4-cylinder TDI engine (2.0 ltr. 4-valve common rail), mechanics — Installing engine — AUDI

🧭 Before you start

Fits: Audi A6 C6 (4F, 2004–2011)

• Renewed: self-locking nuts, clutch release bearing

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• If the clutch plate is not being replaced, it is not necessary to reset the adjuster ring.New self-adjusting pressure plates are already pre-set accordingly, and do not have to be reset.
• 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 for clutch plate splinesG 000 100 to the splines. Do not lubricate guide sleeve.
• Make sure that clutch plate is properly centred (if necessary).
• Check clutch release bearing for wear and make sure that plastic ring is securely seated; renew clutch release bearing if necessary 30.
• A needle bearing must be fitted in the crankshaft; install needle bearing if missing .

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Tighten earth stud (2) to 9 Nm. — 9 Nm (6.6 lb-ft)
2. Tighten nut (arrow) to 15 Nm. — 15 Nm (11 lb-ft)
3. Tighten bolts securing heat shield (1) to 23 Nm. [Note: Renew the bolts tightened with specified tightening angle.Renew self-locking nuts and bolts as well as seals, gaskets and O-rings.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.Fit all cable ties in the original positions when installing.] — 23 Nm (17 lb-ft)
4. When fitting a new clutch plate together with a used pressure plate (self-adjusting clutch), the adjuster ring in the pressure plate has to be reset by turning it back as far as it will go. If this is not done, the pressure plate will operate with reduced clamping force, causing clutch slip 30. [Note: If the clutch plate is not being replaced, it is not necessary to reset the adjuster ring.New self-adjusting pressure plates are already pre-set accordingly, and do not have to be reset.]
5. 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 for clutch plate splinesG 000 100 to the splines. Do not lubricate guide sleeve.

6. Make sure that clutch plate is properly centred (if necessary).
7. Check clutch release bearing for wear and make sure that plastic ring is securely seated; renew clutch release bearing if necessary 30.
8. A needle bearing must be fitted in the crankshaft; install needle bearing if missing .
9. Clean input shaft splines and splines of damper unit on flywheel; remove corrosion and apply only a very thin coating of grease for clutch plate splinesG 000 100 to the splines. Remove any excess grease.
10. No needle bearing must be fitted in the crankshaft; remove needle bearing if necessary .
11. Check whether dowel sleeves (A) for centring engine and gearbox are fitted in cylinder block; install missing dowel sleeves.
12. Install intermediate plate .
13. Bring engine into position on gearbox and screw in one bolt by hand until it makes contact.
14. ⚠ Risk of damage to wing mounting flanges.Release support bracket10 - 222 A before lowering engine. — Lower workshop hoist and place engine/gearbox assembly onto engine mountings.
15. Install engine mountings .
16. Detach workshop hoist and lifting tackle2024 A.
17. Tighten bolts securing engine to gearbox.
18. Install starter Electrical system27.
19. Install particulate filter:
20. Install front exhaust pipe:
21. Align the exhaust system so it is free of stress .
22. Install front cross piece and cross member 50.
23. Install heat shield for drive shaft .
24. Install air conditioner compressor 87.
25. Install power steering pump 48.
26. Install poly V-belt .
27. Install lock carrier with attachments 50.
28. Install torque reaction support .
29. Install headlights Electrical system94.
30. Install bumper cover (front) 63.
31. Electrical connections and routing , .
32. Install engine control unit 23.
33. Install electrical wiring, terminal 30 wiring junction 2TV22 and cover for electronics box in engine compartment Electrical system97.
34. Install and adjust wiper arms Electrical system92.
35. Install body brace 40.
36. Observe notes on procedure for connecting the battery Electrical system27.
37. ⚠ Risk of irreparable damage to control units because of excessive voltage.Never use battery charging equipment for boost starting. — Install fuel filter 20.
38. Install air ducts and air cleaner housing 23.
39. Install air hoses with screw-type clips .
40. Check oil level 405.
41. Connect coolant hoses with plug-in connector .
42. Fill up with coolant . [Note: Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed.Contaminated or dirty coolant must not be used again.]
43. Install wheel housing liners and noise insulation panels 66.

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