 6095-

• Gearbox detached from engine.

– Engage lifting tackle - 2024 A- on engine and workshop hoist
- VAS 6100- .

Note

To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

The support hooks and locating pins on the lifting tackle mustto the correctness of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect
be secured with locking pins (arrows in illustration).

– Lift engine off engine bracket - T10012- using workshop hoist

- VAS 6100- .
Secure engine to engine and gearbox support - VAS 6095- when
dismantling/assembling engine.

22 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.4 Installing engine

• Engine attached to engine bracket - T10012-
Installation is carried out in the reverse order; note the following:

Note

♦ Reinstall all cable ties in the same locations when assembling.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
♦ Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease (⇒ Parts catalogue ) to the splines. Then
move clutch plate back and forth on input shaft until the hub
moves smoothly on the shaft. Remove any excess grease.

– Check whether dowel sleeves for centring the engine/gearbox

assembly are fitted in the cylinder block; install dowel sleeves
if necessary.
– Ensure that the intermediate plate is engaged on the sealing
flange and pushed onto the dowel sleeves -arrows-.
– Check clutch release bearing for wear; renew if necessary.
– Bolt gearbox to engine.

Note

♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques: 15%.

Engine/gearbox securing bolts

Item Bolt Nm
1, 2 M12×65 80
3 1),
4 1) M12×135 80
5…7 M10×60 40
8 M12×90
Protected 65 or commercial purposes, in part or in whole, is not
by copyright. Copying for private
• 1) Bolt with M8 threadedpermitted
pin unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

A: Centring sleeves

1. Removing and installing engine, detaching from gearbox 23

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Push in deflector plate -2- in such a way that the lower lug
engages into the cylinder block and secure on top with bolt
-1-.

Note

Shown in illustration with gearbox removed.

– Guide engine/gearbox assembly into the body.

– Tighten bolts -arrows- of assembly mounting for engine initially

hand-tight.

– Tighten bolts of assembly mounting for gearbox -arrows- ini‐

tially hand-tight.
– Use new securing bolts.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
The bolts are tightened to final torque only after adjusting the en‐
gine mountings ⇒ page 26 .

– Remove engine bracket - T10012- from engine.

24 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Secure pendulum support to gearbox and subframe -1 ... 3-.

– Install drive shafts ⇒ Running gear, front-wheel drive and four-
wheel drive; Rep. gr. 40 .
– Install exhaust system and align it free of stress
⇒ page 221 .
– Charge air conditioner refrigerant circuit ⇒ Air conditioner;
Rep. Gr. 87 .
– Attach and adjust selector mechanism at gearbox ⇒ Rep. gr.
34 .
– Install engine control unit ⇒ Rep. gr. 24 .
– Adjust engine mountings ⇒ page 26 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install air pipes with plug-in connectors ⇒ page 173 .
– Install wiper arms ⇒ Electrical system; Rep. Gr. 92 .
– Install battery ⇒ Electrical system; Rep. gr. 27 .
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Rep. Gr. 24; Servicing fuel injection system .
– Check oil level.
– Fill up with coolant ⇒ page 157 .

Note

♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.
♦ Contaminated or dirty coolant must not be used again.

WARNING

Never use battery charging equipment for boost starting. There

is danger of damaging the vehicle's control units.

Tightening torque
Component Nm
Bolts/nuts M6 10
M8 20
M10
Protected by copyright.45
Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
M12
with 65
respect to the correctness of information in this document. Copyright by AUDI AG.

Except for the following:

Pendulum support to gearbox 40 + 90° 1)2)
Pendulum support to subframe 100 + 90° 1)2)
Terminal B+ to starter 16
Earth wire to gearbox 23
• 1) Renew bolt.
• 2) 90° = one quarter turn.

1. Removing and installing engine, detaching from gearbox 25

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2 Assembly mountings

2.1 Exploded view - assembly mountings

1 - Bolt
❑ Gearbox support to
gearbox
❑ Tightening torque (man‐
ual gearbox) ⇒ Rep. gr.
34
❑ Tightening torque (auto‐
matic gearbox) ⇒ Rep.
gr. 37
2 - Bolts
❑ Pendulum support to
gearbox
❑ Tightening torque (man‐
ual gearbox) ⇒ Rep. gr.
34
❑ Tightening torque (auto‐
matic gearbox) ⇒ Rep.
gr. 37
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Engine support permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

❑ With support arm

with respect to the correctness of information in this document. Copyright by AUDI AG.

4 - Bolt
❑ Engine support to en‐
gine
❑ 45 Nm
5 - Engine mounting
6 - Bolt
❑ Engine mounting to
body
❑ Renew
❑ 40 Nm + 90° (1/4 turn
further)
7 - Connecting bracket
8 - Bolt
❑ Connecting bracket to engine mounting
❑ Renew
❑ 20 Nm + 90° (1/4 turn further)

9 - Bolt
❑ Connecting bracket to body
❑ Renew
❑ 20 Nm + 90° (1/4 turn further)

10 - Bolt
❑ Engine mounting to body
❑ Renew
❑ 40 Nm + 90° (1/4 turn further)

26 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

11 - Bolts
❑ Engine mounting to engine support
❑ Renew
❑ 60 Nm + 90° (1/4 turn further)

12 - Pendulum support
13 - Bolt
❑ Pendulum support to subframe
❑ Tightening torque (manual gearbox) ⇒ Rep. gr. 34
❑ Tightening torque (automatic gearbox) ⇒ Rep. gr. 37
14 - Bolt
❑ Gearbox mounting to gearbox support
❑ Tightening torque (manual gearbox) ⇒ Rep. gr. 34
❑ Tightening torque (automatic gearbox) ⇒ Rep. gr. 37
15 - Bolt
❑ Gearbox mounting to body
❑ Tightening torque (manual gearbox) ⇒ Rep. gr. 34
❑ Tightening torque (automatic gearbox) ⇒ Rep. gr. 37
16 - Gearbox mounting
❑ With support arm
17 - Bolt
❑ Gearbox support to gearbox
❑ Tightening torque (manual gearbox) ⇒ Rep. gr. 34
❑ Tightening torque (automatic gearbox) ⇒ Rep. gr. 37
18 - Bolt
❑ Gearbox support to gearbox
❑ Tightening torque (manual gearbox) ⇒ Rep. gr. 34
❑ Tightening torque (automatic gearbox) ⇒ Rep. gr. 37
19 - Gearbox support

2.2 Checking adjustment of assembly

mountings (engine/gearbox mountings)
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Lift out activated charcoal filter from retainer
-in direction of arrow- with pipes connected and lay aside.

2. Assembly mountings 27
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

The following specifications must be obtained:

♦ There must be a distance of -a- = 16 mm between engine
support -2- and longitudinal member (right-side).
♦ The side surface of the engine support casting -2- must be
aligned parallel to the support arm -1- (dimension x = dimen‐
sion x).

Note

Distance a = 16 mm can also be checked with e.g. a suitable

cylindrical bar.

If the distance measured is too small or too great, proceed as

follows:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

2.3 Adjusting assembly mountings

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

♦ Support bracket - 10 - 222 A-

• Tightening torques ⇒ page 26

• Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
– Remove battery tray -arrows-.

28 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Pull activated charcoal filter with hoses attached upwards out

of the retainer -arrow- and place to side.
– Remove bracket for activated charcoal filter.
– Detach battery tray from front of air duct.

– Position support bracket - 10 - 222 A- on bolted flanges of wing

panels. The spindles face forwards.
– Attach hooks of spindles to engine lifting eyes with shackles -
10 - 222 A /12- .
– Take up weight of engine evenly with both spindles (but do not
raise engine).

– Unscrew bolts -arrows- on engine assembly mounting one af‐

ter the other, renew them (if not already renewed when engine
was installed) and screw in loosely.

– Unscrew bolts -arrows-Protected

on gearbox assembly
by copyright. Copying for mounting one purposes, in part or in whole, is not
private or commercial
after the other, renew them (ifunless
permitted not already
authorised byrenewed when
AUDI AG. AUDI en‐not guarantee or accept any liability
AG does
gine was installed) and screw in loosely.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Slacken bolts on left and right-hand support arms by about two

turns each.

2. Assembly mountings 29
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Using a tyre iron, adjust engine/gearbox assembly between

engine mounting -1- and engine support -4- until the specifi‐
cations listed below are obtained:
• The two bolt heads -2- must be parallel with the edge of the
support arm -3-.
• There must be a distance of -x- = 16 mm between engine
mounting -1- and engine support -4-.

Note

Distance -x- = 16 mm can also be checked with a metal rod of

suitable size, or similar.

– Tighten bolts for assembly mounting at gearbox.

– Ensure that edges of support arm (on gearbox side) -1- and
gearbox mounting -2- are parallel.
• Dimension -x- must be identical on both sides of mounting.
– Tighten bolts for assembly mounting.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Tighten bolts for front section of longitudinal member ⇒ Rep.
gr. 50 .
– Install battery ⇒ Electrical system; Rep. gr. 27 .

30 Rep. gr.10 - Removing and installing engine

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

13 – Crankshaft group
1 Cylinder block (pulley end)

1.1 Exploded view - poly V-belt, bracket for

ancillaries

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tip pen. If the belt runs in the opposite direction when
it is refitted, this can cause breakage. Ensure that the belt is prop‐
erly seated in the pulleys when installing.

1 - Pulley
❑ For poly V-belt
❑ Removing and installing
⇒ page 37
2 - Special bolt
❑ 20 Nm + 90°
Renew ⇒ Parts catalogue

3 - 23 Nm
4 - Tensioner for poly V-belt
❑ Pivot with open-end
spanner to slacken poly
V-belt
❑ Secure tensioner in po‐
sition using locking pin -
T10060A-
5 - Bracket for ancillaries Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 34
6 - 23 Nm
7 - 23 Nm
8 - Alternator
❑ Removing and installing
⇒ Electrical system; Re‐
pair group 27
❑ To facilitate attachment
of alternator, knock
back threaded bushes
for alternator securing
bolts slightly
9 - Bolt
❑ Apply locking fluid when
fitting
❑ Locking fluid ⇒ Parts catalogue
❑ Observe correct tightening sequence ⇒ page 34

1. Cylinder block (pulley end) 31

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

10 - Bush
❑ 2x
11 - 25 Nm
12 - Air conditioner compressor
❑ Removing and installing ⇒ Air conditioning; Repair group 87
13 - Poly V-belt
❑ Routing of poly V-belt ⇒ page 32
❑ Check for wear
❑ Do not kink
❑ Removing and installing ⇒ page 32

Routing of poly V-belt

Tightening sequence on bracket for ancillaries

1. Screw in bolts -1 ... 6- hand-tight.
2. Tighten bolts -1 ... 6- to 40 Nm.

32 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Locking pin - T10060A-

♦ Spring type clip pliers - VAS 5024 A-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Lift out activated charcoal filter from retainer with pipes con‐
nected -arrow- and lay aside.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Before removing, mark direction of rotation of poly V-belt with
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

chalk or felt-tip pen. If the belt runs in the opposite direction when
with respect to the correctness of information in this document. Copyright by AUDI AG.

it is refitted, this can cause breakage.

– Mark direction of rotation of poly V-belt.

– To slacken poly V-belt, turn tensioner in -direction of arrow-.

1. Cylinder block (pulley end) 33

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Lock tensioner in position with locking pin - T10060A- .

– Remove poly V-belt.
Installing
Installation is carried out in the reverse order; note the following:

Note

Before fitting poly V-belt, make sure all ancillary units (alternator
and air-conditioner compressor) are firmly secured.

– Fit the poly V-belt onto the crankshaft and air conditioner com‐
pressor pulleys.
– Then position poly V-belt on alternator pulley and release ten‐
sioner.
– Check that poly V-belt is in correct position.
– Start engine and check that belt runs properly.

1.3 Removing and installing bracket for an‐

cillaries
Special tools and workshop
Protected equipment
by copyright. Copying for privaterequired
or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Locking pinwith- T10060A-
respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Spring type clip pliers - VAS 5024 A-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

34 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove the cover above the fuse box (press release tabs
-arrows-).

WARNING

Observe notes on procedure for disconnecting battery ⇒ Elec‐

trical system; Repair group 27 .

– Lift out activated charcoal filter from retainer with pipes con‐
nected -arrow- and lay aside.

Note

Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tip pen. If the belt runs in the opposite direction when
it is refitted, this can cause breakage.

– To slacken poly V-belt, turn tensioner in -direction of arrow-.

1. Cylinder block (pulley end) 35

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Lock tensioner in position with locking pin - T10060A- .

– Take off poly V-belt.

– Discharge refrigerant system ⇒ Rep. gr. 87 ; Air conditioner

with refrigerant R134a .
– Remove alternator ⇒ Electrical system; Repair group 27 .
– Remove noise insulation ⇒ Rep. gr. 50 .

– Remove noise insulation (right-side) -fasteners 1 ... 3-.

– Remove air conditioner compressor ⇒ Rep. gr. 87 ; Heating
and air conditioning .

– Detach bracket for ancillaries: bolts -1 … 6-.

Installing
Installation is performed in reverse sequence; note the following:
• Tightening torques ⇒ page 31

36 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Tighten bolts in the sequence -1 ... 6-.

– Install alternator ⇒ Electrical system; Repair group 27 .
– Install air conditioner compressor ⇒ Rep. gr. 87 ; Heating and
air conditioning .
– Install poly V-belt ⇒ page 32 .
– Connect battery. Procedures required ⇒ Electrical system;
Repair group 27 .

1.4 Removing and installing vibration damp‐

er
Removing
• Poly V-belt must be removed ⇒ page 32 .
– Remove centre noise insulation -1 ... 3-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove noise insulation (right-side) -fasteners 1 ... 3-.

1. Cylinder block (pulley end) 37

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove vibration damper / pulley.

Note

To loosen and tighten the crankshaft pulley, counterhold central

bolt with a ring spanner.

Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 31

– Install the crankshaft pulley with genuine bolts only: ⇒ Parts

catalogue .
♦ Assembly is only possible in one position: The hole -arrow- in
the crankshaft pulley must fit over the projection on the toothed
belt sprocket.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.5 Front sealing flange - exploded view

38 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Bolt
❑ 90 Nm + 90° (1/4 turn)
further
❑ Renew
❑ Do not lubricate with oil
❑ Attaching counterhold
tool -3415- ⇒ page 64
2 - Crankshaft sprocket
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
❑ Can only be installed in
one position
3 - Bolt
❑ Tightening sequence
⇒ page 39
4 - Oil seal
❑ Renewing ⇒ page 40
❑ Do not lubricate with oil
5 - Sealing flange (front)
❑ Must be positioned on
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
dowel pins with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Removing and installing

⇒ page 42
6 - Dowel pins
7 - Diamond-coated washer for
toothed belt sprocket
❑ Renew washer if tooth‐
ed belt sprocket is re‐
moved
8 - Bolt
❑ Tightening sequence ⇒ page 39
9 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 52
❑ Dismantling and assembling pistons and conrods ⇒ page 58

Tightening sequence for front sealing flange

1. Screw in bolts -1 ... 10- hand-tight.
2. Tighten bolts -1 ... 6- in diagonal sequence and in stages to
15 Nm.
3. Tighten bolts -7 ... 10- to 15 Nm.

1. Cylinder block (pulley end) 39

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.6 Renewing crankshaft oil seal - pulley end

Special tools and workshop

equipment required
♦ Oil seal extractor - 3203-
♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
♦ Torque wrench - V.A.G
1331-
♦ Torque wrench - V.A.G
1332-

Removing
– Remove poly V-belt ⇒ page 32 .
– Remove toothed belt ⇒ page 61 .
– Remove crankshaft toothed belt sprocket. To do this, coun‐
terhold sprocket with special tool - 3415- .

40 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew central bolt -1- for crankshaft toothed belt sprocket

-2- and remove sprocket.
– Remove diamond-coated washer -3- from toothed belt sprock‐
et.
– To guide oil seal extractor, screw central bolt into crankshaft
onto stop by hand.
– Unscrew inner part of oil seal extractor - 3203- nine turns (ap‐
prox. 20 mm) from the outer part and lock in position with the
knurled screw.

– Lubricate threaded head of oil seal extractor - 3203- , place it

in position and, exerting firm pressure, screw it into oil seal as
far as possible.
– Loosen knurled screw and turn inner part against crankshaft
until oil seal is pulled out.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
Installing
• Tightening torques ⇒ page 38
– Clean contact surface and sealing surface.
– Remove oil residue from crankshaft journal with a clean cloth.

– Position guide sleeve T10053/1 from assembly tool - T10053-

on crankshaft journal.
– Push oil seal over guide sleeve onto crankshaft journal.

– Press in oil seal with central bolt of toothed belt sprocket and
thrust sleeve of assembly tool - T10053- until flush.

1. Cylinder block (pulley end) 41

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Install crankshaft toothed belt sprocket -2- with new diamond-

coated washer -3- and new central bolt -1-.

Note

♦ Contact surfaces between toothed belt sprocket, diamond-

coated washer and crankshaft must be free of oil.
♦ Do not lubricate bolt for crankshaft sprocket.

1.7 Removing and installing sealing flange (front)

42 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
♦ Torque wrench - V.A.G
1331-
♦ Torque wrench - V.A.G
1332-
♦ Electric drill with plastic
brush attachment
♦ Safety goggles
♦ Sealant ⇒ Parts catalogue

Removing
– Remove poly V-belt ⇒ page 32 .
– Remove toothed belt ⇒ page 61 .
– Remove crankshaft toothed belt sprocket. To do this, coun‐
terhold sprocket with special tool - 3415- .

1. Cylinder block (pulley end) 43

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew central bolt -1- for crankshaft toothed belt sprocket

-2- and remove sprocket.
– Remove diamond-coated washer -3- from toothed belt sprock‐
et.

– Remove bolts -1 ... 10-.

– Lever off front sealing flange and remove.
– Drive out oil seal with flange removed.
Installing
• Tightening torque ⇒ page 38

Note

Place a cloth over the exposed section of the sump.

– Carefully remove any sealant residue on the cylinder block

and sump.

WARNING

Put on safety goggles.

– Remove sealant residue from sealing flange with rotating plas‐

tic brush or similar.
– Clean sealing surfaces; they must be free of oil and grease.

– Cut off tube nozzle at front marking

Protected by(nozzle approx.
copyright. Copying 2 mmor ∅).
for private commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

44 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.

– Apply the bead of sealant onto the clean sealing surface of the
sealing flange as illustrated -arrow-.
• Thickness of sealant bead: 2 ... 3 mm

Caution

Make sure oil strainer is not clogged by excess sealant.

♦ The sealant bead must not be thicker than specified.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Sealant bead must not be wider than 3 mm, otherwise excess

sealant could ingress into sump and clog strainer in oil intake pipe.

– Coat the lower sealing surface on the sealing flange lightly with
sealant -hatched area-.

Note

The sealing flange must be installed within 5 minutes after apply‐

ing sealant.

– Push the sealing flange carefully onto the dowel pins on the
cylinder block.

Note

Use guide sleeve - T10053/1- to attach sealing flange with oil seal
fitted.

– Tighten sealing flange bolts in three stages as follows:

1. Screw in bolts -1 ... 10- hand-tight.
2. Tighten bolts -1 ... 6- in diagonal sequence and in stages.
3. Then tighten bolts -7 ... 10-.
– Install crankshaft oil seal (pulley end) ⇒ page 41 .

1. Cylinder block (pulley end) 45

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Install crankshaft toothed belt sprocket -2- with new diamond-

coated washer -3- and new central bolt -1-.

Note

♦ Contact surfaces between toothed belt sprocket, diamond-

coated washer and crankshaft must be free of oil.
♦ Do not lubricate bolt for crankshaft sprocket.

– Use counterhold tool - 3415- to tighten crankshaft toothed belt

sprocket.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install toothed belt ⇒ page 61 .
– Install crankshaft pulley ⇒ page 37 .
– Install poly V-belt ⇒ page 32 .

Note

Thread and shoulder must be free of oil and grease.

46 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2 Cylinder block (gearbox end)

2.1 Rear sealing flange and dual-mass flywheel - exploded view

Note

Servicing clutch ⇒ Rep. gr. 30

1 - Bolt
❑ For dual-mass flywheel/
drive plate
❑ 60 Nm + 90° (1/4 turn)
further
❑ Renew
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Dual-mass flywheel permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Removing and installing
dual-mass flywheel
⇒ page 48
❑ Can only be installed in
one position. Holes are
off-set
3 - Intermediate plate
❑ Must be positioned on
dowel sleeves
❑ Do not damage/bend
when assembling
❑ Is fitted onto sealing
flange ⇒ page 48
4 - Bolt
❑ Tightening sequence
⇒ page 48
5 - Sealing flange with oil seal
(rear)
❑ Renew only as com‐
plete unit
❑ Use guide sleeve provi‐
ded when fitting
❑ Removing and installing
⇒ page 49
❑ Do not lubricate/grease
sealing lip of oil seal
❑ Before installing, remove oil residue from crankshaft journal with a clean cloth.
❑ Guide sleeve is not to be removed until sealing flange has been slipped onto crankshaft journal
6 - Dowel pin
7 - Bolt
❑ Tightening sequence ⇒ page 48
8 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 52
❑ Dismantling and assembling pistons and conrods ⇒ page 58

2. Cylinder block (gearbox end) 47

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Tightening sequence (rear)

1. Screw in bolts -1 ... 8- hand-tight.
2. Tighten bolts -1 ... 6- in diagonal sequence and in stages to
15 Nm.
3. Tighten bolts -7 ... 8- to 15 Nm.

– Fit intermediate plate on sealing flange and push onto dowel

sleeves -arrows-.

2.2 Removing and installing dual-mass fly‐

wheel
Special tools and workshop equipment required
♦ Counterhold tool - 3067-

Removing
• Gearbox and clutch removed

Caution

To prevent damage to the dual-mass flywheel when removing,

the bolts -B- must not be removed with an impact wrench or
similar. The bolts may only be removed by hand using con‐
ventional tools.

– Mark position of dual-mass flywheel in relation to engine.

48 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Rotate the dual-mass flywheel -A- so that the bolts -B- align
centrally with the holes -arrows-.
– When unscrewing bolts -B-, ensure that none of the bolt heads
come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged as the bolts are screwed
out further.

– Insert counterhold tool - 3067- in hole on cylinder block -B-.

– Unbolt dual-mass flywheel.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torque ⇒ page 47
– Use new securing bolts.

– Insert counterhold - 3067- in hole on cylinder block -A-.

2.3 Removing and installing sealing flange

(rear)
Special tools and workshop equipment required
♦ Electric drill with plastic brush attachment
♦ Safety goggles

2. Cylinder block (gearbox end) 49

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Sealant ⇒ Parts catalogue

Removing
• Gearbox removed
– Remove dual-mass flywheel ⇒ page 48 .
– Detach intermediate plate at sealing flange and dowel sleeves
-arrows-.

– Remove bolts -1 ... 8-.

– Pull off sealing flange (rear).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.

• Tightening torques ⇒ page 47

Note

Place a cloth over the exposed section of the sump.

– Carefully remove any sealant residue on the cylinder block

and sump.
– Clean sealing surfaces; they must be free of oil and grease.

– Cut off tube nozzle at front marking (nozzle approx. 2 mm ∅).

– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.

50 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Coat the lower sealing surface on the sealing flange lightly with
sealant -hatched area-.

Caution

Make sure oil strainer is not clogged by excess sealant.

♦ The sealant bead must not be thicker than specified.

Note

The sealing flange must be installed within 5 minutes after apply‐

ing sealant. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Carefully push sealing flange -2- together with guide sleeve

-1- (fitted on replacement part) onto crankshaft when instal‐
ling.
– Push the sealing flange carefully onto the dowel sleeves on
the cylinder block.

– Tighten bolts in the specified sequence:

1. Screw in bolts -1 ... 8- hand-tight.
2. Tighten bolts -1 ... 6- in diagonal sequence and in stages.
3. Tighten bolts -7 ... 8-.

Remaining installation steps are carried out in reverse sequence;

note the following:
– Fit intermediate plate on sealing flange and push onto dowel
sleeves -arrows-.
– Install dual-mass flywheel ⇒ page 48 .

2. Cylinder block (gearbox end) 51

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

3 Crankshaft

3.1 Exploded view - crankshaft

Note

Secure engine to repair stand using engine and gearbox support

- VAS 6095- when dismantling/assembling engine ⇒ page 21 .

1 - 65 Nm + 1/4 turn (90 °) fur‐

ther
2 - Bearing caps
❑ Bearing cap 1: Pulley
end
❑ Bearing shell retaining
lugs (cylinder block/
bearing cap) must be on
the same side
3 - 10 Nm + 1/4 turn (90 °) fur‐
ther
❑ Renew
❑ Sender wheel must be
renewed if bolts are
loosened ⇒ page 53
4 - Needle bearing
❑ For vehicles with man‐
ual gearbox
❑ Extracting and driving in
⇒ page 55
5 - Sender wheel
❑ For engine speed send‐
er - G28-
❑ Can only be installed in
one position. Holes are
off-set
❑ Sender wheel must be
renewed if bolts are
loosened Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 53
6 - Crankshaft
❑ Axial clearance when
new: 0.07...0.23 mm; wear limit: 0.30 mm
❑ Check radial clearance with Plastigauge: New: 0.017...0.037 mm; wear limit: 0.15 mm
❑ Do not rotate the crankshaft when checking the radial clearance
❑ Crankshaft dimensions ⇒ page 54
7 - Thrust washers
❑ For bearing No. 3
8 - Bearing shell for cylinder block
❑ With oil groove
❑ Do not interchange used bearing shells (mark positions)

52 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

❑ Classification for replacement parts ⇒ page 53

9 - Chain sprocket
❑ For oil pump chain
❑ Renewing ⇒ page 56
10 - Bearing shell
❑ Without oil groove
❑ Do not interchange used bearing shells (mark positions)
❑ The crankshaft bearing shells in the bearing caps are only supplied as spare parts with “yellow” colour-
coding.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing and installing sender wheel
– Sender wheel -2- must always be renewed after slackening off
bolts -1-.

Note

♦ If the countersunk bolts are tightened a second time, the seats

for the bolt heads in the sender wheel will be deformed to such
an extent that the bolt heads make contact with the crankshaft
-3- -arrows- and the sender wheel beneath the bolts will be
loose.
♦ Sender wheel can only be fitted in one position because holes
are offset.

• Tightening torque ⇒ page 52

Identification of top crankshaft bearings

Note

Arrow points in direction of travel.

Top bearing shells of the correct thickness are allocated to the

cylinder block at the factory. Coloured dots are used to identify
the thickness of the bearing shells.
Letter codes on the lower sealing surface of the cylinder block
indicate the thickness of the bearing shell to be fitted at each lo‐
cation.
B = Blue
R = Red
G = Yellow
S = Black
W = White

Note

♦ Use blue bearing shells if the identification is no longer visible.

♦ The bottom crankshaft bearing shells are only supplied as re‐
placement parts with “yellow” marking.

3. Crankshaft 53
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

3.2 Crankshaft dimensions

(in mm)
Honing dimension Crankshaft main Conrod journal ∅
bearing journal ∅
-0.017 -0.022
Basic dimension 54.00 47.80
-0.037 -0.042

3.3 Measuring axial clearance of crankshaft

Special tools and workshop equipment required
♦ Universal dial gauge bracket - VW 387-

♦ Dial gauge - VAS 6079-

Procedure
– Bolt dial gauge - VAS 6079- with dial gauge bracket - VW 387-
onto cylinder block and set it against crank web.
– Push crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 ... 0.23 mm.
• Wear limit: 0.30 mm.

3.4 Measuring radial clearance of crank‐

shaft
Special tools and workshop equipment required
♦ Plastigauge

54 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Procedure

Note

♦ Do not interchange used bearings.

♦ Bearing shells worn down to nickel layer must be renewed.

– Remove main bearing caps and clean bearing caps and jour‐
nals.
– Place Plastigauge onto bearing journal or into bearing shells
(length of Plastigauge should correspond to width of bearing).
• The Plastigauge must be positioned in the centre of the bear‐
ing shell.
– Fit main bearing caps and tighten to 65 Nm without rotating
crankshaft.
– Remove main bearing caps once more.
– Compare width of Plastigauge with measurement scale:
Radial clearance:
• New: 0.017 ... 0.037 mm.
• Wear limit: 0.15 mm.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

3.5 Extracting and driving in needle bearing

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

for crankshaft
Special tools and workshop equipment required
♦ Puller - T10055-

♦ With adapter - T10055/3-

♦ Centring mandrel - 3176-

♦ Or drift - VW 207 C-
♦ Puller e.g. Kukko - 21/2-

3. Crankshaft 55
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Removing
– Extract with commercially available puller e.g. Kukko - 21/2-
-arrow-, adapter - T10055/3- and puller - T10055- .
Installing

Note

The lettering on the needle bearing must be visible when installed.

– Drive in with drift - VW 207 C- or centring mandrel - 3176- .

3.6 Removing and installing chain sprocket

Special tools and workshop equipment required
♦ Drift sleeve - 30 - 100-

56 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Thrust plate - 40 - 105-

♦ Two-arm puller, commercially available

♦ Protective gloves
Removing
– Remove sump with oil pump ⇒ page 128 .
– Remove front sealing flange ⇒ page 42 .
– Pull chain sprocket off crankshaft with puller -2- (Kukko 44-1
or similar). Use special tool 40-105 to protect end of crank‐
shaft.
Installing
Installation is carried out in the reverse order; note the following:

WARNING

Wear protective gloves.

– Heat chain sprocket in oven for approx. 15 minutes to 220 ℃.

Note

Installation position: wide collar on sprocket facing towards en‐

gine,
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Fit chain sprocket on end ofwith
crankshaft
respect to theusing pliers,
correctness and press
of information in this document. Copyright by AUDI AG.
onto crankshaft as far as the stop using drift sleeve - 30 - 100- .
– Install sump with oil pump ⇒ page 128 .

3. Crankshaft 57
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

4 Exploded view - pistons and conrods

1 - Conrod bolt
❑ Vehicles with engine co‐
des AXX, BPY, BWA: 30
Nm + turn 90° further
❑ Engines with code let‐
ters BHZ, BZC, CDLA,
CDLC: 45 Nm + turn 90°
further
❑ Renew
❑ Lubricate threadsCopying
Protected by copyright. and for private or commercial purposes, in part or in whole, is not
contact
permitted surface
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Use old bolts when
measuring radial clear‐
ance
❑ To measure radial clear‐
ance, tighten to 30 Nm
but do not turn further
2 - Pressure relief valve
27 Nm
❑ Opening pressure:
1.6 ... 1.9 bar
3 - Oil spray jet
❑ For piston cooling
4 - Conrod bearing cap
❑ Note installation posi‐
tion
❑ 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 cylinder number -B-
❑ Installation position: Markings -A- face towards pulley end
5 - Bearing shells
❑ Upper bearing shell with oil hole for piston pin lubrication
❑ Installation position ⇒ page 60
❑ Do not interchange used bearing shells (mark positions)
❑ Axial clearance when new: 0.10...0.30 mm; wear limit: 0.40 mm
❑ Check radial clearance with Plastigauge - (new): 0.02 ... 0.06 mm; wear limit: 0.09 mm. Do not turn
crankshaft when measuring radial clearance
6 - Conrod
❑ Only renew as a complete set
❑ Mark cylinder number -B-
❑ Installation position: Markings -A- face towards pulley end
❑ With oil drilling for piston pin lubrication

58 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

7 - Circlip
8 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift - VW 222 A-
9 - Piston
❑ Checking ⇒ page 60
❑ Mark installation position and cylinder number
❑ Arrow on piston crown points to pulley end
❑ Install using piston ring clamp
❑ Piston and cylinder dimensions ⇒ page 60
❑ Checking cylinder bore ⇒ page 60
10 - Piston rings
❑ Offset gaps by 120 °
❑ Use piston ring pliers to remove and install
❑ “TOP” must face towards piston crown
❑ Checking ring gap ⇒ page 59
❑ Checking ring-to-groove clearance ⇒ page 59

CheckingProtected
pistonbyring gapCopying for private or commercial purposes, in part or in whole, is not
copyright.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Insert ring
with at right
respect angle
to the to cylinder
correctness wall
of information from
in this above
document. and push
Copyright by AUDI AG.
down into lower cylinder opening approx. 15 mm from bottom
of cylinder. Use a piston without rings to push ring into bore.
Piston ring New Wear limit
(in mm)
Compression ring 0.20 … 0.40 0.8
Oil scraper ring 0.25 … 0.55 0.8

Checking ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring New Wear limit
(in mm)
Compression ring 0.035 … 0.075 0.15
Oil scraper ring 0.03 … 0.065 0.15

4. Exploded view - pistons and conrods 59

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Checking piston
– Measure approx. 10 mm from the bottom edge, perpendicular
to the piston pin axis.
♦ Difference between actual and nominal diameter: not more
than 0.04 mm.

Checking cylinder bore

Special tools and workshop equipment required

♦ Cylinder dial gauge 50...100 mm
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
♦ Difference between actual and nominal diameter: not more
than 0.08 mm.
Installation position of bearing shellby AUDI AG. AUDI AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised

Bearing shell -1- with oil drilling -arrow- for conrod.

with respect to the correctness of information in this document. Copyright by AUDI AG.

Bearing shell -2- without oil drilling for conrod bearing cap.
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Dimension -a- must be identical on both sides.

4.1 Piston and cylinder dimensions

Honing dimension Piston ∅ Cylinder bore ∅
Basic dimension mm 82.465 1) 82.51
• 1)Dimensions not including graphite coating (thickness 0.02
mm). The graphite coating will wear down in service.

60 Rep. gr.13 - Crankshaft group

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

15 – Cylinder head, valve gear

1 Toothed belt drive
Toothed belt drive, vehicles without separate toothed belt covers
Exploded view ⇒ page 61
Removing and installing ⇒ page 64
Toothed belt drive, vehicles with separate toothed belt covers
Exploded view ⇒ page 72
Removing and installing ⇒ page 75

1.1 Toothed belt drive - exploded view (ve‐

hicles without separate toothed belt cov‐
ers) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Vehicles from 01/2006 onwards are fitted with a new type of

toothed belt cover. Identification: the top section of the toothed
belt cover has no cap ⇒ Item 25 (page 63) and the toothed belt
cover is divided near the engine support. Vehicles with separate
toothed belt covers - exploded view ⇒ page 75 .

Mark the rotation direction of the toothed belt with chalk or felt-tip
pen before removing. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.

1. Toothed belt drive 61

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Bolt
❑ 10 Nm
❑ Apply locking fluid when
fitting
❑ Locking fluid ⇒ Parts
catalogue
2 - Toothed belt cover (top)
3 - Bolt
❑ 50 Nm + turn 180° fur‐
ther
❑ Renew
❑ Use counterhold tool -
3036- when loosening
and tightening
⇒ page 63
4 - Camshaft sprocket
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Before removing andtoin‐
with respect the correctness of information in this document. Copyright by AUDI AG.
stalling component, re‐
move toothed belt
⇒ page 64
❑ Installation position
fixed by Woodruff key
⇒ Item 7 (page 62)
❑ Detaching camshaft
sprocket ⇒ page 63
5 - Bolt
❑ 10 Nm
❑ Apply locking fluid when
fitting
❑ Locking fluid ⇒ Parts
catalogue
6 - Toothed belt cover (rear)
7 - Woodruff key
❑ Check for firm attachment
8 - Nut
❑ 25 Nm
9 - Semi-automatic tensioning roller
10 - Coolant pump
❑ Removing and installing ⇒ page 165
11 - O-ring
❑ Renew
❑ Lubricate with coolant
12 - Bolt
❑ 25 Nm
13 - Damper wheel
14 - Bolt
❑ 15 Nm
15 - Bolt
❑ 35 Nm

62 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

16 - Damper wheel
17 - Sealing flange
❑ Removing and installing ⇒ page 42
18 - Diamond-coated washer for toothed belt sprocket
❑ Renew washer if toothed belt sprocket is removed
19 - Crankshaft sprocket
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
20 - Bolt
❑ 90 Nm + 90° (1/4 turn) further
❑ Renew
❑ Do not lubricate with oil
❑ Attaching counterhold tool -3415- ⇒ page 64
21 - Toothed belt
❑ Before removing, mark direction of rotation with chalk or felt-tip pen
❑ Check for wear
❑ Removing ⇒ page 64
❑ Installing (adjusting valve timing) ⇒ page 64
22 - Toothed belt cover (bottom)
23 - Engine support
❑ Removing ⇒ Removing and installing toothed belt ⇒ page 64
24 - Bolt
❑ 40 Nm
❑ Observe
Protected by correct tightening
copyright. Copying sequence
for private ⇒purposes,
or commercial page 71 in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
25 - Cap with
for respect
toothedto thebelt coverof information in this document. Copyright by AUDI AG.
correctness

Loosening camshaft sprocket

– Use counterhold - 3036- when loosening and tightening cen‐
tral bolt.

Detaching camshaft sprocket

– Use two-arm puller - T40001- with claws T40001/6 and
T40001/7 to detach camshaft sprocket.

1. Toothed belt drive 63

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Removing and installing crankshaft sprocket

– Use counterhold - 3415- when loosening and tightening cen‐
tral bolt.

1.2 Removing and installing toothed belt

(vehicles without separate toothed belt
covers)

Note

Vehicles from 01/2006 onwards are fitted with a new type of

toothed belt cover. Identification: the top section of the toothed
belt cover has no cap ⇒ Item 25 (page 63) and the toothed belt
cover is divided near the engine support. Removing and installing
toothed belt (vehicles with separate toothed belt covers)
⇒ page 75 .

Special tools and workshop equipment required

♦ Support bracket - 10 - 222 A-

♦ Shackle - 10 - 222 A /12-

64 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Pin wrench - T10020-

♦ Locking pin - T10060A-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover filler cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Remove noise insulation ⇒ Rep. gr. 50 .
– Remove noise insulation (right-side) -fasteners 1 ... 3-.

1. Toothed belt drive 65

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew bolts -1 ... 3- and remove pendulum support.

– Unscrew bolts -arrows- and remove charge air pipe together

with hoses.
– Drain off coolant ⇒ page 157

WARNING

Fuel supply line is pressurised. Wear safety goggles and pro‐

tective clothing to avoid possible injury and skin contact. Before
opening hose connections wrap a cloth around the connection.
Then release pressure by carefully pulling hose off connection.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Mark fuel line -1- and line going to ACF -2-.
– Disconnect fuel line -1-.
– Disconnect ACF line -2-.
– Disconnect ACF line going to tank -3-.
– Lift out ACF in -direction of arrow-.

– Detach the coolant hose at the bracket -1-.

– Remove bracket for activated charcoal filter -arrows-.

66 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unbolt filler neck for windscreen washer reservoir -1-.

– Remove retaining clip; to do so, unscrew bolts -2 and 3-.

– Unplug electrical connector -1- from coolant level indicator.

– Detach coolant expansion tank -arrows-.

– Disconnect coolant pipe -arrow-.

– Remove poly-V belt and remove locking pin - T10060A-
⇒ page 32 .

– Position support bracket - 10 - 222 A- on bolted flanges of wing

panels. The spindles face forwards.
– Attach hooks of spindles with shackles - 10 - 222 A /12- to the
lifting eyes.

1. Toothed belt drive 67

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove securing bolts from assembly mounting/engine sup‐

port -arrows- and remove complete assembly mounting.

Caution

When raising engine with support bracket - 10-222A- , ensure

that components/hoses are not damaged, stretched or torn off.

– Set camshaft sprocket to TDC marking by turning crankshaft.

Marking on camshaft sprocket must align with arrow on tooth‐
ed belt cover.

– Remove vibration damper / pulley.

68 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew bolts from toothed belt cover (bottom) -arrows-.

– Loosen bottom bolt -3- and remove engine support from be‐
low.

– Unscrew remaining toothed belt cover bolts -arrows- and re‐

move toothed belt cover from engine.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.
– Turn crankshaft back slightly.
Installing
• Tightening torques ⇒ page 61
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

♦ When turning the camshaft, the crankshaft must not be at

TDC. Otherwise, there is a risk of damage to valves and piston
crowns.
♦ The engine must be no more than warm to touch.

– Fit toothed belt on crankshaft sprocket (note rotation direc‐

tion).
– Secure toothed belt cover (bottom section) with the two bolts
at the bottom.
– Install vibration damper / pulley with new bolts.

1. Toothed belt drive 69

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Turn crankshaft and camshaft to TDC No. 1 cylinder

-arrows-.

– Fit toothed belt in the sequence: tensioning roller, camshaft

sprocket, coolant pump and last onto idler roller -arrow-.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Check tensioning roller is seated correctly in cylinder head.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Tension toothed belt. To do so, turn hexagon key at the ec‐

centric adjuster clockwise (direction of arrow) until the notch
is above the indicator.
– Then release tension on toothed belt.
– Now tension toothed belt until the notch and the indicator are
aligned.
– Tighten securing nut
– Turn crankshaft two turns in direction of engine rotation and
set again to TDC. Make sure that the engine is rotated without
stopping during the final 45° (1/8 turn).
– Check tension of toothed belt again. Specification: indicator
and notch must align.

70 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Check valve timing again.

If the markings do not align:
– Repeat adjustment of valve timing.
If the markings align:

– Install toothed belt cover -arrows-.

Note

Note different bolt lengths. Bolt -3- is approx. 25 mm shorter than

bolts -1 and 2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Insert bottom securing bolt -3- in engine support.

– Install engine support on cylinder block from below and tighten
bolt finger-tight.
– Raise engine with support bracket - 10-222A- until it is possible
to screw in the two top bolts -1 and 2-.
– Tighten all bolts.
– Lower the engine down to installation position.

1. Toothed belt drive 71

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Secure assembly mounting for engine to engine support

-arrows-; to do so, bring surfaces into contact using support
bracket - 10-222A- .
– Remove support bracket - 10-222A- .
– Attach fuel hoses onto connections. Make sure plug-in con‐
nectors are properly secured.
– Install coolant expansion tank.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Connecting
and disconnecting battery .
– Install engine cover panel.
– Install crankshaft pulley ⇒ page 37 .
– Adjust engine mountings ⇒ page 26 .
– Install poly V-belt ⇒ page 32 .
– Install air pipes with plug-in connectors ⇒ page 173 .
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Rep. Gr. 24; Servicing fuel injection system .
– Install insulation tray.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1.3 Toothed belt drive - exploded view (ve‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

hicles with separate toothed belt covers)

Note

Vehicles from 01/2006 onwards are fitted with a new type of

toothed belt cover. Identification: the top section of the toothed
belt cover has no cap ⇒ Item 25 (page 63) and the toothed belt
cover is divided near the engine support. Vehicles without sepa‐
rate toothed belt covers - exploded view ⇒ page 61 .

72 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - 10 Nm
2 - Toothed belt cover (top)
3 - 50 Nm + 180° (1/2 turn) fur‐
ther
❑ Use counterhold tool -
3036- when loosening
and tightening
⇒ page 74
4 - Camshaft sprocket
❑ Installation position
fixed by Woodruff key
⇒ Item 7 (page 73)
❑ Detaching camshaft
sprocket ⇒ page 74
5 - 10 Nm
❑ Apply locking fluid when
fitting
6 - Toothed belt cover (rear)
7 - Woodruff key
❑ Check for firm attach‐
ment
8 - 25 Nm
9 - Semi-automatic tensioning
roller
10 - Coolant pump
❑ Removing and installing
⇒ page 165
11 - O-ring
❑ Renew
12 - 25 Nm
13 - Damper wheel
14 - 15 Nm
15 - 35 Nm
16 - Damper wheel
17 - Sealing
Protected flange
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑respect
with Removing and installing
to the correctness of information ⇒ page
in this 42 Copyright by AUDI AG.
document.

18 - Diamond-coated washer
❑ Renew
19 - Crankshaft sprocket
❑ Contact surfaces between toothed belt sprocket, diamond-coated washer and crankshaft must be free
of oil
❑ Can only be installed in one position
20 - 90 Nm + 90° (1/4 turn) further
❑ Renew
❑ Do not lubricate with oil
❑ Use counterhold tool - 3415- when loosening and tightening ⇒ page 74
21 - Toothed belt
❑ Before removing, mark direction of rotation with chalk or felt-tip pen

1. Toothed belt drive 73

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

❑ Check for wear

❑ Removing and installing ⇒ page 75
22 - Toothed belt cover (bottom)
23 - Securing bolts
❑ For toothed belt cover (bottom)
❑ 7x
❑ 8 Nm
24 - Engine bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
25 - 45 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

Loosening camshaft sprocket

– Use counterhold - 3036- when loosening and tightening cen‐
tral bolt.

Detaching camshaft sprocket

– Use two-arm puller - T40001- with claws T40001/6 and
T40001/7 to detach camshaft sprocket.

Removing and installing crankshaft sprocket

– Use counterhold - 3415- when loosening and tightening cen‐
tral bolt.

74 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.4 Removing and installing toothed belt

(vehicles with separate toothed belt cov‐
ers)

Note

Vehicles from 01/2006 onwards are fitted with a new type of

Special tools and workshop equipment required

♦ Support bracket - 10 - 222 A-

♦ Shackle - 10 - 222 A /12-

♦ Pin wrench - T10020-

1. Toothed belt drive 75

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Locking pin - T10060A-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
WARNING with respect to the correctness of information in this document. Copyright by AUDI AG.

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Remove noise insulation ⇒ Rep. gr. 50 .
– Remove noise insulation (right-side) -fasteners 1 ... 3-.

– Unscrew bolts -1 ... 3- and remove pendulum support.

– Drain off coolant ⇒ page 157 .

WARNING

Fuel supply line is pressurised. Wear safety goggles and pro‐

tective clothing to avoid possible injury and skin contact. Before
opening hose connections wrap a cloth around the connection.
Then release pressure by carefully pulling hose off connection.

76 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Mark fuel line -1- and line going to ACF -2-.

– Disconnect fuel line -1-.
– Disconnect ACF line -2-.
– Disconnect ACF line going to tank -3-.
– Lift out ACF in -direction of arrow-.

– Detach the coolant hose at the bracket -1-.

– Remove bracket for activated charcoal filter -arrows-.

– Unbolt filler neck for windscreen washer reservoir -1-.

– Remove retaining clip; to do so, unscrew bolts -2 and 3-.

– Unplug electrical connector -1- from coolant level indicator.

– Detach coolant expansion tank -arrows-.

1. Toothed belt drive 77

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Disconnect coolant pipe -arrow-.

– Remove poly V-belt ⇒ page 32 .

– Remove tensioner for poly V-belt -arrows-.

– Detach coolant pipe -arrows-.

– Remove bolts -arrows- and detach toothed belt cover.

78 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Position support bracket - 10 - 222 A- on bolted flanges of wing

panels. The spindles face forwards.
– Attach hooks of spindles with shackles - 10 - 222 A /12- to the
lifting eyes.

– Remove securing bolts from assembly mounting/engine sup‐

port -arrows- and remove complete assembly mounting.

Caution

When raising engine with support bracket - 10-222A- , ensure

that components/hoses are not damaged, stretched or torn off.

– Raise engine with support bracket - 10-222A- until it is possible

to loosen and remove the two top bolts -1 and 2- securing the
engine support.

– Unscrew bolts -arrows- and remove charge air pipe together

with hoses.

1. Toothed belt drive 79

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew the bottom bolt -3- and remove engine support from
below.

– Set camshaft sprocket to TDC marking by turning

Protected crankshaft.
by copyright. Copying for private or commercial purposes, in part or in whole, is not

Marking on camshaft sprocket must align with arrow on tooth‐

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
ed belt cover.

– Remove vibration damper / pulley.

Note

♦ The TDC markings must align before the vibration damper is

detached.
♦ Do not rotate the crankshaft unless the TDC position is marked
by an additional marking.

– Unscrew bottom bolts from toothed belt cover (bottom)

-arrows-.

80 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Mark TDC position -arrow-.

– Unscrew both top bolts from toothed belt cover -arrows- and
remove toothed belt cover from engine downwards.
– Remove engine support from engine upwards.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller and remove toothed belt.
– Turn crankshaft back slightly.
Installing
• Tightening torques ⇒ page 72

Note

♦ When turning the camshaft, the crankshaft must not be at

TDC. Otherwise, there is a risk of damage to valves and piston
crowns.
♦ The engine must be no more than warm to touch.

– Turn camshaft and crankshaft to TDC markings.

– Fit toothed belt on crankshaft sprocket (note rotation direc‐
tion).

– Fit toothed belt in the sequence: tensioning roller, camshaft

sprocket, coolant pump and last onto idler roller -arrow-.

1. Toothed belt drive 81

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Note

Check tensioning roller is seated correctly in cylinder head.

– Tension toothed belt. To do so, turn hexagon key at the ec‐

centric adjuster clockwise (direction of arrow) until the notch
is above the indicator (toothed belt over-tensioned).
– Then release tension on toothed belt.
– Now tension toothed belt until the notch and the indicator are
aligned.
– Tighten securing nut
– Turn crankshaft two turns in direction of engine rotation and
set again to TDC. Make sure that the engine is rotated without
stopping during the final 45° (1/8 turn).
– Check toothed belt tension. Specification: indicator and notch
must align.

– Check valve timing. The markings must align -arrows-.

If the markings do not align:
– Repeat adjustment of valve timing.
If the markings align:
– Install engine support on cylinder block and tighten bolts hand-
tight.

Note different bolt lengths. Bolt -3- is approx. 25 mm shorter than

bolts -1 and 2-.

– Lower engine with support bracket - 10-222A- until it is possi‐

ble to tighten the bolt at the bottom -3-.
– Tighten all bolts.
– Install assembly mounting for engine.

82 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Tighten bolts on assembly mounting for engine and engine

support hand-tight -arrows-; to do so, bring surfaces into con‐
tact using support bracket - 10 - 222 A- .
– Detach support bracket - 10 - 222 A- .
– Reconnect fuel and breather pipes. Make sure plug-in con‐
nectors are properly secured.
– Install coolant expansion tank.
– Install crankshaft pulley ⇒ page 37 .
– Adjust engine mountings ⇒ page 26 .
– Install poly V-belt ⇒ page 32 .
– Install air pipes with plug-in connectors ⇒ page 173 .
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Rep. Gr. 24; Servicing fuel injection system .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body front, noise insulation .
– Install engine cover panel/air cleaner.

1. Toothed belt drive 83

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2 Cylinder head

2.1 Cylinder head - exploded view

Note

♦ Renew the cylinder head bolts.

♦ On assembly, renew oil seals and gaskets as well as self-
locking nuts and bolts that are tightened by turning through to
a specified angle.
♦ When installing an exchange cylinder head with fitted cam‐
shafts, oil the contact surfaces between the roller rocker fin‐
gers and cams.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ When fitting a new cylinder head or cylinder head gasket, drain
off all the old coolant and refill with new coolant.

1 - Bolt
❑ Tightening sequence Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 85 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2 - Cylinder head cover
3 - Gasket
❑ Renew if damaged or
leaking
4 - Valve housing
5 - Oil filler cap
6 - Seal
❑ Renew if damaged or
leaking
7 - Bolt
❑ 4 Nm
8 - Gasket for cylinder head
cover
❑ Renew if damaged or
leaking
9 - Vacuum pump
10 - Bolt
❑ 4 Nm
11 - Camshaft control valve 1 -
N205-
❑ Removing ⇒ page 86
12 - Seal
❑ Renew
13 - Bolt
❑ 10 Nm

84 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

14 - Cable retainer
15 - Seal
❑ Renew if damaged or leaking
16 - Bolt
❑ 10 Nm
17 - Housing
18 - Gasket
❑ Renew
19 - Transport plate
20 - Bolt
❑ 25 Nm
21 - Stud for intake manifold
❑ 10 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

22 - Separating plate
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

23 - Cylinder head gasket

❑ Renew
❑ Check installation position: Part No. towards cylinder head
24 - Bolt
❑ 10 Nm
25 - Hall sender - G40-
26 - Seal
27 - Stud for tensioning roller
❑ 10 Nm
28 - Stud for exhaust manifold
❑ 20 Nm
29 - Cylinder head
❑ Checking for distortion ⇒ page 86
30 - Cylinder head bolt
❑ Renew
❑ Note correct sequence when loosening ⇒ page 86
❑ Note correct sequence when tightening ⇒ page 86
❑ Tightening torque: 40 Nm + 1/2 turn (180°) further

Tightening sequence for cylinder head cover

1. Screw in bolts -1 ... 14- hand-tight.
2. Tighten bolts -1 ... 14- to 10 Nm in diagonal sequence.

2. Cylinder head 85
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Slackening cylinder head bolts

– Loosen cylinder head bolts in the sequence indicated and re‐
move.

Tightening sequence for cylinder head

– Tighten cylinder head bolts in the sequence -1 ... 10- as fol‐
lows:
– 1. Tighten with torque wrench initially to 40 Nm.
– 2. Use rigid wrench to turn 90° further
– 3. Use rigid wrench to turn 90° further

Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure for distortion
at several points.
♦ Max. permissible distortion: 0.05 mm

2.2 Removing and installing camshaft control valve 1 - N205-

86 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Torque wrench - V.A.G
1783-
♦ Torx bit set - V.A.G 1766-
♦ Ratchet insert 1/4" - VAS
6234-
♦ Spring type clip pliers -
VAS 5024 A-

Removing

Note

Always renew seals and gaskets.

– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

– Unplug electrical connector -1-.
– Detach wiring harness -2- from bracket.
– Remove bolt -3-.

Note

Do not pull on electrical connector when removing camshaft con‐

trol valve 1 - N205- .

2. Cylinder head 87
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove bolts -arrows- and take camshaft control valve 1 -

N205- out of housing.
Installing
• Tightening torque ⇒ page 84

Note

♦ Make sure the camshaft control valve 1 - N205- and the hous‐
ing are free from any kind of dirt.
♦ Do not remove camshaft control valve 1 - N205- from pack‐
aging until you are ready to install it.

Caution

♦ Do not expose the camshaft control valve 1 - N205- to

shock impacts.

– Lubricate the seal with engine oil.

– Carefully fit camshaft control valve 1 - N205- into housing and
press in by hand as far as the stop (exert pressure in line with
axis of valve).
– Screw in and tighten bolts using torque wrench - V.A.G 1783-
and ratchet insert 1/4" - VAS 6234- , as well as Torx bit T20
and bit holder from Torx bit set .
Further assembly is basically carried out in reverse order of dis‐
mantling.

2.3 Removing and installing cylinder head

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
cover permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
Special tools and workshop equipment required
♦ Spring type clip pliers - VAS 5024 A-

88 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Puller - T40039-

– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

– Unscrew bolts -arrows-.
– Remove ignition coils with output stages ⇒ Rep. gr. 28 .

– Disconnect ACF pipe from cylinder head cover -1-.

– Detach valve housing from cylinder head cover -arrows-.

2. Cylinder head 89
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew crankcase breather line with heat shield from turbo‐

charger -1-.
– Disconnect ACF line going to turbocharger from cylinder head
cover -2-.
– Loosen cylinder head cover working from outside to inside.
– Remove cylinder head cover.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torque ⇒ page 84

Note

Renew cylinder head cover gaskets if damaged.

– Tighten cylinder head cover working from inside outwards.

– Make sure toothed belt cover (top) is correctly fitted.
– Install ignition coils with output stages ⇒ Rep. gr. 28 .

2.4 Removing and installing cylinder head

Special tools
Protected by and workshop
copyright. Copying for private or commercial purposes, in part or in whole, is not
equipment
permittedrequired
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Counterhold tool - 3036-
♦ Two-arm puller - T40001-
♦ Puller - T40039-
♦ Hose clip pliers - V.A.G

90 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1921-

♦ Support bracket - 10 - 222

A-
♦ Shackle - 10 - 222 A /12-
♦ Locking pin - T10060A-
♦ Pin wrench - T10020-
♦ Socket - T10070-

2. Cylinder head 91
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Engine bung set - VAS 6122-

Removing
• Engine in vehicle.

Note

♦ All cable ties which are released or cut open when removing
must be refitted in the same position when installing.
♦ If engine oil is contaminated, perform oil change ⇒ Mainte‐
nance ; Booklet 808 .
♦ Before applying sealant, check information: ⇒ Parts cata‐
logue .

– Obtain code on vehicles with coded radio / radio and naviga‐

tion system (RNS).
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Remove noise insulation ⇒ Rep. gr. 50 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove noise
with respect insulation
to the correctness (right-side)
of information in this -document.
fasteners -1 ...
Copyright 3-. AG.
by AUDI

– Drain off coolant ⇒ page 157

– Use screwdriver to pry off cover caps on wiper arms and un‐
screw hexagon nuts.
– Pull wiper arms off wiper shafts and remove.

– Unclip washer jets -arrow-.

– Push washer jets through assembly opening back into plenum
chamber, leaving hoses connected.

92 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Detach rubber seal -1- from plenum chamber cover.

– Detach plenum chamber cover -2-.
– Detach engine wiring harness at rear plenum chamber panel.

– Remove electrical connector -arrow- for Lambda probe (be‐

fore catalytic converter) from bracket, unplug and move clear.

– Remove plenum chamber intermediate plate -arrows-.

– Disconnect coolant pipe going to coolant expansion tank

-arrow-.

2. Cylinder head 93
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Disconnect coolant hose -1-.

– Disconnect coolant hose -2-.

– Disconnect earth cable -1-.

– Unplug electrical connector -2-.
– Disconnect water hoses -arrows-.
– Remove intake manifold ⇒ Motronic direct injection and igni‐
tion system (4-cylinder); Rep. Gr. 24; Servicing injection sys‐
tem .
– Remove catalytic converter together with front exhaust pipe.
Engines with code letters AXX, BPY, BWA ⇒ page 218 .
Engines with code letters BHZ, BZC, CDLA, CDLC ⇒ page 225
– Remove drive shaft (right-side) ⇒ Rep. gr. 40 .
Vehicles with four-wheel drive

– Remove heat shield above drive shaft using hexagon key ex‐
tension, 8 mm - 3247- .
Vehicles with front-wheel drive

– Unbolt heat shield for drive shaft (right-side) -arrows-.

All vehicles:

94 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Detach air pipe -arrow- from charge air cooler.

– Unbolt air pipe from turbocharger -arrows-.

– Detach electrical connectors -1 and 2- and move wire clear.

– Unscrew bolts -arrows- and remove air pipe.

Note

Shown in illustration from rear with engine removed.

– Unscrew oil supply line for turbocharger at cylinder block -1-.

– Remove oil supply line for turbocharger -2-.

2. Cylinder head 95
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew coolant supply line for turbocharger at cylinder block

-1-.
– Unscrew coolant supply line at turbocharger -2-.
– Detach coolant supply line for turbocharger -3- from cylinder
block.

– Detach oil return line at turbocharger -arrows-.

– Remove bolts -1- and -2- and remove support for turbocharg‐
er.
– Remove toothed belt ⇒ page 61 .

– Loosen camshaft sprocket bolt using counterhold tool - 3036- .

96 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Detach camshaft sprocket using two-arm puller - T40001- with

claws -T40001/6- and -T40001/7- .

– Unbolt toothed belt cover (rear) from cylinder head -arrows-.

– Remove cylinder head cover ⇒ page 88 .

2. Cylinder head 97
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Slacken cylinder head bolts using special wrench - T10070- ,

keeping to sequence shown.

Note

Check that all hoses, pipes and wiring connections between en‐
gine, gearbox and body have been detached.

– Remove cylinder head.

Installing cylinder head
• Tightening torques and tightening sequence ⇒ page 84
• Tightening torques ⇒ page 216

Note

♦ Renew the cylinder head bolts.

♦ On assembly, renew oil seals and gaskets as well as self-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

locking nuts and bolts that are tightened byto turning through to in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect the correctness of information
a specified angle.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.
♦ If repairing, carefully remove any remaining gasket material
from the cylinder head and cylinder block. Ensure that no long
scores or scratches are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive material.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ High-temperature paste ⇒ Parts catalogue

WARNING

Engine must only be turned in direction of rotation (clockwise)

via crankshaft.

Note

Turn over the engine at the central bolt on the crankshaft.

98 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Align mark on camshaft sprocket with mark on toothed belt

cover. The indentations on the camshafts -arrows- face each
other.
– If crankshaft has been rotated: set No. 1 cylinder piston to top
dead centre and then turn crankshaft back slightly.

2. Cylinder head 99
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Place cylinder head gasket in position.

♦ Note position of centring pins in cylinder block -arrows-.
♦ Note installation position of cylinder head gasket. Part No.
should be legible from inlet side.
– Fit cylinder head.
– Insert and hand-tighten cylinder head bolts.
– Tightening sequence for cylinder head
⇒ Item 13 (page 176) :

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Cylinder head bolts do notpermitted
have to beauthorised
unless torqued by down
AUDI AG.again
AUDI AG later
does not guarantee or accept any liability
after repair work. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install cylinder head cover ⇒ page 90 .

– Install wiper arms ⇒ Electrical system; Rep. Gr. 92 .
– Install toothed belt ⇒ page 61 .
– Install poly V-belt ⇒ page 32 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install intake manifold ⇒ Motronic direct injection and ignition
system (4-cylinder); Rep. Gr. 24; Servicing injection system .
– Install air pipes with plug-in connectors ⇒ page 173 .
– Connect battery ⇒ Electrical system; Rep. Gr. 27 .
– Bleed fuel system ⇒ Motronic direct injection and ignition sys‐
tem (4-cylinder); Rep. Gr. 24; Servicing fuel injection system .
– Check oil level ⇒ Maintenance ; Booklet 808 .
– Fill up with coolant ⇒ page 157 .

Note

♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.
♦ Contaminated or dirty coolant must not be used again.

WARNING

Never use battery charging equipment for boost starting. There

is danger of damaging the vehicle's control units.

2.5 Checking compression

100 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Compression tester - V.A.G
1763-
♦ Spark plug spanner - 3122
B-
♦ Puller - T40039-
♦ Spring type clip pliers -
VAS 5024 A-

Test sequence

Note

♦ Engine oil temperature at least 30 °C

♦ Battery voltage at least 12.7 V

– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

– Remove ignition coils with output stages ⇒ Rep. gr. 28 .
– Remove spark plugs with spark plug spanner - 3122 B- .
– Unplug 8-pin connector for injectors ⇒ Rep. gr. by
Protected 24copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Check compression with compression testerwith
- V.A.G
respect to1763-
the correctness of information in this document. Copyright by AUDI AG.
and adapter - V.A.G 1763/6- .

Note

Using the compression tester ⇒ Operating instructions .

– Operate starter until pressure reading on tester no longer

rises.

2. Cylinder head 101

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Compression:
New pressure in bar Wear limit in bar Permissible differ‐
ence between cylin‐
ders in bar
11.0 … 14.0 7.0 3.0 (maximum)
– Install spark plugs.
– Install ignition coils with output stages ⇒ Rep. gr. 28 .

Note

Faults will have been stored in the memory because connectors

have been unplugged. Interrogate and, if necessary, erase fault
memory after completing the check.

– Read out fault memory of engine control unit ⇒ vehicle diag‐

nostic, testing and information system VAS 5051 in the func‐
tion "Guided Fault Finding" .

102 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

3 Valve gear

Note

♦ Cylinder head and retaining frame must be renewed together.

♦ After installing camshafts, wait for approx. 30 minutes before
starting engine. Hydraulic valve compensation elements have
to settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Always fit new seals and gaskets.
with♦respect to the correctness of information in this document. Copyright by AUDI AG.

3.1 Exploded view - valve gear

1 - Bolt
❑ 50 Nm + turn 180° fur‐
ther
❑ Renew
❑ Use counterhold tool -
3036- when loosening
and tightening
⇒ page 63
2 - Camshaft sprocket
3 - Oil seal
❑ Renewing ⇒ page 121
4 - Cylinder head
❑ Machining limit
⇒ page 105
5 - Valve guide
❑ Checking ⇒ page 121
6 - Valve stem oil seal
7 - Valve spring
8 - Upper valve spring plate
❑ Renewing: with cylinder
head installed
⇒ page 113 , with cylin‐
der head removed
⇒ page 118
9 - Cotters
10 - Hydraulic valve clearance
compensation element
❑ Do not interchange
❑ Lubricate contact sur‐

3. Valve gear 103

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

face
11 - Parallel key
❑ Check for firm attachment
12 - Exhaust camshaft
❑ Check radial clearance with Plastigauge (roller rocker fingers removed)
❑ Radial clearance when bearing ∅ is 24 mm: 0.024 ... 0.066 mm
❑ Radial clearance when bearing ∅ is 32 mm: 0.030 ... 0.051 mm
❑ Runout: max. 0.04 mm
13 - Retaining frame
❑ With integrated camshaft bearings
❑ Clean sealing surface; machining not permitted
❑ Remove old sealant residues
14 - Bolt
❑ Tightening sequence ⇒ page 105
❑ Renew
15 - Camshaft adjuster
16 - Bolt
❑ 20 Nm + turn 45° further
❑ Renew
17 - Inlet camshaft
❑ Check radial clearance with Plastigauge (roller rocker fingers removed)
❑ Radial clearance when bearing ∅ is 24 mm: 0.024 ... 0.066 mm
❑ Runout: max. 0.04 mm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
18 - Chain tensioner with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Remove ⇒ page 105 Removing and installing camshaft adjuster

❑ Before removing, lock in place using locking pin - T10115-
19 - Drive chain
20 - Bolt
❑ 10 Nm
21 - Bolt
❑ 10 Nm
22 - Phase sensor
23 - Exhaust valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 105
❑ Checking valve guides ⇒ page 121
24 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 105
❑ Checking valve guides ⇒ page 121
25 - Sealing cap
❑ Renew
❑ Removing sealing cap with retaining frame installed: pierce on one side with an awl and pry out
❑ Installing: press in 1 ... 2 mm deep without sealant using thrust piece - 3334-

104 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Cylinder head machining limit

– Machining of the cylinder head (surface grinding) is only per‐
missible down to the minimum dimension a.
♦ Minimum dimension a = 139.20 mm

Tightening sequence for retaining frame

– Renew bolts
1. Fit bolts in the sequence -1 ... 6- and hand-tighten in several
stages.
2. Tighten bolts in the sequence -1 ... 6- to 8 Nm using torque
wrench.
3. Turn 90° (1/4 turn) further in the sequence -1 ... 6- using a
rigid wrench.

Note

Take care to keep retaining frame straight.

Valve dimensions

Note

Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.

Dimension Inlet valve Exhaust valve

∅a mm 33.85 + 0.10 28.0 + 0.1
∅b mm 5.98 + 0.01 5.96 + 0.01
c mm 104.0 + 0.2 101.9 + 0.2
α ∠° 45 45

3.2 Removing and installing camshaft adjuster

3. Valve gear 105

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Socket - T40080-
♦ Camshaft clamp - T10252-
♦ Pin wrench - T10020-
♦ Locking pin - T10115-

Removing
– Remove high-pressure pump ⇒ Rep. gr. 24 .
– Remove cylinder head cover ⇒ page 88 .
– Remove vacuum pump.
– Remove housing for camshaft adjuster -arrows-.

106 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Align mark on camshaft sprocket with mark on toothed belt

cover. The indentations on the camshafts -arrows- face each
other.

– Fit camshaft clamp - T10252- as shown and secure -arrows-.

– Loosen securing bolt from camshaft adjuster using special
wrench - T40080- .

– Compress chain tensioner -arrow A- and lock with locking pin

- T10115- -arrow B-.
– Remove securing bolt from camshaft adjuster and remove
camshaft adjuster together with chain.
Installing
• Tightening torques ⇒ page 103
• Tightening torques ⇒ page 84

• The camshafts are located with the camshaft clamp -

T10252- .
– Fit chain onto camshaft adjuster.

3. Valve gear 107

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Hold camshaft adjuster in front of exhaust camshaft so that

notch -A- is aligned with pin -B-.

– Lay chain over inlet camshaft sprocket starting at top -arrow-

without changing its position.

– Turn inlet camshaft slowly in direction of arrow -A- using pin

wrench - T10020- until the camshaft adjuster fits onto the
camshaft.

Note

If it is not possible to fit the pin into the notch: remove chain and
fit chain again.

– Renew securing bolt for camshaft adjuster.

– Tighten securing bolt for camshaft adjuster. Protected
Use special
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
wrench - T40080- for this purpose. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove locking pin - T10115- -arrow B-.

Further assembly is basically carried out in reverse order of dis‐
mantling.
– Install cylinder head cover ⇒ page 88 .
– Install high-pressure pump ⇒ Rep. gr. 24 .
– Install vacuum pump ⇒ Rep. gr. 47 .

3.3 Removing and installing camshafts

Special tools and workshop equipment required

108 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Two-arm puller - T40001-

♦ Counterhold tool - 3036-

Removing

Note

♦ Sealing surfaces at bottom of retaining frame and top of cyl‐

inder head may not be machined.
♦ The camshaft bearings are integrated into the cylinder head
and retaining frame. Toothed belt must be slackened before
removing retaining frame.
♦ Renew camshaft oil seal and sealing cap if retaining frame has
been unfastened.

– Remove cylinder head cover ⇒ page 88 .

– Remove camshaft adjuster ⇒ page 105 .
– Remove toothed belt ⇒ page 61 .
– Loosen camshaft sprocket using counterhold tool - 3036- .

3. Valve gear 109

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Use puller - T40001- , claw - T40001/6- and claw - T40001/7-

to pull off camshaft sprocket.
– Detach toothed belt cover (rear) from cylinder head.

– Unscrew retaining frame bolts in the sequence -6 ... 1- and

carefully remove retaining frame.
– Remove camshafts together with drive chain from cylinder
head.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Make sure dirt and remnants permitted
of sealantunlessdo not drop
authorised into
by AUDI AG.cyl‐
AUDI AG does not guarantee or accept any liability
inder head. with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing
• Tightening torques ⇒ page 103
• Tightening torques ⇒ page 84

Note

♦ The sealing surfaces must be free of oil and grease.

♦ Pistons must not be at TDC.
♦ Ensure that all roller rocker fingers contact the valve ends cor‐
rectly.

– Remove old sealant from groove in retaining frame and from

sealing surfaces.
– Make sure dirt and remnants of sealant do not drop into cyl‐
inder head.
– Lubricate running surfaces of the camshafts with oil.

– Position drive chain on chain sprockets as follows (with cam‐

shafts removed):
– Lubricate running surfaces of camshafts.
• Cams -A- of cylinder 4 must face each other.
• Recesses -arrows- on both camshafts must face each other.
• The side surfaces of the recesses should be positioned exactly
vertical.
– Insert camshafts together with drive chain into cylinder head
and chain tensioner.

110 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Check TDC position of camshafts again.

• Cams -A- of cylinder 4 must face each other.
• Recesses -arrows- on both camshafts must face each other.
• The side surfaces of the recesses should be positioned in ex‐
actly vertical line to the cylinder head.
– Lubricate running surfaces of camshafts.

– Apply an even, slightly projecting sealant bead into the clean

groove of the retaining frame.
Sealant ⇒ Parts catalogue

Note

♦ Do not apply the sealant thicker than prescribed.

♦ No time should be allowed to elapse when fitting and securing
retaining frame, as sealant starts to harden as soon as sealing
surfaces make contact.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Note the use-by date of the sealant.

– Fit retaining frame so that it goes past the exhaust gas recir‐
culation valve - N18- -arrow-.
– Renew bolts for retaining frame.
– Tighten bolts lightly in several stages, working from inside out‐
wards.

– Tighten bolts in several stages; tightening sequence

⇒ page 105 .

Note

Take care to keep retaining frame straight.

3. Valve gear 111

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Then check that camshafts are in TDC position (insert cam‐

shaft clamp - T10252- as far as stop).

Note

♦ If necessary, turn camshafts slightly backwards or forwards

when inserting camshaft clamp - T10252- .
♦ Disregard -arrows-.

– If it is not possible to insert camshaft clamp - T10252- , retain‐

ing frame must be removed and camshafts installed for a
second time ⇒ page 110 .
– Detach camshaft clamp - T10252- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Drive in cap ⇒ Item 25 permitted
(page unless
104)authorised
approx.by1AUDI... 2AG.mmAUDIdeep
AG does not guarantee or accept any liability
using thrust piece - 3334- .
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install camshaft oil seal ⇒ page 121 .

– Install toothed belt cover (rear).
– Insert parallel key into camshaft.

– Install camshaft sprocket. To tighten bolt, hold camshaft

sprocket in position using counterhold tool - 3036- .

Note

♦ When turning the camshaft, the pistons must not be at TDC.

This could otherwise result in damage to valves and pistons.
♦ Make sure parallel key is correctly seated.

– Install toothed belt ⇒ page 61 .

– Install camshaft adjuster ⇒ page 105 .
– Install cylinder head cover ⇒ page 88 .
Further assembly is basically carried out in reverse order of dis‐
mantling.

3.4 Checking axial clearance of camshafts

Special tools and workshop equipment required
♦ Universal dial gauge bracket - VW 387-

112 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Dial gauge - VAS 6079-

Test sequence
– Perform measurement with retaining frame removed.
– Fit camshaft to be tested in retaining frame.
– Attach dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder head.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
• Axial clearance: 0.05 ... 0.17 mm

3.5 Renewing valve stem oil seals with cylinder head installed

3. Valve gear 113

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Spark plug spanner - 3122
B-
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Adapters - T40012-
♦ Torque wrench - V.A.G
1331-
♦ Removal and installation
device for valve cotters -
VAS 5161-
♦ Guide plate for 2.0 ltr. and
3.0 ltr. FSI engine - VAS
5161/19B-

Removing valve stem oil seals

– Remove camshafts ⇒ page 108 .

Note

In order to renew the valve stem oil seals of exhaust valves of

cylinder 3 and cylinder 4, the exhaust gas recirculation valve -
N18- must also be removed.

– Remove roller rocker fingers and place onto a clean surface.

When doing so, make sure that roller rocker fingers are not
interchanged.
– Remove spark plugs using spark plug spanner - 3122 B- .

114 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Secure guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS
5161/19B- to cylinder head with knurled screws - VAS
5161/12- as shown.
– Set piston of the respective cylinder to “bottom dead centre”.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Screw adapter - T40012- into spark plug hole and connect to in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information
compressed air supply of at least 6 bar.
– Knock loose sticking valve cotters using punch - VAS 5161/3-
and a plastic-headed hammer.

For inlet side

– Screw snap-in device - VAS 5161/6- with engaging fork - VAS
5161/5- into centre thread on guide plate for 2.0 ltr. and 3.0 ltr.
FSI engine - VAS 5161/19B- .
– Insert assembly cartridge - VAS 5161/8- into guide plate for
2.0 ltr. and 3.0 ltr. FSI engine - VAS 5161/19B- .
– Engage pressure fork - VAS 5161/2- on snap-in device - VAS
5161/6- .

For exhaust side

– Screw snap-in device - VAS 5161/6- with engaging fork - VAS
5161/5- into outer thread on guide plate for 2.0 ltr. and 3.0 ltr.
FSI engine - VAS 5161/19B- .
– Press down assembly cartridge - VAS 5161/8- and at the same
time, turn knurled screw of assembly cartridge - VAS 5161/8-
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork - VAS 5161/2- .
– Take out assembly cartridge - VAS 5161/8- .

3. Valve gear 115

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Pull off valve stem oil seal with valve stem seal puller - 3364- .

– If valve stem seal puller - 3364- cannot be used

Protected on account
by copyright. Copying forof
private or commercial purposes, in part or in whole, is not
restricted space, knock out pin -arrow- with a punch and re‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
move the impact extractor attachment.

– Position lower part of valve stem seal puller - 3364- on valve

stem oil seal.
– Insert a punch -1- through hole in lower section of puller.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.
Installing valve stem oil seals

– To prevent damage to the new valve stem seals -B-, attach

plastic sleeve -A- to valve stem.
– Lubricate sealing lip of valve stem oil seal -B-, place it in the
valve stem seal fitting tool - 3365- and push carefully onto
valve guide.
– Remove plastic sleeve -A-.
– Insert valve spring and valve spring plate.
– Set up removal and installation device - VAS 5161- as shown.

116 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Inlet side

Exhaust side

Note

♦ If valve cotters have been removed from assembly cartridge,

they need to be put into insertion device - VAS 5161/18- first.
♦ Press assembly cartridge -VAS 5161/8- onto insertion device
from above and pick up valve cotters.

– Press down assembly cartridge - VAS 5161/8- with pressure

fork - VAS 5161/2- and pull knurled screw of assembly car‐
tridge up, at the same time turning it in both directions.
– Release the pressure fork - VAS 5161/2- with knurled screw
still in pulled-out position.
– Take off removal and installation device - VAS 5161- .
Further assembly is basically carried out in reverse order of dis‐
mantling.
– Install camshafts ⇒ page 108 .

3. Valve gear 117

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

3.6 Renewing valve stem oil seals with cyl‐

inder head removed

Special tools and workshop equipment required

♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Removal and installation device for valve cotters - VAS 5161-
♦ Guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS 5161/19B-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
Procedure
– Remove camshafts ⇒ page 108 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Secure cylinder headProtected
in cylinder head
by copyright. tensioning
Copying for private device - VAS
or commercial purposes, in part or in whole, is not
6419- , as illustrated.permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Connect cylinder head tensioning device - VAS 6419- to com‐
pressed air supply.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seals are to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.

118 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Fit guide plate -VAS 5161/19B- from removal and installation

device for valve cotters - VAS 5161- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .

– Apply drift -VAS 5161/3- to guide plate and use plastic-headed

hammer to release sticking valve cotters.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Screw snap-in device -VAS 5161/6- with engaging fork
permitted unless -
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
VAS 5161/5- into guide plate. with respect to the correctness of information in this document. Copyright by AUDI AG.

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

Inlet side:
– Engage pressure fork -VAS 5161/2- at snap-in device, as
shown in illustration.

Exhaust side:
– Engage pressure fork -VAS 5161/2- at snap-in device, as
shown in illustration.
Both sides (continued):
– Press down with pressure fork for assembly cartridge.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Turn knurled screw in both directions.
• The valve cotters are forced apart and are taken up by the
cartridge.
– Release pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
– Detach valve spring with valve spring plate.

3. Valve gear 119

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Pull off valve stem oil seal with valve stem seal puller - 3364- .

Caution

Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.

– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.

If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert valve spring and valve spring plate.
– Secure guide plate back onto cylinder head.
– Insert assembly cartridge with knurled spacer ring in guide
plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions.
• This will insert the valve cotters.
– Release the pressure fork with knurled screw still in pulled po‐
sition.
– Repeat procedure for each valve.
Installation is carried out in the reverse order; note the following:
– Install camshafts ⇒ page 108 .

120 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

3.7 Checking valve guides

Special tools and workshop equipment required
♦ Universal dial gauge bracket - VW 387-

♦ Dial gauge - VAS 6079-

Test sequence
– Insert valve into guide. End of valve stem must be flush with
guide. Only insert inlet valve into inlet guide and exhaust valve
into exhaust guide, as the stem diameters are different.
– Measure the amount of sideways play.
Wear limit
Inlet valve guide Exhaust valve guide
0.80 mm 0.80 mm

Note

♦ If the wear limit is exceeded, repeat the measurement with

new valves. Renew cylinder head if wear limit is still exceeded.
♦ If the valve has to be renewed as part of a repair, use a new
valve for the measurement.

3.8 Renewing exhaust camshaft oil seal

3. Valve gear 121

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Oil seal extractor - 2085-
♦ Assembly tool - 3066-
♦ Assembly tool - T10071-
♦ Puller - T40001-

Special tools and workshop equipment required

♦ Support bracket - 10 - 222 A-

122 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Shackle - 10 - 222 A /12-

♦ Pin wrench - T10020-

♦ Locking pin - T10060A-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

WARNING

Hot steam/hot coolant may escape when opening expansion

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

tank. Cover cap with cloth and open carefully.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Open filler cap on coolant expansion tank.

– Remove noise insulation ⇒ Rep. gr. 50 .
– Drain off coolant ⇒ page 157 .
– Remove toothed belt ⇒ page 61 .

3. Valve gear 123

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Loosen camshaft sprocket (apply counterhold tool - 3036- ).

– Detach the camshaft sprocket using puller - T40001- and

claws T40001/6 and T40001/7.

– To guide oil seal extractor, screw special tool 2085/2 from oil
seal extractor - 2085- by hand into camshaft as far as it will go.
– Unscrew inner part of oil seal extractor - 2085- two turns (ap‐
prox. 3 mm) from the outer part and lock in position with the
knurled screw.

– Lubricate threaded head of oil seal extractor - 2085- , place it

in position and, exerting firm pressure, screw it into oil seal as
far as possible.
– Loosen knurled screw and turn inner part of extractor against
camshaft until oil seal has been extracted.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
Installing
• Tightening torques ⇒ page 103
– Do not lubricate sealing lip of oil seal.

124 Rep. gr.15 - Cylinder head, valve gear

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Fit guide sleeve - T10071/1- from assembly tool - T10071- on‐

to camshaft journal.
– Push oil seal over guide sleeve onto shaft.
– Detach guide sleeve.

– Press in oil seal all the way using guide sleeve - T10071/3-
and bolt - T10071/4- from assembly tool - T10071- .

– Install camshaft sprocket.

♦ Check installation position: The thinner web of the camshaft
sprocket faces outwards -arrows- and the marking for No. 1
cylinder TDC is visible.

– Fit securing bolt of camshaft sprocket (use counterhold tool -

3036- ).

Note

If a piston is at TDC the valves could strike the piston when

Protected turning
by copyright. Copying for private or commercial purposes, in part or in whole, is not
the camshaft. Pistons must therefore not be at TDC This
permitted could
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
otherwise result in damage to valves and pistons.with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install toothed belt ⇒ page 61 .

3. Valve gear 125

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

17 – Lubrication
1 Oil pump and sump

Note

If large quantities of metal shavings or other particles are found

in the engine oil when repairing the engine (possibly caused by
partial seizure of crankshaft and conrod bearings), clean the oil
passages thoroughly and renew the oil cooler to prevent further
damage occurring later.

Check oil pressure ⇒ page 145 .

Viscosity grades and oil specifications: ⇒ Maintenance ; Booklet
808
For oil capacities refer to ⇒ Maintenance tables .

1.1 Sump - exploded view

Balance shaft assembly with oil pump ⇒ page 131
Oil filter bracket ⇒ page 138

1 - Bolt
❑ 9 Nm
2 - Oil level and oil temperature
sender - G266-
❑ Removing and installing
⇒ page 127
3 - Seal
❑ Renew
4 - Bolt
❑ Tightening torque and
sequence ⇒ page 39
5 - Sump
❑ Clean sealing surface
before installing
❑ Removing and installing
⇒ page 128
6 - Baffle plate
7 - Bolt
❑ 9 Nm
8 - Oil return line
9 - Bolt
❑ Tightening torque
⇒ Item 13 (page 176)
10 - Gasket
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renewwith respect to the correctness of information in this document. Copyright by AUDI AG.

11 - Bolt
❑ Tightening torque and
sequence ⇒ page 127

126 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

12 - Oil drain plug

❑ 30 Nm
13 - Seal
❑ Renew
14 - Cover

Sump - tightening torque and sequence

– Tighten bolts securing sump in three stages as follows:
1. Tighten bolts -1 ... 20- securing sump to cylinder block in
diagonal sequence initially to 5 Nm.
2. Tighten bolts securing sump to gearbox -arrows- to 40 Nm.
3. Tighten bolts -1 ... 20- securing sump to cylinder block in
diagonal sequence to 15 Nm.

Guide tube for oil dipstick - tightening torque

– Tighten centre hex stud -arrow- to 6 Nm.

1.2 Removing and installing oil level and oil

temperature sender - G266-
Removing
– Drain off engine oil ⇒ Maintenance ; Booklet 808 .
– Unplug electrical connector -5-.
– Unscrew three bolts -1- and remove coverpermitted
-2-. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

with respect to the correctness of information in this document. Copyright by AUDI AG.
– Pull oil level and oil temperature sender - G266- -item 3- off
sump and remove together with seal -4-.
Installing
• Tightening torque ⇒ page 126
Installation is carried out in the reverse order; note the following:

Note

Renew seal.

– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
808 .

1. Oil pump and sump 127

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.3 Removing and installing sump

Special tools and workshop equipment required
♦ Socket - T10058-

♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Silicone sealant ⇒ Parts catalogue
Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Remove noise insulation ⇒ Rep. gr. 50 .
– Remove noise insulation (right-side) -fasteners 1 ... 3-.

– Detach air pipe -arrow- from charge air cooler.

128 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unbolt air pipe from turbocharger -arrows-.

– Unscrew bolts -arrows- and remove air pipe.

– Detach air pipe -1- from charge air cooler.

– Unplug connector from charge pressure sender - G31- ⇒ Rep.
gr. 24 ; Overview of fitting locations .
– Remove air pipe. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unplug electrical connector -1- at oil level and oil temperature

sender - G266- .
– Unbolt oil return line from turbocharger -arrows-.
– Drain off engine oil.

1. Oil pump and sump 129

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew sump/gearbox bolts -arrows-.

– Unscrew bolts -1 ... 20- in diagonal sequence.
– Take off sump: if necessary loosen it by striking lightly with a
rubber hammer.
Installing
• Tightening torques ⇒ page 126
♦ Silicone sealant ⇒ Parts catalogue

Note

♦ Note expiry date of silicone sealant.

♦ The sump must be installed within 5 minutes after applying the
silicone sealant.

– Remove sealant residue from cylinder block using a flat scra‐

per.

WARNING

Put on safety goggles.

– Remove remaining sealant from sump (with rotating plastic

brush or similar).
– Clean sealing surfaces; they must be free of oil and grease.

– Cut off nozzle of tube at front marking (∅ of nozzle approx. 3

mm).

130 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Apply the bead of silicone sealant onto the clean sealing sur‐
face of the sump, as illustrated.
♦ Thickness of sealant bead: 2 ... 3 mm

Note

♦ The sump must be installed within 5 minutes after applying the

silicone sealant.
♦ The bead of sealant must not be thicker than specified, other‐
wise excess sealant
Protected can enter
by copyright. the
Copying sumpor and
for private obstruct
commercial the
purposes, in part or in whole, is not
strainer in the oil intake
permitted pipe. by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Take particular care when applying sealant bead in area of
rear sealing flange -arrows- as shown in this figure.

– Fit sump immediately and tighten bolts; tightening sequence

⇒ page 127 .

Note

♦ When installing sump with engine removed from vehicle, en‐

sure that sump is positioned flush with cylinder block at fly‐
wheel end.
♦ After fitting sump assembly, the sealant must dry for approx.
30 minutes. Then (and only then) fill the engine with engine
oil.

– Fill up with engine oil and check oil level.

The remaining installation steps are carried out in the reverse se‐
quence. Note the following points:
– Install air pipes with plug-in connectors ⇒ page 173 .

1.4 Balance shaft assembly with oil pump -

exploded view
Balance shaft assembly ⇒ page 126
Oil filter bracket ⇒ page 138

1. Oil pump and sump 131

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Chain guard
2 - Chain
❑ Before removing, mark
running direction (fitting
position) with paint
3 - Dowel sleeves
4 - Intermediate plate
5 - Balance shaft assembly
with oil pump
❑ Before installing, check
that the two dowel
sleeves for centring oil
pump/cylinder block are
fitted
❑ Removing and installing
⇒ page 133
6 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ 9 Nm
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7 - Cover
❑ Prevents foam build-up
in engine oil
8 - Bolt
❑ 20 Nm
9 - Bolt
❑ 8 Nm
10 - Oil intake pipe
❑ Clean strainer if dirty
11 - O-ring
❑ Renew
12 - Bolt
❑ Renew
❑ Note different bolt lengths ⇒ page 133
❑ Tightening sequence ⇒ page 133
13 - Bolt
❑ Renew
❑ Note different bolt lengths ⇒ page 133
❑ Tightening sequence ⇒ page 133
14 - Outer rotor
❑ Check contact surfaces for scores
❑ Marking must be visible
15 - Inner rotor
❑ Check contact surfaces for scores
16 - Oil pump cover
17 - Chain sprocket
18 - Bolt
❑ 20 Nm + turn 90° further
❑ Renew

132 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

19 - Chain tensioner with tensioning rail

❑ Pre-tensioning before installing ⇒ page 137
20 - Bolt
❑ 15 Nm

Positions of bolts for balance shaft housing

A - Hexagon collared bolt M7x40
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
B - Hexagon collared boltpermitted
M7x70 unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
C - Hexagon collared bolt M7x90
D - Hexagon collared bolt M7x55
E - Screw plug with O-ring

Tightening sequence for balance shaft housing

1. Screw in bolts -arrows- hand-tight.
2. Tighten bolts -arrows- to 15 Nm in diagonal sequence start‐
ing from inside and working outwards.
3. Turn bolts -arrows- 90° further (1/4 turn) in diagonal se‐
quence starting from inside and working outwards using a
rigid wrench.

1.5 Removing and installing balance shaft

assembly with oil pump
Special tools and workshop equipment required
♦ Locking pin - T10027 A-

Removing
– Remove sump ⇒ page 128 .

WARNING

Engine must only be turned in direction of rotation (clockwise)

via crankshaft.

1. Oil pump and sump 133

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Note

Turn over the engine at the central bolt on the crankshaft.

– Set camshaft sprocket to TDC marking by turning crankshaft.

Marking on camshaft sprocket must align with arrow on tooth‐
ed belt cover.

– Pull off chain guard. Retaining tabs can be released with a

small screwdriver (insert in openings -arrows-).

– Loosen bolt on oil pump chain sprocket. Counterhold on cen‐

tral bolt of vibration damper.

134 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Use screwdriver to slacken chain rail -arrow- and lock it in po‐

sition using a 3 mm Allen key -1-.

– Detach oil pump chain sprocket and disengage chain at bal‐

ance shaft drive.

– Unscrew bolts -1 and 2- and remove baffle plate.

– Loosen bolts -arrows- on balance shaft assembly, working

from outside inwards, and then remove balance shaft assem‐
bly.
Installing
• Tightening torques ⇒ page 131
• Chain tensioner must be pre-tensioned ⇒ page 137 .
– Renew all bolts on balance shaft assembly.
– Renew seal on bolt for balance shaft assembly
⇒ Item 13 (page 132) .

1. Oil pump and sump 135

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Fit intermediate plate onto dowel sleeves on balance shaft as‐

sembly as shown -arrows-.

– Install balance shaft assembly with oil pump and intermediate

plate. Tighten securing bolts -arrows-, working from inside
outwards.

Note

♦ Note different bolt lengths ⇒ page 133 .

♦ Note tightening sequence ⇒ page 133
♦ Note the dowel sleeves.

– Install baffle plate. To do so, insert pins in balance shaft as‐

sembly -arrows-.

Note

Turn over the engine at the central bolt on the crankshaft.

– Rotate engine to TDC of No. 1 cylinder by turning central bolt

of crankshaft sprocket in normal direction of rotation. Marking
on camshaft sprocket and marking on crankshaft must be
aligned to TDC of cylinder No. 1 -arrows-.

136 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Marking on chain sprocket of balance shaft -arrow- must be

positioned opposite the locating hole. Use locking pin - T10027
A- to lock chain sprocket in this position. Place chain on chain
sprocket of balance shaft.
– Install oil pump chain sprocket with new bolt and hand-tighten
the bolt.

Note

The oil pump chain sprocket can only be installed correctly in one
position. When installing, you may ONLY turn the oil pump.

– Remove locking pin - T10027 A- and Allen key -1-. Secure

chain sprocket for oil pump. Counterhold on central bolt of vi‐
bration damper.
Further assembly is basically carried out in reverse order of dis‐
mantling.
– Install sump ⇒ page 128 .

1.5.1 Pre-tensioning chain tensioner

– Compress piston by hand -arrow-.

– Press chain rail in direction of arrow and lock in position using

a 3 mm Allen key -1-.

1. Oil pump and sump 137

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2 Oil filter bracket and oil cooler

2.1 Exploded view - oil filter bracket

Sump with balance shaft housing ⇒ page 126
Balance shaft assembly with oil pump ⇒ page 131

1 - Pipe
❑ For crankcase breather
2 - Oil pressure switch - F1-
❑ 1.4 bar - black
❑ Checking ⇒ page 145
❑ Removing and installing
⇒ page 147
❑ 21 Nm
3 - Bolt
❑ 15 Nm
❑ With earth wire forProtected
oil by copyright. Copying for private or commercial purposes, in part or in whole, is not
pressure switch permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Bracket
5 - Bolt
❑ 15 Nm
6 - Oil cooler
❑ See note ⇒ page 126
❑ Ensure clearance from
surrounding compo‐
nents
❑ Connection diagram -
coolant hoses
⇒ page 156
❑ Removing and installing
⇒ page 140
7 - Gasket
❑ Renew
8 - Oil filter housing
❑ Remove and install us‐
ing oil filter tool - 3417-
or 36 mm socket, e.g.
socket, 36 mm - T10125-
❑ Draining ⇒ page 139
9 - Plug
10 - Seal
❑ Renew
❑ Lubricate lightly with oil
❑ Installation position ⇒ page 139
11 - Oil filter element
❑ Observe change intervals ⇒ Maintenance ; Booklet 810
12 - Bolt
❑ 15 Nm

138 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

13 - Baffle plate
❑ Installation position ⇒ page 139
14 - Seal
❑ Renew
15 - Oil filter bracket
❑ Removing and installing ⇒ page 142

Installation position of baffle plate

Installation position of seal

– Note position of service tab on seal -arrow-.
– Flat side of seal must face outwards.

2.2 Draining oil filter housing

Note

A valve in the oil filter housing will be opened when the oil drain
adapter - T40057- is screwed in. The valve will be closed again
as soon as the oil drain adapter - T40057- is unscrewed.

Special tools and workshop equipment required

2. Oil filter bracket and oil cooler 139

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Oil drain adapter - T40057-

– Unscrew dust cap from oil filter housing -arrow-.

– Direct hose of oil drain adapter - T40057- into a drip tray and
screw oil drain adapter - T40057- into oil filter housing.
– Drain engine oil

2.3 Removing and installing oil cooler

Special tools and workshop equipment required
♦ Drip tray for workshop hoist - VAS 6208-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

140 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Spring type clip pliers - VAS 5024 A-

Removing

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Remove noise insulation ⇒ Rep. gr. 50 .
– Drain off coolant ⇒ page 157 .
– Remove intake manifold and fuel rail ⇒ Motronic direct injec‐
tion and ignition system (4-cylinder); Repair group 24; Servic‐
ing injection system .
– Unbolt bracket for connectors -arrows- from coolant pipe.

– Disconnect coolant hose -1-.

– Remove bolt -2-.

2. Oil filter bracket and oil cooler 141

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Detach coolant hoses -arrows- from coolant pipe.

– Unscrew bolt -1- and detach coolant pipe.

– Remove oil cooler -arrows-.

Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 138

Note

♦ Renew gaskets and seals.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .

– Fill up with coolant ⇒ page 157 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

2.4 Removing and installing oil filter bracket

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

♦ Drip tray for workshop hoist - VAS 6208-

♦ Spring type clip pliers - VAS 5024 A-

142 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Locking pin - T10060A-

Removing

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove noise insulation ⇒ Rep. gr. 50 .
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Drain off coolant ⇒ page 157 .
– To slacken poly V-belt, turn tensioner in -direction of arrow-.

– Lock tensioner in position with locking pin - T10060A- .

– Take off poly V-belt.

2. Oil filter bracket and oil cooler 143

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove tensioner for poly V-belt -arrows-.

– Remove alternator ⇒ Electrical system; Repair group 27 .
– Remove intake manifold and fuel rail ⇒ Motronic direct injec‐
tion and ignition system (4-cylinder); Repair group 24; Servic‐
ing injection system .

– Unbolt bracket for connectors -arrows- from coolant pipe.

– Disconnect coolant hose -1-.

– Remove bolt -2-.

– Detach coolant hoses -arrows- from coolant pipe.

– Unscrew bolt -1- and detach coolant pipe.

144 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove oil cooler -arrows-.

– Detach pipe -1- for crankcase breather system.

– Unscrew earth cable -2- for oil pressure switch.
– Unscrew bolts -arrows- and remove oil filter bracket.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 138

Note

♦ Renew gaskets and seals.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .

– Install baffle plate ⇒ Item 13 (page 139) .

– Fill up with coolant ⇒ page 157 .

2.5 Checking oil pressure and oil pressure switch

2. Oil filter bracket and oil cooler 145

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools 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-
Test requirements
• Engine oil level OK, checking ⇒ Maintenance ; Booklet 808 .
• Oil pressure warning lamp must light up for approx. 3 seconds
when ignition is switched on.
• In vehicles
Protected bywith auto-check
copyright. system,
Copying for private the “OK”
or commercial display
purposes, must
in part lightis not
or in whole,
up (select symbol).
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Engine oil temperature at least 80°C (radiator fan must have
run once).

Note

Functional check and servicing the visual and acoustic oil pres‐
sure warning: Current flow diagrams, ⇒ Vehicle diagnostic tester;
“Function and component selection” .

146 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Test sequence
• Tightening torques ⇒ page 138
– Remove oil pressure switch - F1- -A- and screw it onto tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (–).
– Connect voltage tester - V.A.G 1527 B- with adapter leads
from auxiliary measuring set - V.A.G 1594 C- to battery posi‐
tive (+) and oil pressure switch - F1- -B-. LED must not light
up.
– If LED lights up, renew 1.4 bar oil pressure switch.
If LED does not light up:
– Start engine and run at increased speed: at 1.2 ... 1.6 bar
pressure the LED should light up, otherwise oil pressure
switch - F1- must be renewed. Increase engine speed further.
At 2,000 rpm and an oil temperature of 80 °C the oil pressure
should be between 2.7 ... 4.5 bar.

2.6 Removing and installing oil pressure

switch - F1-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special permitted
tools and workshop
unless authorised by equipment
AUDI AG. AUDI required
AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Assembly tool - T10118-

♦ U/J extension and socket for oil pressure switch -T40175-

Removing:
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .

2. Oil filter bracket and oil cooler 147

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove charge air hose (left-side) -items 1 and 2-.

– Take electrical connector -1- out of bracket and unplug it from

oil pressure switch - T10118- -arrow- using assembly tool -
F1- .

– Unscrew oil pressure switch using articulated wrench, 24 mm

- T40175- .
Installing:
• Tightening torque ⇒ page 138
Installation is carried out in the reverse order; note the following:

Note

♦ 1-pin oil pressure switch: Check that earth wire is connected.

♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .

2.7 Checking oil pressure and oil pressure

switch (1-pin oil pressure switch)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Note
with respect to the correctness of information in this document. Copyright by AUDI AG.

Check which oil pressure switch version is installed (1-pin or 2-

pin oil pressure switch). Checking oil pressure and oil pressure
switch (2-pin oil pressure switch) ⇒ page 150

148 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ 0
♦ Voltage tester - V.A.G 1527
B-
♦ Auxiliary measuring set -
V.A.G 1594C-

• Engine oil level OK

• Engine oil temperature at least 80 °C (radiator fan must have
run once)

Functional check and servicing the visual and acoustic oil pres‐
sure warning: Current flow diagrams, ⇒ Vehicle diagnostic tester;
“Function and component selection” .

– Remove oil pressure switch - F1- ⇒ page 147 .

2. Oil filter bracket and oil cooler 149

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Screw oil pressure tester - V.A.G 1342- into bore for oil pres‐
sure switch in oil filter bracket.
– Connect brown wire of tester to earth (–).
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
and oil pressure switch with adapter cable from auxiliary
measuring set - V.A.G 1594C- . LED must not light up.
– If the LED lights up, renew oil pressure switch - F1- (1.4 bar).
If the LED does not light up:
– Start engine and run at increased speed: At a pressure of
1.2 ... 1.6 bar the LED should light up; otherwise oil pressure
switch must be renewed.
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be between
2.7 ... 4.5 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.

2.8 Checking oil pressure and oil pressure

switch (2-pin oil pressure switch)

Note

Check which oil pressure switch version is installed (1-pin or 2-

pin oil pressure switch). Checking oil pressure and oil pressure
switch (1-pin oil pressure switch) ⇒ page 148

Special tools and workshop equipment required

♦ Oil pressure tester - V.A.G 1342-

♦ Test instrument adapter/DSO

authorised by (2-pin) - VAS 5256-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

150 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Hand-held multimeter - V.A.G 1526D-

Procedure
• Engine oil level OK
• Engine oil temperature at least 80 °C (radiator fan must have
run once)

Note

Functional check and servicing the visual and acoustic oil pres‐
sure warning: Current flow diagrams, ⇒ Vehicle diagnostic tester;
“Function and component selection” .

– Remove oil pressure switch - F1- ⇒ page 147 and screw switch
into oil pressure tester - V.A.G 1342- .
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
place of oil pressure switch.
– Attach test instrument adapter/DSO (2-pin) - VAS 5256- to oil
pressure switch.
– Connect hand-held multimeter - V.A.G 1526D- to test instru‐
ment adapter/DSO (2-pin) - VAS 5256- and set to continuity
test.
• At pressures below 1.2 bar, oil pressure switch must be open.

– Start engine and run at increased speed: At a pressure of

1.2 ... 1.6 bar the oil pressure switch should close; otherwise
oil pressure switch must be renewed.
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be between
2.7 ... 4.5 bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.

2.9 Checking oil pressure

Special tools and workshop equipment required

2. Oil filter bracket and oil cooler 151

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Oil pressure tester - V.A.G 1342-

Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch ⇒ page 147 .
– Screw oil pressure switch into oil pressure tester -
V.A.G 1342- .
– Screw oil pressure tester - V.A.G 1342- into bore for oil pres‐
sure switch in oil filter bracket.
– Start engine.
• Oil pressure at idling speed: at least 1.2 bar.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Oil pressure at 2000permitted
rpm: at least 2.7 bar.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install oil pressure switch ⇒ page 147 .

152 Rep. gr.17 - Lubrication

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

19 – Cooling
1 Parts of cooling system (on engine)

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

Note

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

If necessary, relieve pressure before commencing repair work.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .
♦ Hose clip pliers - V.A.G 1921- or spring-type clip pliers - VAS
5024 A- are recommended for installing spring-type clips.
♦ Renew gaskets and seals.
♦ The arrow markings on coolant pipes and on ends of hoses
must align.

1.1 Cooling system components (on engine) - exploded view

1. Parts of cooling system (on engine) 153

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Bolt
❑ 40 Nm
2 - Bolt
❑ 23 Nm
3 - Coolant pipe
4 - Connecting hose
5 - O-ring
❑ Renew
6 - Connection
7 - Bolt
❑ 10 Nm
8 - Retaining clip
9 - O-ring
❑ Renew
10 - Coolant temperature
sender - G62-
❑
11 - Connecting hose
12 - Connecting piece
13 - Connecting hose
14 - Connecting hose
15 - Connecting hose
16 - Coolant pipe
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
17 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 9 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

18 - Connecting hose
19 - Coolant pipe
20 - Bolt
❑ 10 Nm
21 - Coolant distributor housing
❑ With thermostat
❑ Starts to open at 87°C
22 - Bolt
❑ 15 Nm
23 - Coolant pump
❑ Removing and installing ⇒ page 165
24 - Bolt
❑ 15 Nm

154 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.2 Exploded view - continued coolant circulation pump - V51-

1 - Nut
❑ 3 Nm
2 - Coolant pipe
3 - Spring-type clip
4 - Coolant pipe
❑ To turbocharger
5 - Bolt
❑ 5 Nm
6 - Spring-type clip
7 - Coolant hose
8 - Bracket
9 - Coolant hose
❑ Going to radiator
10 - Spring-type clip
11 - Continued coolant circula‐
tion pump - V51-
12 - Bolt
❑ 5 Nm
13 - Spring-type clip
14 - Nut
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 5 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Parts of cooling system (on engine) 155

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.3 Connection diagram - coolant hoses

1 - Radiator
❑ Removing and installing
⇒ page 168
❑ If renewed, refill system
with fresh coolant
2 - Continued coolant circula‐
tion pump - V51-
3 - Return hose from turbo‐
charger
❑ With bypass thermostat
in hose
4 - Map-controlled engine cool‐
ing thermostat - F265-
❑ Removing and installing
⇒ page 164
5 - Coolant pump
❑ Removing and installing
⇒ page 165
6 - Cylinder head/cylinder
block
❑ If renewed, refill system
with fresh coolant
7 - Turbocharger
❑ Removing and instal‐
ling, vehicles with en‐
gine codes AXX, BPY,
BWA ⇒ page 178
❑ Removing and instal‐
ling, engines with code
letters BHZ, BZC,
CDLA, CDLC
⇒ page 202
8 - Expansion tank
❑ With filler cap
❑ Checking pressure relief valve in filler cap ⇒ page 160
9 - Heat exchanger (for heating system)
❑ If renewed, refill system with fresh coolant
10 - Hose
❑ For automatic gearbox only
11 - Gear oil cooler
❑ For automatic gearbox only
12 - Hose
❑ For automatic gearbox only
❑ With bypass thermostat inProtected
hose by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
13 - Coolant connection with respect to the correctness of information in this document. Copyright by AUDI AG.

14 - Engine oil cooler

15 - Intake manifold
❑ Removing and installing ⇒ Rep. gr. 24

156 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

16 - Hose
❑ Only fitted in vehicles with auxiliary radiator
17 - Auxiliary radiator
18 - Hose
❑ Only fitted in vehicles with auxiliary radiator

1.4 Draining and filling cooling system

Special tools and workshop

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

Draining

Note

Collect drained coolant in a clean container for re-use or disposal.

1. Parts of cooling system (on engine) 157

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Remove noise insulation ⇒ Rep. gr. 50 .
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– To drain off coolant, detach bottom coolant hose -arrow-.
Filling

Note

♦ The cooling system is filled all year round with a mixture of

water and coolant additive. Mixture ratio ⇒ page 159 .
♦ Use only the coolant additive listed in the ⇒ Electronic parts
catalogue . If you use other coolant additives, this can signifi‐
cantly impair in particular the corrosion protection effect. The
resulting damage could lead to loss of coolant and conse‐
quently to serious engine damage.
♦ The specified coolant (based on recommended mixture ratio)
⇒ page 159 prevents frost and corrosion damage and stops
scaling. Such additives also raise the boiling point of the cool‐
ant. It is therefore essential to use the correct coolant additive
in the cooling system all year round.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Frost protection is required down to about -25 °C (in countries
with arctic climate: down to about -35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant concentration must be at least 40 %.
♦ If greater frost protection is required in very cold climates, the
concentration of coolant additive can be increased, but only
up to 60 % (this gives frost protection to about –40 °C). If the
concentration exceeds 60%, frost protection decreases again
and cooling efficiency is also impaired.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Use only clean tap water for mixing coolant. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ If the radiator, heat exchanger, cylinder head, cylinder head
gasket or cylinder block have been renewed, do not re-use old
the coolant.
♦ Contaminated or dirty coolant must not be used again.
♦ For checking anti-freeze protection in cooling system, use re‐
fractometer - T10007- .

158 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Connect bottom coolant hose to radiator -arrow-.

– Fill reservoir of cooling system charge unit - VAS 6096- with

at least 8 litres of premixed coolant (based on recommended
ratio) ⇒ page 159
Recommended mixture ratio for coolant
• Coolant (40 %) and water (60 %) for frost protection to -25 ℃
• Coolant (50 %) and water (50 %) for frost protection to -35 °C
♦ Coolant ⇒ Electronic parts catalogue
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Fit cooling system charge unit - VAS 6096- onto adapter for
cooling system tester - V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-. (The vented air
draws along a small amount of coolant, which should be col‐
lected.)
– Close the two valves -A- and -B- (levers at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar

1. Parts of cooling system (on engine) 159

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Open valve -B- (lever in direction of flow).

The suction jet pump generates a partial vacuum in the cooling
system.
• The needle on the gauge should move into the green zone.
– Additionally open valve -A- briefly (lever in direction of flow) so
that hose from cooling system charge unit - VAS 6096- is filled
with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
The suction jet pump will continue generating a vacuum in the
cooling system.
• The needle on the gauge should remain in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
If the needle does not reach the green zone, repeat the process.
If the vacuum level drops, there is a leak in the cooling system.
– Detach compressed air hose.
– Open valve -A-.
The partial vacuum in the cooling system causes the coolant to
be drawn up out of the cooling system charge unit - VAS 6096- ;
the cooling system is then filled.

– Check the coolant level and top up coolant as far as the max
mark.
– Start engine, run for 2 minutes (maximum) at approx. 1500
rpm and top up coolant to overflow hole on expansion tank
with engine running.
– Fit expansion tank cap.
– Run engine until radiator fan cuts in.

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Check coolant level and top up if necessary. When engine is

at normal operating temperature, coolant level should be at
max. mark; when engine is cold it should be between min. and
max. marks.
– Switch off engine.

1.5 Checking cooling system for leaks

160 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Cooling system tester -
V.A.G 1274-
♦ Adapter for cooling system
tester - V.A.G 1274/8-
♦ Adapter for cooling system
tester - V.A.G 1274/9-

Test condition
• Engine must be warm.
Test sequence

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

1. Parts of cooling system (on engine) 161

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Fit cooling system tester - V.A.G 1274- with adapter for cooling
system tester - V.A.G 1274/8- on coolant expansion tank.
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
– If this pressure is not maintained, locate and rectify leaks.
Checking pressure relief valve in filler cap

– Fit cooling system tester - V.A.G 1274- with adapter for cooling
system tester - V.A.G 1274/9- on filler cap.
– Operate hand pump.
♦ The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.

1.6 Removing and installing coolant pipes

Special tools and workshop equipment required
♦ Spring type clip pliers - VAS 5024A-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Remove pipe -A- and hose -B- -arrows-.
– Remove noise insulation ⇒ Rep. gr. 50 .

162 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove air pipe -1 and 2- for charge air cooler.

– Slacken clip -2-.

– Unplug electrical connector -4-.
– Remove nut -3- and bolt -1-.
– Take out intake connecting pipe downwards.
– Drain off coolant ⇒ page 157 .

– Unplug electrical connectors -arrows-.

– Detach coolant hoses from coolant pipes -arrows-.

1. Parts of cooling system (on engine) 163

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Detach hose -A- and unscrew bolt -B-. Remove front coolant
pipe.

– Release connectors -A- from bracket, detach hose -B- and

unscrew bolts -C-. Remove rear coolant pipe.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 153

Note

♦ Renew gaskets and seals.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .

– Fill up with coolant ⇒ page 157 .

1.7 Removing and installing coolant distrib‐

utor housing with map-controlled engine
cooling thermostat - F265-
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator .
– Remove coolant pipes ⇒ page 162 .
– Detach coolant hose -2- from coolant distributor housing;
by AUDIto
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised AG. AUDI AG does not guarantee or accept any liability
do so, pull out retaining clip -1-. with respect to the correctness of information in this document. Copyright by AUDI AG.

164 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew bolts -arrows- and remove coolant distributor hous‐

ing with map-controlled engine cooling thermostat - F265-
from engine.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 153

Note

♦ Renew gaskets and seals.

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .

– Clean sealing surface for O-ring.

– Renew O-ring and lubricate with coolant.
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator .
– Fill up with coolant ⇒ page 157 .

1.8 Removing and installing coolant pump

Special tools and workshop equipment required
♦ Drip tray for workshop hoist - VAS 6208-

♦ Spring type clip pliers - VAS 5024 A-

Removing

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

1. Parts of cooling system (on engine) 165

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Open filler cap on coolant expansion tank.

– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Remove noise insulation ⇒ Rep. gr. 50 .
– Drain off coolant ⇒ page 157 .
– Remove toothed belt ⇒ page 61 .
– Unscrew coolant pump securing bolts -1- and remove coolant
pump -2-.
– Remove O-ring -3-.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 153
– Clean and smoothen sealing surface for O-ring.

– Moisten new O-ring -3- with coolant.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Fit coolant pump -2-.
• Installation position: Sealing plug in housing faces down‐
wards.
– Install toothed belt ⇒ page 61 .
– Install poly V-belt ⇒ page 32 .
– Fill up with coolant ⇒ page 157 .

166 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2 Parts of cooling system (on body)

WARNING

Hot steam/hot coolant can escape - risk of scalding.

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

WARNING

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

♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

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

2.1 Exploded view - radiator and radiator fans

2. Parts of cooling system (on body) 167

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Radiator fan - V7-

❑ Removing and installing
⇒ page 167
2 - Nut
❑ 10 Nm
3 - Radiator cowl
4 - Coolant hose (top)
❑ To connection at cylin‐
der head
5 - O-ring
❑ Renew if damaged
6 - Radiator
❑ Removing and installing
⇒ page 168
❑ If renewed, change
coolant in entire system
7 - O-ring
❑ Renew if damaged
8 - Coolant hose (bottom)
❑ To connection for ther‐
mostat
9 - Bolt
❑ 5 Nm
❑ To charge air cooler
10 - Nut
❑ 10 Nm
11 - Bolt
❑ 5 Nm
❑ To radiator
12 - Radiator fan 2 - V177-
❑ Removing and installing ⇒ page 167

2.2 Removing and installing radiator

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment required permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Drip tray for workshop hoist - VAS 6208-

168 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Spring type clip pliers - VAS 5024 A-

Removing

Note

If there are slight impressions on the fins, refer to ⇒ page 7 .

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Use spring type clip pliers - VAS 5024 A- to disconnect intake
connecting pipe -1-.
– Unscrew intake connecting pipe from lock carrier -arrows- and
remove.

– Unscrew bolts -1- from above. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Remove noise insulation ⇒ Rep. gr. 50 .

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Parts of cooling system (on body) 169

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove air pipe -1 and 2- for charge air cooler.

– Unplug electrical connector -2-.

– Unscrew the bolts -3- and remove radiator cowl from below.
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.

– To drain off coolant, detach bottom coolant hose -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Detach electrical connector
with respect -1- at longitudinal
to the correctness member
of information in this document.(left-
Copyright by AUDI AG.
side) from bracket.
– Remove retainer for connector -2-.

170 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unplug electrical connector at bonnet lock -1-.

– Detach top coolant hose from radiator -2-.

– Unscrew bolts -arrows- on backside of radiator.

– Lift up radiatorProtected
slightly and remove
by copyright. upwards.
Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.

Installation is carried out in the reverse order; note the following:

• Tightening torques ⇒ page 167
– Install air pipes with plug-in connectors ⇒ page 173 .
– Fill up with coolant ⇒ page 157 .

2.3 Removing and installing radiator cowl

Special tools and workshop equipment required
♦ Hose clip pliers - V.A.G 1921-

Removing
– Unscrew bolts -1- from above.
– Remove noise insulation ⇒ Rep. gr. 50 .

2. Parts of cooling system (on body) 171

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove air pipe -1 and 2- for charge air cooler.

– Unplug electrical connector -2-.

– Unscrew the bolts -3- and remove radiator cowl from below.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 167
– Install air pipes with plug-in connectors ⇒ page 173 .

2.4 Removing and installing radiator fan -

V7- and radiator fan 2 - V177-
Removing
– Remove radiator cowl ⇒ page 171 .
– Unplug electrical connector -1-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Move wiring clear. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew nuts -arrows- and remove fans.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 167
– Install radiator cowl ⇒ page 171 .

172 Rep. gr.19 - Cooling

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

21 – Turbocharging/supercharging
1 Turbocharger with charge air system,
engine codes AXX, BPY, BWA

Note

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment).
♦ Hose connections and charge
Protected airCopying
by copyright. system hoses
for private must be
or commercial free in part or in whole, is not
purposes,
of oil and grease permitted
prior tounless
fitting. However
authorised by AUDI(applies
AG. AUDI AGonlydoesto plug-
not guarantee or accept any liability
in connectors); thewith
seal andto the
respect sealingofsurface
the correctness informationof plug-in
in this document. Copyright by AUDI AG.
connectors should be lubricated lightly with oil ⇒ page 173 .
♦ Charge air system must be free of leaks, checking for leaks
⇒ page 195 .
♦ Renew self-locking nuts.
♦ Hose clip pliers - VAS 5024A- or spring-type clip pliers - V.A.G
1921- are recommended for installing spring-type hose clips.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing turbocharger, allow engine to idle for approx.
1 minute and do not rev up immediately to ensure turbocharger
is supplied with oil.
♦ Observe rules for cleanliness ⇒ page 5 .

Fitting hose connections with plug-in connectors ⇒ page 173 .

1.1 Fitting hose connections with plug-in

connectors - vehicles with engine codes
AXX, BPY, BWA

Caution

The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.
This can cause leakage. Note assembly instructions.

Removing:
– Release plug-in connector by pulling out retaining clip
-arrow-. Disconnect pipe/hose (do not use tools of any kind).
Installing
– When renewing seal, fit seal in groove on charge air hose.
Make sure that the seal is correctly seated in the groove all
round the complete circumference and that it is not twisted.
– Lubricate sealing surface and seal with oil.

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 173
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Move securing clip to released position -1-.

– Push charge air hose into connector as far as stop.
– Move securing clip to locked position -2- and press charge air
hose in once again.
– Then pull hose to check that it is fitted correctly and that plug-
in connector is locked.

1.2 Turbocharger - exploded view, vehicles

with engine codes AXX, BPY, BWA
Part I
Part II ⇒ page 176
Part III ⇒ page 176
Part IV ⇒ page 177
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

174 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 178
2 - Gasket
❑ Renew
3 - 9 Nm
4 - Crankcase breather hose
5 - Heat shield
6 - ACF line
7 - Vacuum unit for turbocharg‐
er
❑ Removing and installing
⇒ page 186
❑ Adjusting ⇒ page 187
8 - Nipple
9 - Seal
❑ Renew
10 - Hose
11 - Hose
12 - 3 Nm
13 - Charge pressure control
solenoid valve - N75-
14 - 8 Nm
15 - Seal
❑ Renew
16 - Connection
17 - Securing clip
18 - 9 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
19 - Hose with respect to the correctness of information in this document. Copyright by AUDI AG.

20 - 7 Nm
21 - Bracket
22 - 7 Nm
23 - Turbocharger air recirculation valve - N249-
❑ Note installation position ⇒ page 176
24 - Seal
❑ Renew

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 175
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Fitting location of turbocharger air recirculation valve - N249-

– Heed installation position -arrows-.
Part II
Part I ⇒ page 174
Part III ⇒ page 176
Part IV ⇒ page 177

1 - Seal
❑ Renew
2 - 30 Nm
3 - Oil supply line
4 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 178
5 - 9 Nm
6 - 30 Nm
7 - Seal
❑ Renew
8 - 35 Nm
9 - Seal
❑ Renew
10 - Coolant supply line
11 - 23 Nm
12 - 35 Nm
13 - Bolt
❑ 9 Nm
14 - Seal
❑ Renew
15 - Gasket
❑ Renew
16 - Oil return line
17 - 9 Nm
18 - Gasket
❑ Renew

Part III
Part I ⇒ page 174
Part II ⇒ page 176

176 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Part IV ⇒ page 177

1 - Gasket
❑ Renew
2 - 21 Nm
❑ Renew
❑ Coat studs of exhaust
manifold with high-tem‐
perature paste
❑ High-temperature paste
⇒ Parts catalogue
3 - 35 Nm
4 - Seal
❑ Renew
5 - 9 Nm
6 - 23 Nm
❑ Not fitted on all versions
7 - Coolant return line
8 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 178
9 - Bracket
10 - 30 Nm
❑ Lubricate bolts with
high-temperature paste
❑ High-temperature paste for private or commercial purposes, in part or in whole, is not
Protected by copyright. Copying
⇒ permitted
Parts catalogue
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
11 - 30 Nm
❑ Lubricate bolts with high-temperature paste
❑ High-temperature paste ⇒ Parts catalogue
12 - Bracket
13 - 23 Nm
14 - 30 Nm
❑ Do not slacken when removing turbocharger
❑ Renew
❑ Coat studs of exhaust manifold with high-temperature paste
❑ High-temperature paste ⇒ Parts catalogue
15 - Fastening strip

Part IV
Part I ⇒ page 174
Part II ⇒ page 176
Part III ⇒ page 176

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 177
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 178
2 - Vacuum unit for turbocharg‐
er
❑ Removing and installing
⇒ page 186
❑ Checking ⇒ page 185
❑ Adjusting ⇒ page 187
3 - 10 Nm
4 - Retaining clip
5 - 9 Nm
❑ Secure with sealing
paint
❑ Sealing paint ⇒ Parts
catalogue
6 - Knurled nut

1.3 Removing and installing turbocharger,

vehicles with engine codes AXX, BPY,
BWA
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Spring type clip pliers - VAS 5024 A-
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

178 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Socket (8 mm) - 3247-

♦ Engine bung set - VAS 6122-

Caution

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

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check the air cleaner housing, air filter element and intake
hoses for dirt and foreign particles.
♦ Check the entire charge air system (including the charge
air cooler) for foreign matter.
If foreign matter is found in the charge air system, clean all
relevant ducts and hoses and renew the charge air cooler if
necessary.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Drain off coolant ⇒ page 157 .
– Use screwdriver to pry off cover caps on wiper arms and un‐
screw hexagon nuts.
– Pull wiper arms off wiper shafts and remove.

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 179
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unclip washer jets -arrow-.

– Push washer jets through assembly opening back into plenum
chamber, leaving hoses connected.

– Detach rubber seal -1- from plenum chamber cover.

– Detach plenum chamber cover -2-.
– Detach engine wiring harness at rear plenum chamber panel.

– Remove electrical connector -arrow- for Lambda probe - G39-

and Lambda probe heater - Z19- (before catalytic converter)
from bracket, unplug and move clear.

– permitted
Remove plenum
authorisedchamber
by AUDI AG.intermediate plate -arrows-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

180 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unplug connectors -1- on ignition coils.

Note

Shown in illustration from rear with engine removed.

– Remove heat shield -arrows-.

– Disconnect coolant pipe going to coolant expansion tank

-arrow-.

– Disconnect coolant hose -1-.

– Disconnect coolant hose -2-.
– Unscrew coolant line -3-.

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 181
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew crankcase breather line with heat shield from turbo‐

charger -1-.
– Disconnect crankcase breather line from cylinder head cover
-2- and remove.
– Disconnect ACF line going to turbocharger from cylinder head
cover -3-.
– Unscrew oil supply line from turbocharger -4-.
– Remove catalytic converter together with front exhaust pipe.
Engines with code letters AXX, BPY, BWA ⇒ page 218 .
Engines with code letters BHZ, BZC, CDLA, CDLC ⇒ page 225
– Remove noise insulation ⇒ Rep. gr. 50 .

– Remove noise insulation (right-side) -fasteners 1 ... 3-.

– Remove drive shaft (right-side) ⇒ Rep. gr. 40 .

– Remove heat shield above drive shaft using hexagon key ex‐
tension, 8 mm - 3247- .

Vehicles with front-wheel drive

– Unbolt heat shield for drive shaft (right-side) -arrows-.

182 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

All vehicles:
– Detach air pipe -arrow- from charge air cooler.

– Unbolt air pipe from turbocharger -arrows-.

– Detach electrical connectors -1 and 2- and move wire clear.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew bolts -arrows- and remove air pipe.

Note

Shown in illustration from rear with engine removed.

– Unscrew oil supply line from turbocharger -2-.

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 183
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew coolant supply line at turbocharger -2-.

– Detach oil return line at turbocharger -arrows-.

– Remove bolts -1- and -2- and remove support for turbocharg‐
er.

– Disconnect coolant pipe -arrow-.

Note

♦ Shown in illustration from rear with engine removed.

♦ Nuts of fastening strip do not have to be unscrewed.

184 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove coolant pipe bolt -1- (if fitted) from cylinder head.
– Unscrew top nuts -arrows-.
– Lift out turbocharger/exhaust manifold.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 174

Note

♦ Renew seals, gaskets and self-locking nuts.

♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ Hose connections and charge air system hoses must be free
of oil and grease prior to fitting.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue .

– Install exhaust system and align it free of stress

⇒ page 221 .
– Install drive shaft ⇒ Rep. gr. 40 .
– Install air pipes with plug-in connectors ⇒ page 173 .
– Fill up with coolant ⇒ page 157 .
– Check oil level ⇒ Maintenance ; Booklet 808 .

Note

After installing turbocharger, allow engine to idle for approx. 1 mi‐

nute and do not rev up immediately to ensure turbocharger is
supplied with oil.

1.4 Checking vacuum unit for turbocharger,

engines with code letters AXX, BPY,
BWA
Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-

Test condition:
♦ Hose from turbocharger via charge pressure control solenoid
valve - N75- to vacuum unit must not be blocked.

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 185
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

♦ Charge pressure control solenoid valve - N75- OK.

Procedure:
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Connect hand vacuum pump - VAS 6213- to vacuum unit
-arrow-.

– Move adjuster ring -1- on hand vacuum pump - VAS 6213- to

position -B- to select “pressure”.

Caution

The pressure must not exceed 750 mbar. The vacuum unit
could be damaged if the pressure is exceeded.

– Operate hand vacuum pump - VAS 6213- several times and

at the same time observe linkage.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The linkage -A- should startunless
permitted to move at abypressure
authorised AUDI AG. AUDI ofAGapprox.
does not guarantee or accept any liability
300 mbar and be at its with
limit stopto at
respect the a pressure
correctness of approx.
of information in this document. Copyright by AUDI AG.
700 mbar.

The linkage should travel approx. 10 mm.

Note

If it is not possible to build up pressure with hand vacuum pump

- VAS 6213- or if the pressure drops again immediately, check
hand vacuum pump - VAS 6213- and connecting hoses for leaks.
If no fault is found: renew vacuum unit ⇒ page 186 .

1.5 Removing and installing vacuum unit for

turbocharger
Removing
– Remove turbocharger ⇒ page 178 .

186 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Detach locking plate -1- on turbocharger linkage.

– Slacken lock nut -2-.

– Disconnect linkage from turbocharger -3-.
– Detach vacuum unit -1- from turbocharger -arrows-.
Installing
Installation is carried out in the reverse order; note the following:
Tightening torques ⇒ page 177
– Adjust vacuum unit for turbocharger ⇒ page 187 .
– Install turbocharger ⇒ page 178 .

1.6 Adjusting vacuum unit for turbocharger,

engines with code letters AXX, BPY,
BWA
Turbocharger removed
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 187
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Special tools and workshop

equipment required
♦ Universal dial gauge brack‐
et - VW 387-
♦ Hand vacuum pump - VAS
6213-
♦ Pressure control valve -
VAS 6342-
♦ Turbocharger tester -
V.A.G 1397A-
♦ Dial gauge set, 4-part - VAS
6341-
♦ Torque wrench - V.A.G
1783-

♦ Open end spanner insert (10 mm) - V.A.G 1783/1-

Adjusting
• Tightening torques ⇒ page 177Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

188 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Disconnect hose -arrow- at vacuum unit on turbocharger.

– Detach locking plate above turbocharger linkage.

– Loosen lock nut -2-.

– Pre-adjust bypass flap -1- at knurled nut -arrow- so that bypass

flap can still just be turned by hand.
– Hand-tighten lock nut.

– Connect up hand vacuum pump - VAS 6213- , turbocharger

tester - V.A.G 1397A- (connection II) and pressure control
valve - VAS 6342- as shown in illustration.
– Close pressure control valve - VAS 6342- at lever -1-.

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 189
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Move adjuster ring -1- on hand vacuum pump - VAS 6213- to

position -B- to select “pressure”.
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
switch to position II.

190 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Secure universal dial gauge bracket - VW 387- to turbocharger

-arrow-.

Note

The dial gauge values (mm) listed here include the 1 mm preload
that is initially set on the gauge.

– Attach dial gauge - VAS 6341/1- with extension, 30 mm - VAS

6341/3- and flat probe - VAS 6341/4- to universal dial gauge
bracket - VW 387- .
– With pressure at 0 bar, set dial gauge - VAS 6341/1- to 1 mm
preload.
– Set scale of dial gauge - VAS 6341/1- to 0.
– Make sure that dial gauge can move freely.
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 350 by
Protected +/-copyright.
5 mbar. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– The dial gauge should now indicate a value
with respect betweenof4.1
to the correctness mm in this document. Copyright by AUDI AG.
information
and 4.3 mm. If not, turn knurled nut until this value is indicated.
– Hand-tighten lock nut.
– Repeat measurement.
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 0 mbar.
– Set dial gauge - VAS 6341/1- to 0.

Note

The following measurements must be performed in continuous

sequence. Do not allow the pressure to drop to 0 between meas‐
urements.

– Operate hand vacuum pump - VAS 6213- until turbocharger

tester - V.A.G 1397A- indicates 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Operate hand vacuum pump - VAS 6213- until turbocharger
tester - V.A.G 1397A- indicates 650 to 700 mbar.
– Vent system via pressure control valve - VAS 6342- so that
pressure reading drops to 350 +/- 5 mbar.
– Read off and note value indicated on dial gauge - VAS
6341/1- .
– Add values 1 and 2 together and divide by 2.
– The result (mean value) should be 5 +/- 0.25 mm.
– If the result (mean value) is not 5 +/- 0.25 mm, correct the
setting accordingly, tighten the lock nut hand-tight and repeat
the measurement.
– If the result (mean value) is 5 +/- 0.25 mm, tighten the lock nut
and secure with sealing paint. For sealing paint refer to ⇒
Parts catalogue .

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 191
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Secure locking plate -1- on linkage of vacuum unit.

1.7 Charge air cooler - exploded view, engine codes AXX, BPY, BWA

1 - Bolt
❑ 5 Nm
2 - Mounting
❑ For charge air cooler
3 - Charge air cooler
4 - Charge air pipe
❑ Fitting hose connec‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
tions with plug-in con‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
nectors ⇒ page 173 with respect to the correctness of information in this document. Copyright by AUDI AG.

5 - Bolt
❑ 10 Nm
6 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 173
7 - Hose clip
8 - Charge air hose
❑ To throttle valve module
- J338-
9 - Hose clip
10 - Bolt
❑ 10 Nm
11 - Charge air pipe
12 - Hose clip
13 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 173
14 - Seal
❑ Renew
15 - Charge pressure sender - G31-
16 - Bolt
❑ 5 Nm
17 - Bolts
❑ 10 Nm

192 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.8 Diagram of turbocharger system, engines with code letters AXX, BPY, BWA

1 - Vacuum unit
2 - Charge pressure control
solenoid valve - N75-
3 - Turbocharger air recircula‐
tion valve - N249-
4 - Turbocharger
5 - Brake servo
6 - Non-return valve
7 - Coolant connection
8 - Vacuum pump
9 - Non-return valve
10 - Oil filter bracket
11 - Activated charcoal filter
solenoid valve 1 - N80-
12 - Dual non-return valve
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - Charge
permitted air cooler
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
14 - Throttle valve module -
J338-
15 - Pressure control valve
16 - To activated charcoal filter
17 - Air mass meter - G70-

1.9 Removing and installing charge air cool‐

er - vehicles with engine codes AXX,
BPY and BWA
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 193
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Removing

Note

If there are slight impressions on the fins, refer to ⇒ page 7 .

– Remove radiator ⇒ page 168 .

– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 .

Note

To prevent damage to the condenser, refrigerant pipes and re‐

frigerant hoses, ensure that the pipes and hoses are not stretch‐
ed, kinked or bent.

WARNING

The air conditioner refrigerant circuit must not be opened.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew bolts -arrows-; to do so, release air unless
permitted ductsauthorised
(left andby AUDI AG. AUDI AG does not guarantee or accept any liability
right) and swivel towards headlights. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Tilt top edge of charge air cooler slightly to rear.

– Disengage charge air cooler from bottom mounting points by
lifting charge air cooler.
– Push charge air cooler towards engine.
– Support charge air cooler from below to prevent it from drop‐
ping.

– Remove bolts -arrows-.

– Detach charge air cooler upwards and remove from below.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 192
– Install air pipes with plug-in connectors ⇒ page 173 .
– Fill up with coolant ⇒ page 157 .
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 .

194 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.10 Checking charge air system for leaks,

vehicles with engine codes AXX, BPY,
BWA
Special tools and workshop equipment required
♦ Charge air system tester - V.A.G 1687-

♦ Adapters - V.A.G 1687/5-

– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body - front, noise insulation .
– Release clip -A- and detach hose -B- from charge air pipe.

– Fit adapter - V.A.G 1687/5- onto charge air hose -A- and turn
adapter through approx. 90° -B-.
Prepare charge air system tester - V.A.G 1687- as follows:

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 195
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew pressure control valve -2- all the way and close
valves -3- and -4-.

Note

Make sure knob is pulled out before turning pressure control valve
-2-.

– Connect charge air system tester - V.A.G 1687- as illustrated.

196 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Connect pressure hose -1- (compressed air supply line) to

charge air system tester - V.A.G 1687- .

Note

If sight glass contains water, loosen drain plug and drain water
-6-.

– Open valve -3-.

– Adjust pressure to 0.5 bar via pressure control valve -2-.

Caution
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

The pressure must not exceed 0.5 bar. If the pressure is set
with respect to the correctness of information in this document. Copyright by AUDI AG.

too high this can damage the engine.

– Open valve -4- and wait until test system is pressurised. Re-
adjust pressure to 0.5 bar if necessary.
– Check charge air system for visible or audible leaks and apply
commercially available leak detecting spray or use ultrasonic
tester - V.A.G 1842- .

Note

♦ A small amount of air escapes through the valves and enters

the engine. Therefore it is not possible to perform a pressure
retention test.
♦ Operation of ultrasonic tester - V.A.G 1842- ⇒ Operating in‐
structions .
♦ Release pressure by detaching coupling from adapter - V.A.G
1687/5- before removing adapter.
♦ Hose connections and charge air system hoses must be free
of oil and grease prior to fitting.

– Install air pipes with plug-in connectors ⇒ page 173 .

1. Turbocharger with charge air system, engine codes AXX, BPY, BWA 197
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2 Turbocharger with charge air system,

engines with code letters BHZ, BZC,
CDLA, CDLC

Note

♦ Observe the rules for cleanliness ⇒ page 5 .

♦ Secure all hose connections with the correct type of hose clips
(same as original equipment).
♦ Hose connections and charge air system hoses must be free
of oil and grease prior to fitting. However (applies only to plug-
in connectors); the seal and the sealing surface of plug-in
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
connectors should be lubricated lightly with oil ⇒ page 173 .
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Charge air system must be free of leaks, checking for leaks
⇒ page 213 .
♦ Renew self-locking nuts.
♦ Hose clip pliers - VAS 5024A- or spring-type clip pliers - V.A.G
1921- are recommended for installing spring-type hose clips.
♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing turbocharger, allow engine to idle for approx.
1 minute and do not rev up immediately to ensure turbocharger
is supplied with oil.

Fitting hose connections with plug-in connectors ⇒ page 173 .

2.1 Turbocharger - exploded view, engines

with code letters BHZ, BZC, CDLA,
CDLC
Part I
Part II ⇒ page 200
Part III ⇒ page 201

198 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 202
2 - ACF line
3 - Gasket
❑ Renew
4 - Bolt
❑ 9 Nm
5 - Heat shield
6 - Crankcase breather hose
7 - Air hose
❑ Note installation posi‐
tion ⇒ page 200
8 - Seal
❑ Renew
9 - To turbocharger air recircu‐
lation valve - N249-
❑ Refer to
⇒ Item 9 (page 209)
10 - Spring-type clip
11 - Seal
❑ Note installation posi‐
tion ⇒ page 200
12 - Vacuum unit for turbo‐
charger
❑ Checking ⇒ page 185
13 - Nipple
14 - Hose
15 - Seal
❑ Renew
16 - Bolt
❑ 8 Nm
17 - Hose
18 - Bolt
❑ 3 Nm
19 - Charge pressure control solenoid valve - N75-
20 - Hose
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
21 -with
Seal
respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Renew
22 - Connection
23 - Securing clip
24 - Bolt
❑ 9 Nm

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 199
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Installation position of air hose

– Note installation position -arrows-
Part II
Part I ⇒ page 198
Part III ⇒ page 201

1 - Seal
❑ Renew
2 - Bolt
❑ 30 Nm
3 - Oil supply line
4 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 202
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 30 Nm
7 - Seal
❑ Renew
8 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 35 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Seal
❑ Renew
10 - Coolant supply line
11 - Bolt
❑ 23 Nm
12 - Bolt
❑ 23 Nm
13 - Bolt
❑ 9 Nm
14 - Seal
❑ Renew

200 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

15 - Gasket
❑ Renew
16 - Oil return line
17 - Bolt
❑ 9 Nm
18 - Gasket
❑ Renew

Part III
Part I ⇒ page 198
Part II ⇒ page 200

1 - Gasket
❑ Renew
2 - Nut
❑ 21 Nm
❑ Renew
❑ Coat studs of exhaust
manifold with high-tem‐
perature paste
❑ High-temperature paste
⇒ Parts catalogue
3 - Bolt
❑ 35 Nm
4 - Seal
❑ Renew
5 - Bolt
❑ 9 Nm
6 - Coolant return line
7 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold and vacuum
unit as one unit
❑ Removing and installing
⇒ page 202
8 - Bracket
9 -byBolt
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not

with respect to30

❑ the Nm
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
correctness of information in this document. Copyright by AUDI AG.
❑ Lubricate bolts with
high-temperature paste
❑ High-temperature paste
⇒ Parts catalogue
10 - Bolt
❑ 30 Nm
❑ Lubricate bolts with high-temperature paste
❑ High-temperature paste ⇒ Parts catalogue

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 201
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

11 - Bracket
12 - Bolt
❑ 23 Nm
13 - Nut
❑ 30 Nm
❑ Do not slacken when removing turbocharger
❑ Renew
❑ Coat studs of exhaust manifold with high-temperature paste
❑ High-temperature paste ⇒ Parts catalogue
14 - Fastening strip

2.2 Removing and installing turbocharger,

engines with code letters BHZ, BZC,
CDLA, CDLC
Special tools and workshop equipment required
♦ Spring type clip pliers - VAS 5024 A-

♦ Socket (8 mm) - 3247-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .

202 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove air hose -1 and 2- using hose clip pliers - V.A.G

1921- .

WARNING

Hot steam/hot coolant may escape when opening expansion

tank. Cover cap with cloth and open carefully.

– Open filler cap on coolant expansion tank.

– Drain off coolant ⇒ page 157 .
– Use screwdriver to pry off cover caps on wiper arms and un‐
screw hexagon nuts.
– Pull wiper arms off wiper shafts and remove.

– Unclip washer jets -arrow-.

– Push washer jets through assembly opening back into plenum
chamber, leaving hoses connected.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Detach rubber sealto-1-
with respect from plenum
the correctness chamber
of information cover. Copyright by AUDI AG.
in this document.

– Detach plenum chamber cover -2-.

– Detach engine wiring harness at rear plenum chamber panel.

– Remove electrical connector -arrow- for Lambda probe - G39-

and Lambda probe heater - Z19- (before catalytic converter)
from bracket, unplug and move clear.

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 203
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Remove plenum chamber intermediate plate -arrows-.

– Unplug connectors -1- on ignition coils.

Note

Shown in illustration from rear with engine removed.

– Remove heat shield -arrows-.

– Disconnect coolant pipe going to coolant expansion tank

-arrow-.

204 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Disconnect coolant hose -1-.

– Disconnect coolant hose -2-.
– Unscrew coolant line -3-.

– Unscrew crankcase breather line with heat shield from turbo‐

charger -1-.
– Disconnect crankcase breather line from cylinder head cover
-2- and remove.
– Disconnect ACF line going to turbocharger from cylinder head
cover -3-.
– Unscrew oil supply line from turbocharger -4-.
– Remove catalytic converter with front exhaust pipe
⇒ page 225 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove noise insulation ⇒ Rep. gr. 50 .permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove noise insulation (right-side) -fasteners 1 ... 3-.

– Remove drive shaft (right-side) ⇒ Rep. gr. 40 .

– Remove heat shield above drive shaft using hexagon key ex‐
tension, 8 mm - 3247- .

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 205
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Detach air pipe -arrow- from charge air cooler.

– Unbolt air pipe from turbocharger -arrows-.

– Unscrew bolts -arrows- and remove air pipe.

Note

Shown in illustration from rear with engine removed.

– Unscrew oil supply line from turbocharger -2-.

206 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew coolant supply line at turbocharger -2-.

– Detach oil return line at turbocharger -arrows-.

– Remove bolts -1- and -2- and remove support for turbocharg‐
er.

– Disconnect coolant pipe -arrow-.

Note

♦ Shown in illustration from rear with engine removed.

♦ The nuts on the fastening strip (bottom) do not have to be
loosened.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 207
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew top nuts -arrows-.

– Lift out turbocharger/exhaust manifold.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 174

Note

♦ Renew seals, gaskets and self-locking nuts.

– Install exhaust system and align it free of stress

⇒ page 221 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install drive shaft ⇒ Rep. gr. 40 . with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install air pipes with plug-in connectors ⇒ page 173 .

– Fill up with coolant ⇒ page 157 .
– Check oil level ⇒ Maintenance ; Booklet 808 .

Note

After installing turbocharger, allow engine to idle for approx. 1 mi‐

nute and do not rev up immediately to ensure turbocharger is
supplied with oil.

2.3 Charge air system - exploded view, engines with code letters BHZ, BZC,
CDLA, CDLC

208 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1 - Bolt
❑ 5 Nm
2 - Mounting
❑ For charge air cooler
3 - Charge air cooler
4 - Hose clip
5 - Bolt
❑ 10 Nm
6 - Charge air pipe
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 173
7 - Charge air hose
❑ Fitting hose connec‐
tions with plug-in con‐
nectors ⇒ page 173
8 - Hose clip
9 - Leading to air intake hose
❑ Refer to
⇒ Item 9 (page 199)
10 - Charge air hose
❑ To throttle valve module
- J338-
11 - Hose clip
12 - Charge air pipe
13 - Bolt
❑ 10 Nm
14 - Hose clip
15 - Charge air hose
16 - Hose clip
17 - Seal
❑ Renew
18 - Charge pressure sender - G31-
19 - Bolt
❑ 5 Nm
20 - Bolt
❑ 10 Nm
21 - Hose clip
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
22 - Hose permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
23 - Hose clip
24 - Housing
25 - Turbocharger air recirculation valve - N249-
❑ Installation position ⇒ page 210
26 - Bolt
❑ 7 Nm

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 209
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

27 - Seal
❑ Renew
28 - Hose clip
29 - Hose

Fitting location of turbocharger air recirculation valve - N249-

– The marks -arrows- must align.

210 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2.4 Diagram of turbocharger system, engines with code letters BHZ, BZC,
CDLA, CDLC

1 - Vacuum unit
2 - Charge pressure control
solenoid valve - N75-
3 - Turbocharger
4 - Brake servo
5 - Non-return valve
6 - Coolant connection
7 - Vacuum pump
8 - Non-return valve
9 - Oil filter bracket
10 - Activated charcoal filter
solenoid valve 1 - N80-
11 - Dual non-return valve
12 - Charge pressure sender -
G31-
13 - Charge air cooler
14 - Turbocharger air recircu‐
lation valve - N249-
15 - Throttle valve module -
J338-
16 - Pressure control valve
17 - To activated charcoal filter
18 - Air recirculation hose
19 - Air mass meter - G70-

2.5 Removing and installing charge air cool‐

er, engines with code letters BHZ, BZC,
CDLA, CDLC
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 211
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Removing

Note

If there are slight impressions on the fins, refer to ⇒ page 7 .

– Remove radiator ⇒ page 168 .

– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 .

Note

To prevent damage to the condenser, refrigerant pipes and re‐

frigerant hoses, ensure that the pipes and hoses are not stretch‐
ed, kinked or bent.

WARNING

The air conditioner refrigerant circuit must not be opened.

– Unscrew bolts -arrows-; to do so, release air ducts (left and

right) and swivel towards headlights.
– Tilt top edge of charge air cooler slightly to rear.
– Disengage charge air cooler from bottom mounting points by
lifting charge air cooler.
– Push charge air cooler towards engine.
– Support charge air cooler from below to prevent it from drop‐
ping.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Removepermitted
bolts -arrows-.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Detach charge air cooler upwards and remove from below.

Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 192
– Install air pipes with plug-in connectors ⇒ page 173 .
– Fill up with coolant ⇒ page 157 .
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 .

212 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2.6 Checking charge air system for leaks,

engines with code letters BHZ, BZC,
CDLA, CDLC
Special tools and workshop equipment required
♦ Charge air system tester - V.A.G 1687-

♦ Adapters - V.A.G 1687/5-

– Remove noise insulation tray ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body - front, noise insulation .
– Release clip -A- and detach hose -B- from charge air pipe.

– Fit adapter - V.A.G 1687/5- onto charge air hose -A- and turn
adapter through approx. 90° -B-.
Prepare charge air system tester - V.A.G 1687- as follows:

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 213
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew pressure control valve -2- all the way and close
valves -3- and -4-.

Note

Make sure knob is pulled out before turning pressure control valve
-2-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Connect charge air system tester - V.A.G 1687- as illustrated.
with respect to the correctness of information in this document. Copyright by AUDI AG.

214 Rep. gr.21 - Turbocharging/supercharging

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Connect pressure hose -1- (compressed air supply line) to

charge air system tester - V.A.G 1687- .

Note

If sight glass contains water, loosen drain plug and drain water
-6-.

– Open valve -3-.

– Adjust pressure to 0.5 bar via pressure control valve -2-.

Caution

The pressure must not exceed 0.5 bar. If the pressure is set
too high this can damage the engine.

Note

♦ A small amount of air escapes through the valves and enters

– Install air pipes with plug-in connectors ⇒ page 173 .

2. Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC 215
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

26 – Exhaust system
1 Exhaust system, engines with code
letters AXX, BPY, BWA

Note

♦ The flexible joint in the front exhaust pipe must not be bent
more than 10° – otherwise it can be damaged.
♦ Renew gaskets and self-locking nuts.
♦ After working on the exhaust system, ensure that the system
is not under stress and that it has sufficient clearance from the
body. If necessary, loosen clamp and align silencers and ex‐
haust pipe so that sufficient clearance is maintained to the
body at all points and the mountings are evenly loaded.
♦ The exhaust manifold and the turbocharger are combined as
one unit; removing and installing ⇒ page 178 .

1.1 Exhaust system - exploded

Protected by copyright. view,
Copying for private engines
or commercial with
purposes, code
in part letters
or in whole, is not AXX, BPY, BWA
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Nut
❑ 40 Nm
❑ Renew
❑ Coat studs of turbo‐
charger with high-tem‐
perature paste
❑ High-temperature paste
⇒ Parts catalogue
2 - Front exhaust pipe with cat‐
alytic converters and front si‐
lencer
❑ With front exhaust pipe
❑ Protect against knocks
and impact
❑ With flexible joint
❑ Do not bend flexible joint
more than 10° - other‐
wise it can be damaged
❑ Removing and installing
⇒ page 218
❑ Align exhaust system so
it is free of stress
⇒ page 221
3 - Lambda probe after catalyt‐
ic converter - G130- and Lamb‐
da probe heater 1 after catalyt‐
ic converter - Z29-
❑ Tightening
torque: 55 Nm
❑ Grease only the threads
with high-temperature
paste. The paste must
not penetrate into the
slots on the probe body.

216 Rep. gr.26 - Exhaust system

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

❑ High-temperature paste
⇒ Parts catalogue
❑ Removing and installing ⇒ Rep. gr. 24
4 - Rubber mounting
❑ Renew if damaged
5 - Nut
❑ 23 Nm
6 - Rubber mounting
❑ Renew if damaged
7 - Rear silencer
❑ Combined in one unit with centre silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point ⇒ page 221
❑ Align exhaust system so it is free of stress ⇒ page 221
8 - Mounting
❑ Renew if damaged
9 - Bolt
❑ 23 Nm
10 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
❑ Installation position ⇒ page 218
❑ Tighten bolt connections evenly.
11 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point ⇒ page 221
❑ Align exhaust system so it is free of stress ⇒ page 221
12 - Rubber mounting
❑ Renew if damaged
13 - Bolt
❑ 23 Nm
14 - Clamp (front)
❑ Align exhaust system so it is free of stress before tightening clamp ⇒ page 221
❑ Installation position ⇒ page 218
❑ Tighten bolt connections evenly.
15 - Nut
❑ 23 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
16 - Mounting permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
17 - Bolt
❑ 23 Nm
18 - Mounting
19 - Support
20 - 40 Nm
21 - Gasket
❑ Renew
22 - Lambda probe - G39- and Lambda probe heater - Z19-
❑ Tightening torque: 55 Nm

1. Exhaust system, engines with code letters AXX, BPY, BWA 217
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Installation position of front clamp

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

Installation position of rear clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolted connection faces to rear

1.2 Removing and installing front exhaust

pipe with catalytic converters and front
silencer, engines with code letters AXX,
BPY, BWA
Special tools and workshop equipment required
♦ Spring type clip pliers - VAS 5024 A-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

218 Rep. gr.26 - Exhaust system

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unplug electrical connector -arrow- for Lambda probe - G39-

and Lambda probe heater - Z19- and move wiring clear.

– Unscrew securing nuts -arrows- of front exhaust pipe/turbo‐

charger accessible from above.
Vehicles with four-wheel drive
– Remove propshaft (front) ⇒ Rep. gr. 39 .
All vehicles:

– Remove underbody cover (right-side) -arrows-.

– Unplug electrical connector -arrow- for Lambda probe after

catalytic converter - G130- and Lambda probe 1 heater after
catalytic converter - Z29- and move wiring clear.

1. Exhaust system, engines with code letters AXX, BPY, BWA 219
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew remaining securing nuts -arrows- for front exhaust

pipe/turbocharger from below.
– Remove support for front exhaust pipe with catalytic converter
(unscrew bolts -1 and 2-).

Note

To avoid damage, the flexible joints in the front exhaust pipe must
not be bent more than 10 °.

– Separate exhaust system at clamp -arrows-.

– Remove front cross-piece for underbody -arrows-.

– Remove front exhaust pipe with catalytic converters and front

silencer.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 216

Note

Renew gaskets and self-locking nuts.

– Install propshaft (front) ⇒ Rep. gr. 39 .

– Align the exhaust system so it is free of stress ⇒ page 221 .

220 Rep. gr.26 - Exhaust system

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

1.3 Separating centre and rear silencers,

engines with code letters AXX, BPY,
BWA
♦ The connecting pipe can be cut through at the cutting point
provided in order to renew the centre and rear silencers sep‐
arately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.
Special tools and workshop equipment required
♦ Chain pipe cutter - VAS 6254-

Procedure
• Tightening torques ⇒ page 216
– Cut through exhaust pipe at the position marked -arrow 2- us‐
ing chain pipe cutter - VAS 6254- .
– Position clamp -4- centrally at side marks when installing - ar‐
rows -1- and -3-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install clamp so that the bolt end does not protrude beyond
bottom of clamp -arrow-.
• Bolted connection faces to rear
– Align the exhaust system so it is free of stress ⇒ page 221 .

1.4 Stress-free alignment of exhaust sys‐

tem, vehicles with engine codes AXX,
BPY, BWA
• The exhaust system must be aligned when it is cool.
• Tightening torques ⇒ page 216

1. Exhaust system, engines with code letters AXX, BPY, BWA 221
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Loosen bolt connections of front clamp

⇒ Item 14 (page 217) .
– Push exhaust system towards front of vehicle so that mounting
for rear silencer is preloaded by a = 5 ... 11 mm.

– Install clamp so that ends of bolts do not protrude beyond bot‐

tom of clamp.
• Bolt connection faces right
– Tighten bolt connections on clamp evenly.
Aligning tailpipe:

– Align tailpipes so that distance -a- (left-side) is the same as

distance -a- (right-side).
– At the same time, distance -b- must be obtained between
bumper cut-out and top of tailpipes.
♦ Dimension b = min. 22 mm
– If necessary, unfasten rear silencer mounting to align tailpipes.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
1.5 Checking exhaust system for leaks, ve‐
hicles with engine codes AXX, BPY,
BWA
– Start engine and run at idling speed.
– Plug the tailpipe (e. g. with rags or stopper) and leave plugged
until the check is complete.
– Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
any leaks.
– Rectify any leaks that are found.

222 Rep. gr.26 - Exhaust system

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

2 Exhaust system, engines with code

letters BHZ, BZC, CDLA, CDLC

Note

2.1 Exhaust system - exploded view, engines with code letters BHZ, BZC,
CDLA, CDLC

1 - Centre silencer
❑ Combined with rear si‐
lencer
❑ Align exhaust system so Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
it is free of stress with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “2.3 Stress-free align‐
ment of exhaust system,
engines with code let‐
ters BHZ, BZC, CDLA,
CDLC”, page 227
2 - Rubber mounting
❑ Renew if damaged
3 - Bolt
❑ 23 Nm
4 - Bracket for exhaust system
5 - Bolt
❑ 23 Nm
6 - Mounting
❑ Renew if damaged
7 - Gasket
❑ Renew
8 - Nut
❑ 40 Nm
❑ Renew
❑ Coat studs of turbo‐
charger with high-tem‐
perature paste
❑ High-temperature paste
⇒ Parts catalogue
9 - Lambda probe - G39- and
Lambda probe heater - Z19-
❑ 55 Nm

2. Exhaust system, engines with code letters BHZ, BZC, CDLA, CDLC 223
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

❑ Grease only the threads with high-temperature paste. The paste must not penetrate into the slots on the
probe body.
❑ High-temperature paste ⇒ Parts catalogue
❑ Removing and installing ⇒ Rep. gr. 24
10 - Front exhaust pipe with catalytic converter and front silencer
❑ Do not bend flexible joint more than 10° - otherwise it can be damaged
❑ Install flexible joint so that it is not under tension.
❑ Take care not to damage wire mesh on flexible joint
❑ Protect catalytic converter from damage by knocks and impact
❑ Removing and installing ⇒ page 225
❑ Align exhaust system so it is free of stress ⇒ page 227
11 - Lambda probe after catalytic converter - G130- and Lambda probe heater 1 after catalytic converter - Z29-
❑ 55 Nm
❑ Grease only the threads with high-temperature paste. The paste must not penetrate into the slots on the
probe body. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ High-temperature paste ⇒ permitted
Parts catalogue
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Removing and installing ⇒ Rep. gr. 24
12 - Clamp
❑ Align exhaust system so it is free of stress before tightening clamp
⇒ “2.3 Stress-free alignment of exhaust system, engines with code letters BHZ, BZC, CDLA, CDLC”,
page 227
❑ Installation position ⇒ page 225
❑ Tighten bolt connections evenly.
13 - Nut
❑ 23 Nm
❑ Renew
14 - Mounting
❑ Renew if damaged
15 - Bolt
❑ 23 Nm
16 - Rear silencer
❑ Combined with centre silencer
❑ Align exhaust system so it is free of stress
⇒ “2.3 Stress-free alignment of exhaust system, engines with code letters BHZ, BZC, CDLA, CDLC”,
page 227
17 - Rubber mounting
❑ Renew if damaged
18 - Bracket for exhaust system
19 - Bolt
❑ 23 Nm
20 - Bracket for exhaust system
21 - Bolt
❑ 23 Nm
22 - Rubber mounting
❑ Renew if damaged

224 Rep. gr.26 - Exhaust system

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

Installation position of clamp

– Fit clamp in horizontal position.
• Bolt connection faces to right.

2.2 Removing and installing front exhaust

pipe with catalytic converter and front si‐
lencer, engines with code letters BHZ,
BZC, CDLA, CDLC
Special tools and workshop equipment required
♦ Spring type clip pliers - VAS 5024 A-

Removing
– Detach engine cover panel with air cleaner ⇒ Rep. gr. 24 .
– Unplug electrical connector -arrow- for Lambda probe - G39-
and Lambda probe heater - Z19- and move wiring clear.

2. Exhaust system, engines with code letters BHZ, BZC, CDLA, CDLC 225
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Unscrew securing nuts -arrows- of front exhaust pipe/turbo‐

charger accessible from above.
– Remove propshaft (front) ⇒ Rep. gr. 39 .

– Remove underbody cover (right-side) -arrows-.

– Unplug electrical connector -arrow- for Lambda probe after

catalytic converter - G130- and Lambda probe 1 heater after
catalytic converter - Z29- and move wiring clear.

– Unscrew remaining securing nuts -arrows- for front exhaust

pipe/turbocharger from below.

Note

To avoid damage, the flexible joints in the front exhaust pipe must
not be bent more than 10 °.

226 Rep. gr.26 - Exhaust system

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Separate exhaust system at clamp -arrows-.

– Remove front cross-piece for underbody -arrows-.

– Unbolt bracket for exhaust system -arrows-.

– Remove front exhaust pipe with catalytic converters and front
silencer.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques ⇒ page 223

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Renew gaskets and self-locking nuts. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install propshaft (front) ⇒ Rep. gr. 39 .

– Align the exhaust system so it is free of stress
⇒ “2.3 Stress-free alignment of exhaust system, engines with
code letters BHZ, BZC, CDLA, CDLC”, page 227 .

2.3 Stress-free alignment of exhaust sys‐

tem, engines with code letters BHZ,
BZC, CDLA, CDLC
• The exhaust system must be aligned when it is cool.
• Tightening torques ⇒ page 223

2. Exhaust system, engines with code letters BHZ, BZC, CDLA, CDLC 227
Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

– Loosen bolts of clamp ⇒ Item 12 (page 224) .

– Push rear section of exhaust system towards front of vehicle
-arrow- so that mounting ⇒ Item 22 (page 224) between centre
and rear silencer is preloaded by -a- = 13 ... 17 mm.

– Fit clamp in horizontal position.

• Bolt connection faces to right.
– Tighten bolt connections on clamp evenly.

Aligning tailpipes
– Align rear silencer so that there is an equal distance -a- and
-b- between the cut-out in the bumper and the pipe ends.
– If necessary, loosen mountings for rear silencer to adjust the
tailpipes.

2.4 Checking exhaust system for leaks, en‐

gines with code letters BHZ, BZC,
CDLA, CDLC
– Start engine and run at idling speed.
– Plug the tailpipe (e. g. with rags or stopper) and leave plugged
until the check is complete.
– Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
any leaks.
– Rectify any leaks that are found.

228 Rep. gr.26 - Exhaust system

Audi A3 2004 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2017

3 Exhaust manifold

Note

Exhaust manifold and turbocharger are combined as one unit.

– Removing and installing exhaust manifold: vehicles with en‐

gine codes AXX, BPY, BWA ⇒ page 178 , vehicles with engine
codes BHZ, BZC, CDLA, CDLC ⇒ page 202

3. Exhaust manifold 229

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