2008-2010 Audi A6 C6 Service & Repair Manual
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Lifetime Access
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Online & Offline Access
Access PDF Contents & Bookmarks
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Print one or all pages of your manual
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Workshop Manual
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve
turbo), mechanics
Engine ID
BPJ BYK
Edition 03.2012
Service
Service Department. Technical Information
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.
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt A005A603220
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.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.7 Installing radiators, condensers and charge air coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.1 Poly V-belt - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2 Routing of poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.4 Removing and installing crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.5 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2 Sealing flanges and flywheel/drive plate - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3 Removing and installing dual mass flywheel/ drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.1 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.3 Removing and installing chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.1 Toothed belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2012
Contents i
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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.
2.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2 Removing and installing camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.4 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 94
4.5 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 98
4.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.7 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1 Part I: Sump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Part II: Balance shaft assembly with oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . 109
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.4 Removing and installing balance shaft assembly with oil pump . . . . . . . . . . . . . . . . . . . . . . 118
2 Oil filter bracket - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.1 Draining oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.3 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.4 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Connection diagram for coolant hoses (vehicles without auxiliary heater) . . . . . . . . . . . . . . 135
1.2 Connection diagram for coolant hoses (vehicles with auxiliary heater) . . . . . . . . . . . . . . . . 137
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.4 Thermostat - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.5 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.7 Removing and installing coolant pipes (at side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.9 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.10 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.11 Renewing radiator fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.12 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.1 Fitting hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.2 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.4 Checking vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.5 Removing and installing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.6 Adjusting vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.7 Charge air cooling - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.8 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.9 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.1 Silencers - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.2 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.3 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.4 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2012
ii Contents
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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.
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2012
Contents iii
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2012
iv Contents
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with respect to the correctness of information in this document. Copyright by AUDI AG.
00 – Technical data
1 Technical data
The engine number („Engine code“ and „Serial number“) can be
found at the front of the joint between engine and gearbox.
Additionally there is a sticker on the toothed belt cover showing
the „engine code“ and „serial number“.
The engine code is also indicated on the vehicle data stickers.
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2012
1. Technical data 1
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 Engine data
Code letters BPJ BYK
Capacity ltr. 1.984 1.984
Power output kW at rpm 125/4200 125/4200
Torque Nm at rpm 280/1800 280/1800
Bore ∅ mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 10.5 10.5
RON
98
1)
98
1)
Injection/ignition system FSI FSI
Firing order 1-3-4-2 1-3-4-2
Knock control yes yes
Turbocharging/super‐
charging
yes yes
Exhaust gas recirculation no no
Intake manifold change-
over
no no
Variable valve timing yes yes
Secondary air system no no
•
1)
Unleaded petrol RON 95 can also be used, but results in
reduced power
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2012
2 Rep. gr.00 - Technical data
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.
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:
♦ Observe notes on procedure for disconnecting the battery.
♦ 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. Procedure ⇒ Rep. gr. 24 .
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2012
3. Safety precautions 3
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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.
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:
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
Avoid 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.
Audi A6 2005 ➤
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics - Edition 03.2012
4 Rep. gr.00 - Technical data
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Audi A6 C6 2008 2009 2010 Service Repair Manual provides comprehensive coverage for all your car repair and maintenance needs. Whether you are a professional mechanic or a DIY enthusiast, this manual equips you with the necessary information to effectively service your vehicle.
The manual is available in PDF format, ensuring easy readability, zooming, and printability. It is compatible with both Windows and MAC systems, offering convenience and accessibility for all users.
