Audi Q7 2007 Instruction manual

Service 6
Service Department. Technical Information
Workshop Manual
Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common
rail), mechanics
Edition 01.2006
Engine code BUN BUG
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Service
6
All rights reserved.
No reproduction without prior agreement from publisher. Printed in Germany
A00.5Q70.11.20
Copyright © 2006 Audi AG, Ingolstadt
Repair Group overview for workshop manual
Audi Q7 2007 !
When filing a Technical Bulletin, enter the bulletin number in the column adjacent to the Repair
Group. When using the Maintenance Manual you can then see at a glance whether Technical
Bulletins have been published which refer to the Repair Group you are looking for.
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must,
as a matter of course, be observed.
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics
Edition 01.2006
Repair Group Technical Bulletins
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
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Contents iii
6
Contents
00 – Technical data ...................................................................................
1 Technical data ................................................................................
1.1 Engine number ...............................................................................
1.2 Engine data ...................................................................................
2 General repair instructions ..................................................................
2.1 Rules for cleanliness when working on the injection system .............................
2.2 Checking for leaks in the fuel system ......................................................
10 – Removing and installing engine .............................................................
1 Removing and installing engine .............................................................
1.1 Removing engine .............................................................................
1.2 Separating engine and gearbox .............................................................
1.3 Securing engine to assembly stand .........................................................
1.4 Installing engine ..............................................................................
13 – Crankshaft group ...............................................................................
1 Servicing work on pulley end ...............................................................
1.1 Poly V-belt drive - exploded view of components .........................................
1.2 Removing and installing poly V-belt ........................................................
1.3 Removing and installing tensioner for poly V-belt .........................................
1.4 Removing and installing vibration damper ..................................................
1.5 Renewing crankshaft oil seal (pulley end) ..................................................
1.6 Removing and installing sealing flange (front) .............................................
1.7 Toothed belt for high-pressure pump - exploded view of components ...................
1.8 Removing and installing toothed belt for high-pressure pump ............................
1.9 Exhauster pump - exploded view of components ..........................................
1.10 Removing and installing exhauster pump ...................................................
2 Servicing work on timing chain end ........................................................
2.1 Drive plate - exploded view of components ................................................
2.2 Removing and installing drive plate .........................................................
2.3 Renewing crankshaft oil seal (timing chain end) ...........................................
2.4 Timing chain covers - exploded view of components .....................................
2.5 Removing and installing timing chain covers ...............................................
2.6 Camshaft timing chains - exploded view of components .................................
2.7 Removing and installing camshaft timing chains ...........................................
2.8 Detaching camshaft timing chains from camshafts ........................................
2.9 Drive chain for valve gear - exploded view of components ...............................
2.10 Removing and installing drive chain for valve gear ........................................
2.11 Drive chain for oil pump and balance shaft - exploded view of components ............
2.12 Removing and installing drive chain for oil pump and balance shaft .....................
2.13 Balance shaft - exploded view of components .............................................
2.14 Removing and installing balance shaft ......................................................
3 Removing and installing crankshaft .........................................................
3.1 Crankshaft - exploded view of components ................................................
3.2 Crankshaft dimensions ......................................................................
3.3 Measuring axial clearance ...................................................................
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4
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Contents
6
iv
3.4 Measuring radial clearance ..................................................................
4 Dismantling and assembling pistons and conrods .........................................
4.1 Pistons and conrods - exploded view of components .....................................
4.2 Checking piston projection at “TDC” .......................................................
4.3 Piston and cylinder dimensions .............................................................
4.4 Checking radial clearance of conrod bearings ..............................................
15 – Cylinder head, valve gear .....................................................................
1 Removing and installing cylinder head ......................................................
1.1 Cylinder head - exploded view of components ............................................
1.2 Cylinder head cover - exploded view of components .....................................
1.3 Removing and installing cylinder head cover ...............................................
1.4 Removing and installing cylinder head ......................................................
1.5 Checking compression .......................................................................
2 Servicing valve gear .........................................................................
2.1 Valve gear - exploded view of components ................................................
2.2 Checking axial clearance of camshafts .....................................................
2.3 Renewing camshaft oil seal .................................................................
2.4 Removing and installing camshafts .........................................................
2.5 Checking hydraulic valve compensation elements .........................................
2.6 Renewing valve stem oil seals ..............................................................
2.7 Valve dimensions ............................................................................
2.8 Machining valve seats .......................................................................
2.9 Checking valve guides .......................................................................
2.10 Checking valves .............................................................................
17 – Lubrication ........................................................................................
1 Removing and installing parts of lubrication system ......................................
1.1 Oil pump, sump (bottom section) - exploded view of components .......................
1.2 Removing and installing sump (bottom section) ...........................................
1.3 Removing and installing oil pump ...........................................................
1.4 Sump (top section) - exploded view of components ......................................
1.5 Removing and installing sump (top section) ...............................................
1.6 Oil cooler, pressure control valve, and oil filter housing - exploded view of components
1.7 Removing and installing oil cooler ..........................................................
1.8 Removing and installing oil filter housing ..................................................
1.9 Removing and installing pressure control valve for crankcase breather system .........
1.10 Removing and installing mounting plate for oil cooler, pressure control valve and oil filter
housing .......................................................................................
1.11 Removing and installing oil pressure switch -F1- ..........................................
1.12 Checking oil pressure ........................................................................
1.13 Engine oil .....................................................................................
1.14 Checking oil level ............................................................................
19 – Cooling ............................................................................................
1 Removing and installing parts of cooling system ..........................................
1.1 Diagram of coolant hose connections ......................................................
1.2 Draining and filling cooling system .........................................................
1.3 Coolant pump and thermostat - exploded view of components ..........................
1.4 Removing and installing coolant pump .....................................................
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102
102
102
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107
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167
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Contents v
6
1.5 Removing and installing continued coolant circulation pump -V51- ......................
1.6 Removing and installing hose connection with thermostat ................................
1.7 Removing and installing coolant temperature sender -G62- ...............................
1.8 Removing and installing coolant pipe (front) ...............................................
1.9 Removing and installing coolant pipe (left-side) ............................................
1.10 Removing and installing coolant pipes (rear left) ...........................................
1.11 Removing and installing coolant pipe (right-side) ..........................................
1.12 Removing and installing coolant pipe (rear right) ..........................................
1.13 Removing and installing radiator ............................................................
1.14 Removing and installing fuel cooler .........................................................
1.15 Checking cooling system for leaks ..........................................................
1.16 Removing and installing radiator cowl ......................................................
1.17 Removing and installing radiator fans -V7- and -V177- ...................................
21 – Turbocharging/supercharging ................................................................
1 Servicing charge air system with turbocharger ............................................
1.1 Rules for cleanliness .........................................................................
1.2 Turbocharger - exploded view of components .............................................
1.3 Removing and installing turbocharger ......................................................
1.4 Removing and installing intermediate flange ...............................................
1.5 Charge air cooler - exploded view of components .........................................
1.6 Removing and installing charge air cooler ..................................................
1.7 Removing and installing charge air pressure sender -G31- ................................
26 – Exhaust system .................................................................................
1 Removing and installing parts of exhaust system .........................................
1.1 Exhaust system - exploded view of components ..........................................
1.2 Renewing tailpipes ...........................................................................
1.3 Removing and installing starter catalytic converter ........................................
1.4 Removing and installing particulate filter ...................................................
1.5 Exhaust manifold - exploded view of components .........................................
1.6 Removing and installing exhaust manifold (left-side) ......................................
1.7 Removing and installing exhaust manifold (right-side) .....................................
1.8 Removing and installing intermediate pipe (left-side) ......................................
1.9 Removing and installing intermediate pipe (right-side) .....................................
1.10 Stress-free alignment of exhaust system ...................................................
1.11 Checking exhaust system for leaks .........................................................
2 Removing and installing parts of exhaust gas temperature control .......................
2.1 Removing and installing exhaust gas temperature sender 1 -G235- ......................
2.2 Removing and installing temperature sender before particulate filter -G506- ............
3 Exhaust gas recirculation system ...........................................................
3.1 Exhaust gas recirculation system - exploded view of components .......................
3.2 Removing and installing mechanical exhaust gas recirculation valve .....................
3.3 Removing and installing exhaust gas recirculation cooler .................................
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Contents
6
vi
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
1 Technical data 1
6
1Technicaldata
1.1 Engine number
The engine code is also included on the vehicle data sticker.
The following steps are required to make the stamped engine
number visible.
–Carefully pull engine cover panel off four retaining pins one
after the other -arrows-.
Before removing, mark direction of rotation of poly V-belt with
chalk or felt-tipped pen. If the belt runs in the opposite direc-
tion when it is refitted, this can cause breakage.
–Slacken poly V-belt by swivelling tensioner in direction of
-arrow-, using a lever with TORX 60 bit.
–Remove poly V-belt from tensioning roller.
–Unscrew bolts -arrows- and detach idler roller from front
sealing flange.
00– Technical data
Note
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Repair Group 00 – Technical data
6
2
♦The engine number (“engine code” and “serial number”)
can be found at the front below the toothed belt for the
high-pressure pump (left-side) -arrow-.
♦There is also a sticker on the toothed belt cover showing
the “engine code” and “serial number”.
1.2 Engine data
Audi Q7 models with a 3.0 ltr. TDI engine are always
equipped with steel glow plugs.
2 General repair instructions
2.1 Rules for cleanliness when working on the
injection system
Even small amounts of dirt can cause faults in the injection
system. When working on the fuel supply/injection system,
pay careful attention to the following basic rules:
Code letters BUG BUN
Capacity ltr. 2.967 2.967
Power output kW at rpm 171/4000 1551/4000
Torque Nm at rpm 500/1500 … 2750 500/1400 … 2750
Bore ∅in mm 83.0 83.0
Stroke mm 91.4 91.4
Compression ratio 17 17
CN at least 51 51
Firing order 1-4-3-6-2-5 1-4-3-6-2-5
Exhaust gas recirculation yes yes
Turbocharging/supercharging yes yes
Self-diagnosis yes yes
Glow plugs Steel glow plugs Steel glow plugs
Catalytic converter yes yes
Charge air cooling yes yes
Lambda control yes yes
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
2 General repair instructions 3
6
♦Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and allow to dry thor-
oughly before opening.
♦Plug open lines and connections with suitable protective
caps immediately.
♦Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦Only install clean components; replacement parts should
only be unpacked immediately prior to installation. Do not
use parts that have been previously unpacked and stored
away loose (e.g. in toolboxes, etc.).
♦When the system is open: Do not work with compressed
air. Do not move the vehicle unless absolutely necessary.
2.2 Checking for leaks in the fuel system
–Start the engine and let it run at medium speed for a few
minutes.
–Switch off ignition.
–Check the entire fuel system for leaks.
–If leaks are found although the connections have been
tightened to the correct torque, the relevant component
must be renewed.
–Then carry out a test drive with at least one full-power ac-
celeration.
–Then check high-pressure part of fuel system again for
leakage.
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Repair Group 10 – Removing and installing engine
6
4
1 Removing and installing engine
♦The engine is removed from underneath together with the
gearbox and subframe (with lock carrier installed).
♦All cable ties which are released or cut open when remov-
ing must be fitted in the same position when installing.
♦Collect drained coolant in a clean container for re-use or
disposal.
1.1 Removing engine
Special tools and workshop
equipment required
♦Spring tensioner
-VW 552-
♦Removal lever -80-200-
♦Hose clamps for hoses
up to 25 mm Ø -3094-
♦Used oil collection and
extraction unit
-V.A.G 1782-
♦Hose clip pliers
-V.A.G 1921-
♦Stepladder -VAS 5085-
10 – Removing and installing engine
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
1 Removing and installing engine 5
6
♦Scissor-type assembly platform -VAS 6131- with support
set for Audi -VAS 6131/10- and support set -VAS 6131/
11-, -VAS 6131/13- and 3x -VAS 6131/10-2-
♦Drip tray for workshop hoist -VAS 6208-
Procedure
–Activate jacking-up mode on vehicles with air suspension
⇒Rep. Gr. 43.
–Move driver's seat as far back as possible and to highest
position, using range of full seat adjustment.
–Switch off ignition.
–Reach under driver's seat and release retaining clips on rear
side of cover -1- in direction of -arrow A-.
–Then detach cover from driver's seat console in direction
of -arrow B-.
–Use removal lever -80-200- to pry out cover -1- from floor
covering.
–Lift floor covering -2- slightly around earth wire.
–Unscrew nut -3- and detach earth wire -4- from earth
point.
–Discharge the refrigerant system ⇒Air conditioner system
- with refrigerant R134a.
–Extract hydraulic fluid for power steering from reservoir us-
ing used oil collection and extraction unit -V.A.G 1782-.
–Open filler cap on coolant expansion tank.
WARNING!
Hot steam or hot coolant can escape when expansion tank
is opened; cover filler cap with cloth and open carefully.
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Repair Group 10 – Removing and installing engine
6
6
–Remove both front wheels.
–Unscrew bolts and take off front noise insulation -1- and
rear noise insulation -2-.
–Remove front wheel housing liners (right and left)
⇒Rep. Gr. 66.
–Disconnect air intake hoses -1- and -4-.
–Unscrew bolts -2- and -3- and remove air pipe (bottom).
–Place drip tray for workshop hoist -VAS 6208- under en-
gine.
–Disconnect coolant hose -arrow- from coolant pipe (left-
side) and drain off coolant.
–Unplug electrical connector -2- at radiator outlet coolant
temperature sender -G83-.
–Disconnect coolant hose (bottom right) -1- at radiator and
drain off coolant.
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
1 Removing and installing engine 7
6
–Disconnect coolant hoses from coolant pipes -arrows- and
drain off coolant.
–Disconnect coolant hose from coolant pipe (right-side) -ar-
row- and drain off remaining coolant.
–Carefully pull engine cover panel off four retaining pins one
after the other -arrows-.
–Detach cover above radiator -arrows-.
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Repair Group 10 – Removing and installing engine
6
8
–Detach coolant hose -1-.
–Disconnect vacuum hose going to vacuum reservoir -2-.
–Lay a clean cloth under the separating points to catch es-
caping fuel.
–Detach fuel supply hose -6- from fuel filter.
–Detach fuel hose going to fuel cooler at the connections
marked -3- and -5-.
–Remove bolts -1- and -2- and nut -4-.
–Move fuel lines at bulkhead clear and lay aside fuel filter
with fuel hoses connected.
–Remove bolts -1 ... 4-.
The fuel filter bracket remains installed.
–Open cover above terminal B+ -arrow-.
–Unscrew positive cable -1- going to starter and alternator
and move electrical wiring clear.
Caution!
Observe rules for cleanliness when working on the injection
system ⇒page 2.
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
1 Removing and installing engine 9
6
–Remove air intake hose -arrows-.
–Unplug electrical connector -3-.
–Remove bolts -1- and -2- and detach throttle valve module
-J338- from intake connecting pipe.
Lay a cloth under the separating point to catch escaping hy-
draulic fluid.
–Clamp off hydraulic hose for power steering pump using a
hose clamp -3094-.
–Disconnect hydraulic hose -1- from power steering pump.
Disregard -item 2-.
To prevent damage to the refrigerant lines, ensure that the
pipes and hoses are not stretched, kinked or bent.
–Unplug electrical connector -2-.
–Remove retaining clips -1- and -5-.
–Disconnect refrigerant lines -3- and -4- from air conditioner
compressor.
Seal open pipes and connections at air conditioner compres-
sor with suitable caps (to prevent ingress of dirt and mois-
ture).
Note
Note
Note
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Repair Group 10 – Removing and installing engine
6
10
–Detach coolant hose (top left) -arrow- from radiator.
–Detach coolant hose -1-.
Ignore -arrows-.
–Detach air intake hose (top) at the connections marked -1-
and -2-.
–Detach air intake hose (bottom) -3-.
–Unclip differential breather hose -1- from air cleaner hous-
ing (top section).
–Unplug electrical connector -3- at air mass meter -G70-.
–Detach air intake hose -4- from turbocharger.
–Release retaining clips -2- and detach top section of air
cleaner housing.
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
1 Removing and installing engine 11
6
–Take electrical connector -arrow- out of bracket and un-
plug it.
–Unbolt bracket for electrical connector at cylinder head
cover.
–Disconnect vacuum hose -arrow- going to exhauster
pump.
–Disconnect fuel supply pipe -1- and fuel return pipe -2- at
bulkhead.
–Remove fuel filter together with fuel hoses (fuel hoses re-
main connected to filter).
–Detach electrical connectors -1- and -2- for exhaust gas
temperature sender 1 -G235- and Lambda probe -G39-
from bracket.
–Unplug electrical connectors and move wiring clear.
Disregard items marked -3- and -4-.
WARNING!
The fuel system is pressurised. Before opening the system
place a clean cloth around the connection. Then dissipate
pressure by carefully unfastening the connection.
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Repair Group 10 – Removing and installing engine
6
12
–Pry off caps on windscreen wiper arms with a screwdriver.
–Unscrew nuts -1- and -3- several turns.
–Tilt windscreen wiper arms one by one and loosen from
wiper shafts.
–Remove nuts completely and take off wiper arms.
Use puller (commercially available) to remove wiper arm if
necessary.
–Pull off rubber seal -5- on plenum chamber covers.
–Detach plenum chamber covers -2- and -4-.
–Remove cover for electronics box in plenum chamber -ar-
rows-.
–Unplug electrical connectors -1 ... 3- at electronics box
connector point in plenum chamber.
–Move electrical wiring harness clear.
–Unscrew earth connection -2-.
–Remove engine control unit -1- ⇒Rep. Gr. 23.
–Move clear wiring harness leading to engine.
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
1 Removing and installing engine 13
6
–Remove bolts -arrows- and take off bulkhead plate at rear
left of engine compartment.
–Remove bolts -arrows- and take off bulkhead plate at rear
right of engine compartment.
–Remove grommets from drillings above suspension struts.
–Secure suspension struts (left and right) using spring ten-
sioner -VW 552-.
Securing the suspension struts ensures the drive shafts are
not under load after removing the top suspension strut bolts
at a later stage.
–Unscrew suspension struts (left and right) from suspension
turret -arrows-.
Note
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Audi Q7 2007 !
6-cylinder TDI engine (3.0 ltr. 4-valve common rail), mechanics 01.2006
Repair Group 10 – Removing and installing engine
6
14
–Unplug electrical connector -1- at front left vehicle level
sender -G78- in wheel housing.
–Disconnect brake lines -3- on both sides of vehicle
⇒Rep. Gr. 46.
–Detach retaining clips -2- for brake lines.
–Plug brake lines with suitable bleeder valve cap.
–Unplug electrical connectors -arrow- at speed sensors for
left and right front wheels.
–Move wiring clear.
–Release electrical connectors -arrow- for pad wear limit
sensors on left and right side of vehicle.
–Release electrical connectors from retainer and move wir-
ing clear.
–Unbolt coupling rod from anti-roll bar -arrow- on left and
right side of vehicle.
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