VOLKS CITY BEECH AVENUE CATTEDOWN PLYMOUTH PL4 0QQ

VOLKS CITY BEECH AVENUE CATTEDOWN PLYMOUTH PL4 0QQ Telephone: 01752 667007 Fax: 01752 663399 Email: mail@volkscity.com 1 Accelerator pedal position (APP) sensor - above pedal 2 Brake pedal position (BPP) switch 1/2 - above pedal 3 Camshaft position (CMP) actuator 1 4 Camshaft position (CMP) actuator 2 5 Camshaft position (CMP) sensor 1 6 Camshaft position (CMP) sensor 2 7 Clutch pedal position (CPP) switch - above pedal 8 Crankshaft position (CKP) sensor 9 Data link connector (DLC) - fascia, driver's side 10 Engine control module (ECM) - LHD 11 Engine control module (ECM) - RHD 12 Engine coolant temperature (ECT) sensor 13 Evaporative emission (EVAP) canister purge valve 14 Fuel filter - tank exterior 15 Fuel pressure regulator 16 Fuel pump - in tank 17 Fuel pump relay - fascia relay plate 2 18 Heated oxygen sensor (HO2S) 1, bank 1 - before cat 19 Heated oxygen sensor (HO2S) 2, bank 1 - if fitted - after cat 20 Heated oxygen sensor (HO2S) 1, bank 2 - before cat 21 Heated oxygen sensor (HO2S) 2, bank 2 - if fitted - after cat 22 Ignition amplifier 23 Ignition coil 24 Injectors 1-3 25 Injectors 4-6 26 Intake air temperature (IAT) sensor 27 Intake manifold air control solenoid 28 Knock sensor (KS) 1 29 Knock sensor (KS) 2 30 Mass air flow (MAF) sensor 31 Secondary air injection (AIR) pump - if fitted 32 Secondary air injection (AIR) pump relay - if fitted - engine bay relay plate - LHD 33 Secondary air injection (AIR) pump relay - if fitted - engine bay relay plate - RHD 34 Secondary air injection (AIR) solenoid - if fitted 35 Throttle control unit 36 Throttle motor 37 Throttle motor position sensor 1/2 38 Vehicle speed sensor (VSS) - transmission

VOLKS CITY BEECH AVENUE CATTEDOWN PLYMOUTH PL4 0QQ Telephone: 01752 667007 Fax: 01752 663399 Email: mail@volkscity.com Notes Specified value Measured value Vehicle identification No. of cylinders Type 6/DOHC Capacity (Fiscal) cc 2393 Compression ratio :1 10,5 Suitable for unleaded petrol Yes Minimum octane rating RON 95 Ignition system Make Bosch Ignition system Type Motronic Ignition system Description Map-DIS Trigger location Cam / Crankshaft Fuel system Make Bosch Fuel system Type Motronic Fuel system Description MFI-s Air metering Type Mass Combined ignition and fuel ECM Yes Diagnostic socket Yes Ignition system Ignition coil Make Bosch Secondary resistance Ohm 8000-14000 Firing order 1-4-3-6-2-5 Tuning and emissions 47 Tuning conditions Ignition timing - basic BTDC Engine/rpm Not adjustable Ignition advance checks Engine/rpm ECM Controlled Idle speed rpm 670-770 Not adjustable Oil temperature for CO test C 80 CO level at idle speed - tailpipe Vol. % CO 0,5 Max Not adjustable HC level at idle speed ppm 100 CO2 level at idle speed Vol. % CO2 14,5-16 O2 level at idle speed Vol. % O2 0,1-0,5 Increased idle speed for CO test rpm 2500-2800 CO content at increased idle speed Vol. % 0,3 Lambda at increased idle λ 0,97-1,03 Spark plugs Spark plugs Original equipment NGK Spark plug Type BKR6EKUB Electrode gap mm 0,9-1,1 Spark plugs Make NGK Spark plug Type BKR6EKUB Electrode gap mm 0,9-1,1 Fuel system System pressure bar 3,8-4,2 Regulated pressure with vacuum bar 3,2-3,8 Engine coolant temperature (ECT) sensor Ohm/ C 275-375/80 Injector Ohm 13,5-15,5

Service checks and adjustments Valve clearance -INLET mm Hydraulic Valve clearance -EXHAUST mm Hydraulic Compression pressure bar 9-14 Oil pressure bar/rpm 2,0/2000 Radiator cap bar 1,4-1,6 Thermostat opens C 86 Lubricants and capacities Engine oil options Ambient temperature range All temperatures Engine oil grade SAE 0W/30 275 Engine oil classification OEM VW 503.00 Ambient temperature range All temperatures Engine oil grade SAE 5W/30, 5W/40 Engine oil classification OEM VW 500.00/502.00 Ambient temperature range -35 C > 15 C Engine oil grade SAE 5W/30, 5W/40 Engine oil classification OEM VW 501.01 Ambient temperature range All temperatures Engine oil grade SAE 5W/50 Engine oil classification OEM VW 501.01 Ambient temperature range All temperatures Engine oil grade SAE 10W/30, 10W/40 Engine oil classification OEM VW 500.00/502.00 Ambient temperature range -20 C > 15 C Engine oil grade SAE 10W/30, 10W/40 Engine oil classification OEM VW 501.01 Ambient temperature range All temperatures Engine oil grade SAE 10W/50, 10W/60 Engine oil classification OEM VW 501.01 Ambient temperature range -15 C > 40 C Engine oil grade SAE 15W/40, 15W/50 Engine oil classification OEM VW 501.01 Ambient temperature range -15 C > 40 C Engine oil grade SAE 20W/40, 20W/50 Engine oil classification OEM VW 501.01 Engine with filter(s) litres 5,7 Other lubricants and capacities Manual gearbox oil grade SAE 75W/90 Synthetic Manual gearbox litres 2,25-2,75 257 Automatic transmission fluid Type 255 Automatic transmission (drain & refill) litres 259 Differential oil grade - front SAE Synthetic 258 Differential front/at litres Differential oil grade - rear SAE 75W/90 Synthetic Differential rear litres 1,3 Cooling system litres 8,0 Brake fluid Type DOT 4 Brake fluid litres 1,0 Power steering fluid Type VW G 002 000 Power steering fluid litres 0,85 Tightening torques Cylinder head instructions Cylinder head Renew bolts Yes Stage 1 Tighten 40 Nm Stage 2 Tighten 60 Nm Stage 3 Tighten 90

Stage 4 Tighten 90 Other engine tightening torques Main bearings Renew bolts/nuts Yes 178 Main bearings Stage 1 Big end bearings Renew bolts/nuts Yes 129 Big end bearings Stage 1 Oil pump to cylinder block 22 Nm 133 Sump bolts Sump drain bolt 30 Nm 79 Flywheel/driveplate Clutch to flywheel 20 Nm 72 Crankshaft pulley/damper centre bolt 62 Camshaft sprocket/gear 55 Nm Camshaft carrier/cap 10 Nm Camshaft/rocker cover 10 Nm Inlet manifold to cylinder head 10 Nm 62 Exhaust manifold to cylinder head 25 Nm 62 Exhaust downpipe to manifold 25 Nm Water pump 10 Nm Spark plugs 30 Nm Fuel rail 10 Nm Lambda sensor (Oxygen) 50 Nm Knock sensor (KS) 20 Nm Engine oil pressure switch 25 Nm Chassis tightening torques 92 Front hub 93 Rear hub Steering rack/box mounting 35 Nm 210 Steering track rod end 156 Brake caliper to carrier Front 25 Nm 155 Brake caliper carrier to hub Front 62 Brake caliper to carrier Rear 35 Nm Brake caliper carrier to hub Rear 95 Nm Road wheels 120 Nm Starting and charging Battery V/RC(Ah) 12 Brake disc and drum dimensions 183 Minimum disc thickness - ventilated Front 186 Minimum disc thickness Rear 8 mm Minimum pad thickness Front 2 mm Minimum pad thickness Rear 2 mm Air conditioning Air conditioning refrigerant Type R134a 127 Air conditioning refrigerant quantity grams 83 Air conditioning oil Type Air conditioning oil quantity cm³ 275±25 Autodata Note 47 Ignition timing, idle speed and CO level - with Cat and Lambda sensor Use VAG 1551 or equivalent equipment and initiate basic setting mode before checks. Autodata Note 275 Engine oil classification Longlife oil Autodata Note 257

Automatic transmission fluid type Tiptronic gearbox = G 052 162 Multitronic gearbox (CVT) = G 052 180 Autodata Note 255 Automatic transmission fluid - drain and refill Tiptronic gearbox = 2,6-3,0 litres Multitronic gearbox (CVT) = 4,5-5,0 litres Autodata Note 259 Differential oil grade - front Tiptronic gearbox = 75W/90 Multitronic gearbox (CVT) = G 052 190 A2 Autodata Note 258 Differential oil - front Tiptronic gearbox = 0,8 litres Multitronic gearbox (CVT) = 1,3 litres Autodata Note 178 Main bearings Use new bolts. Horizontal bolts = 25 Nm Vertical bolts = 60 Nm + 90. Autodata Note 129 Big end bearings M8 = 30 Nm + 90 M8.5 = 40 Nm + 90. Autodata Note 133 Sump bolts Use new nuts. M6 = 10 Nm M7 = 15 Nm M10 = 45 Nm M8 = 22 Nm. Autodata Note 79 Flywheel/drive plate Use new bolts and tighten as follows: Flywheel = 60 Nm + 180 Drive plate = 60 Nm + 90. Autodata Note 72 Crankshaft pulley Use new bolts and tighten to 200 Nm + 180. Autodata Note 62

Use new bolts/nuts. Autodata Note 92 Front hub Use new bolts. M14 bolt = 115 Nm + 180 M16 bolt = 190 Nm + 180. Autodata Note 93 Rear hub - 4x4 Use new bolts. M14 bolt = 115 Nm + 180 M16 bolt = 190 Nm + 180 Rear hub assembly to axle = 60 Nm. Autodata Note 210 Steering track rod end Combination bolt = 7 Nm Use new self locking nut and tighten to 45 Nm. Autodata Note 156 Brake caliper to carrier FNR caliper = 30 Nm HP2 steel caliper = use new bolts and tighten to 25 Nm. Autodata Note 155 Brake caliper carrier to hub - front M12 = 130 Nm M14 = 200 Nm Twin piston caliper = 190 Nm Twin piston caliper (steel) = 200 Nm FN3 caliper = 120 Nm Brembo caliper = use new bolts and tighten to 110 Nm. Autodata Note 183 Minimum disc thickness FN3 caliper 15/16" wheels = 23 mm FNR-G60 caliper/hp 2 caliper 16" wheels = 28 mm Brembo caliper 18" wheel = 32 mm. Autodata Note 186 Minimum disc thickness Ventilated disc = 20 mm. Autodata Note 127 Refrigerant quantity 97-11.97 = 800-850 grams 11.97-8.98 = 850-900 grams 08.98-4.99: 20 mm condenser = 750-800 grams 10.98-12.98: 16 mm condenser = 550-600 grams

04.99 : 18 mm condenser = 650-700 grams. Autodata Note 83 Oil type Zexel = G052 154 A2 Denso = G052 300 A2. Cylinder layout Tightening sequence

VOLKS CITY BEECH AVENUE CATTEDOWN PLYMOUTH PL4 0QQ Telephone: 01752 667007 Fax: 01752 663399 Email: mail@volkscity.com Important note Important note The intervals and procedures given are subject to alteration by the manufacturer at any time. Check the regularly updated Timing Belts section on our website to ensure that you are kept informed of any changes that may occur between issues of the Autodata CD. http://www.autodata-cd.com Timing belt replacement intervals Where possible the recommended intervals have been compiled from vehicle manufacturers' information. In a few instances no recommendation has been made by the manufacturer and the decision to replace the belt must be made from the evidence of a thorough examination of the condition of the existing belt. Apart from the visible condition of the belt, which is explained fully in the General Instructions/Toothed Timing Belts section, there are several other factors which must be considered when checking a timing belt: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Is the belt an original or a replacement. When was the belt last replaced and was it at the correct mileage. Is the service history of the vehicle known. Has the vehicle been operated under arduous conditions which might warrant a shorter replacement interval. Is the general condition of other components in the camshaft drive, such as the tensioner, pulleys, and other ancillary components driven by the timing belt, typically the water pump, sound enough to ensure that the life of the replacement belt will not be affected. If the condition of the existing belt appears good, can you be satisfied that the belt will not fail before the next check or service is due. If the belt does fail, have you considered the consequences. If the engine is an INTERFERENCE type then considerable expensive damage may well be the result. The cost of replacing a belt as part of a routine service could be as little as 5 to 10% of the repair cost following a belt failure. Make sure your customer is aware of the consequences. If in doubt about the condition of the belt - RENEW it. Refer to the Toothed Timing Belts/Service Replacement section for further information relating to arduous or adverse operating conditions, inspection and service replacement. Replacement Interval Guide Replacement Interval Guide Audi recommend: A4 2,4/2,8 2002MY: Replacement every 120,000 kilometres (74,564 miles) - (tensioner pulley must also be replaced). A4 2,4/2,8 - except BDV 2002MY : Replacement every 80,000 miles - (tensioner pulley must also be replaced). A4 2,4 - BDV:

No manufacturer's recommended replacement interval. A6 2,4 2000MY: Replacement every 80,000 miles or 5 years - (tensioner pulley must also be replaced). A6/allroad 2,7 2000MY: Replacement every 80,000 miles or 5 years - (tensioner pulley, guide pulley and tensioner lever must also be replaced). A6/A8 2,8 2000MY: Replacement every 80,000 miles or 5 years - (tensioner pulley must also be replaced). A6 2,4 - except BDV 2001MY : Replacement every 80,000 miles or 8 years - (tensioner pulley must also be replaced). A6 2,4 - BDV 2001MY : Replacement every 115,000 miles. A6/allroad 2,7 2001MY : Replacement every 80,000 miles or 8 years - (tensioner pulley, guide pulley and tensioner lever must also be replaced). A6/A8 2,8 2001MY : Replacement every 80,000 miles or 8 years - (tensioner pulley must also be replaced). RS4 2,7: Replacement every 60,000 kilometres (37,282 miles) - (tensioner pulley, guide pulley and tensioner lever must also be replaced). S4 2,7: Replacement every 120,000 kilometres (74,564 miles) - (tensioner pulley, guide pulley and tensioner lever must also be replaced). NOTE: For some models the vehicle manufacturer publishes this information in kilometres. The conversion to miles is included for reference purposes only. The previous use and service history of the vehicle must always be taken into account. Check For Engine Damage Check For Engine Damage CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s). Repair Times - hrs Repair Times - hrs All other transmissions Remove and install 3,85 01J gearbox Remove and install 3,85 Special Tools Special Tools Crankshaft locking pin - No.3242. Camshaft sprocket puller - No.T40001. Camshaft sprocket holding tool - No.3036. Camshaft locking tool - No.3391. Viscous fan holder - No.3212. Viscous fan spanner - No.3312. Support guides - No.3369. Auxiliary drive belt tensioner locking pin - No.3204.

Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove spark plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Removal Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Remove: Engine cover. Engine undershield. Intercooler hoses (Turbo). A4/A6/S4: Remove: Front bumper. Air intake pipe between radiator support panel and air filter. Radiator support panel bolt [1]. A4/A6/S4: Install support guides No.3369 through holes in support panel [2]. A4/A6/S4: Remove radiator support panel bolts [3] & [4]. A4/A6/S4: Move radiator support panel into service position. Disconnect secondary air injection hose (if fitted). Remove: Viscous fan (LH thread). Use tool Nos.3212 & 3312. Auxiliary drive belt. Use tool No.3204. NOTE: Mark direction of rotation on belt with chalk if belt is to be reused. Remove: Auxiliary drive belt tensioner. Timing belt covers [5], [6] & [7]. Turn crankshaft clockwise until crankshaft pulley timing marks aligned [8]. Ensure large holes in locking plates of camshaft sprockets face in towards each other [9]. If large holes face outwards: Turn crankshaft one turn clockwise. Remove blanking plug from cylinder block. Fit locking pin No.3242 [10]. NOTE: TDC hole in crankshaft web must be aligned with blanking plug hole. Remove: Crankshaft pulley bolts [11]. Crankshaft pulley [12]. Viscous fan mounting bracket. NOTE: Two bolts of mounting bracket accessed through hole in pulley. Timing belt lower cover [13]. 14. 15. 16. 17. 18. 19. 20. Hold camshaft sprockets. Use tool No.3036. Slacken bolt of each camshaft sprocket approximately five turns [14]. Remove camshaft sprocket holding tool. Tool No.3036. Loosen camshaft sprockets from taper. Use tool No.T40001 [15]. Turn tensioner pulley slowly clockwise until holes in pushrod and tensioner body aligned. Use Allen key [16]. Lock tensioner pushrod in position with a 2 mm diameter pin [17]. Remove timing belt. NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation Installation NOTE: Replace tensioner pulley (2,7/2,8 engines). 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Ensure crankshaft locking pin located correctly [10]. Lightly tighten bolt of each camshaft sprocket [14]. Ensure camshaft sprockets can turn freely but not tilt. Ensure large holes in locking plates of camshaft sprockets face in towards each other [9]. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets on non-tensioned side. NOTE: If reusing old belt: Observe direction of rotation marks. Temporarily install camshaft locking tool No.3391 to camshaft sprockets [18]. Turn tensioner pulley clockwise as far as possible. Use Allen key [16]. Remove pin from tensioner body [17] to release pushrod. Remove Allen key. Install torque wrench to tensioner pulley [19]. Apply anti-clockwise torque of 15 Nm to tensioner pulley [20]. Remove torque wrench. Tighten bolt of each camshaft sprocket. Tightening torque: (A) 30 Nm [14]. Remove camshaft locking tool [18]. Tool No.3391. Hold camshaft sprockets. Use tool No.3036. Tighten bolt of each camshaft sprocket. Tightening torque: (B) 55 Nm [14]. Fit timing belt lower cover [13]. Install crankshaft pulley ensuring notches on pulley and hub are aligned [21]. Remove crankshaft locking pin [10]. Fit blanking plug to cylinder block. Install components in reverse order of removal. Tighten crankshaft pulley bolts to 20-22 Nm [11].

VIN plate/engine code location