Audi Q7 2007 Operating instructions

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.
Repair Manual
Audi Q7 2007 ➤
6-Cylinder Direct Injection 3.0L 4V TFSI
Supercharged Engine
Engine ID CJTB CJTC CNA
A
CJW
B
CJW
C
CJW
E
CTW
A
CTW
B
Edition 01.2016
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 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
21 - Turbocharger, Supercharger
26 - Exhaust System, Emission Controls
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 © 2018 Audi AG, Ingolstadt D3E802C3CFE

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 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Safety Precautions when Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Safety Precautions when Working on Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Safety Precautions when Working on Vehicles with Start/Stop System . . . . . . . . . . . . . . 3
3.4 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 3
3.5 Safety Precautions when Working on Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.6 Safety Precautions when Working on Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Fuel Supply, Injection System and Charging System, Clean Working Conditions . . . . . . . . 5
4.2 Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Engine Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.5 Routing and Securing Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.6 Cooler and Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.7 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2Engine and Transmission, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Engine, Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1 Overview - Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 Engine Mount, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Engine Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1Cylinder Block - Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.1 Overview - Supercharger Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.2 Supercharger Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.3 Supercharger Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 52
1.4 Overview - Auxiliary Component Bracket Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . 52
1.5 Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.6 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.7 Vibration Damper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.8 Sealing Flange with Crankshaft Seal, Belt Pulley Side, Removing and Installing . . . . . . . . 58
2Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Overview - Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3 Sensor Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.4 Sensor Wheel, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.5 Crankshaft Seal, Removing and Installing, Transmission Side . . . . . . . . . . . . . . . . . . . . . . 64
3Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.3 Crankshaft, Measuring Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Audi Q7 2007 ➤
6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
Contents i

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.
3.4 Crankshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.1 Overview - Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2 Connecting Rod, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3 Pistons, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.4 Pistons and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.1 Overview - Timing Chain Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.2 Left and Right Timing Chain Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 85
1.3 Lower Timing Chain Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.4 Overview - Camshaft Timing Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.5 Camshaft Timing Chains, Removing from Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.6 Camshaft Timing Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.7 Overview - Timing Mechanism Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.8 Timing Mechanism Drive Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.9 Overview - Power Take-Off Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.10 Power Take-Off Drive Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.11 Overview - Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.12 Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.2 Left Cylinder Head Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.3 Right Cylinder Head Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.4 Cylinder Heads, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.5 Compression Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.2 Camshafts, Checking Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.3 Camshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.4 Camshafts, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.5 Hydraulic Adjusting Elements, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.6 Valve Stem Seals, Cylinder Head Installed, Removing and Installing . . . . . . . . . . . . . . . . 144
3.7 Valve Stem Seals, Removing and Installing with Cylinder Head Removed . . . . . . . . . . . . 147
3.8 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.9 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.10 Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1Oil Pan Upper and Lower Sections, Oil Pump and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . 158
1.1 Oil Pan Upper and Lower Sections, Oil Pump and Oil Cooler Overview . . . . . . . . . . . . . . 158
1.2 Engine Oil Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Oil Level Thermal Sensor G266 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 162
1.4 Lower Oil Pan Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.5 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.6 Upper Oil Pan Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2Oil Filter Housing and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.1 Overview - Oil Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.2 Oil Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.3 Oil Pressure Switch F22 / Reduced Oil Pressure Switch F378 , Checking . . . . . . . . . . . . 173
2.4 Oil Pressure Switch F22 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.5 Reduced Oil Pressure Switch F378 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 173
Audi Q7 2007 ➤
6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
ii Contents

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.
2.6 Oil Pressure Regulation Valve N428 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 174
2.7 Oil Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3Oil Separator, Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.1 Overview - Oil Separator, Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.2 Crankcase Ventilation Hoses, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.3 Cover with Oil Separator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.4 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.5 Oil Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.2 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.3 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2Coolant Pump and Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.1 Overview - Coolant Pump and Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.2 Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.3 Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3Coolant Pipe and After-Run Coolant Pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.1 Overview - Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.2 Coolant Hoses, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.3 Engine Coolant Temperature Sensor G62 , Removing and Installing . . . . . . . . . . . . . . . . 199
3.4 Front Coolant Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3.5 Left Front Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3.6 Left Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.7 Left Rear Coolant Pipes on Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . 204
3.8 Upper Coolant Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.9 Right Coolant Pipe on Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 206
3.10 Supercharger Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.11 Charge Air Cooling Pump V188 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 210
3.12 Overview - After-Run Coolant Pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.13 After-Run Coolant Pump V51 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4Radiator, Fan Shroud and Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.1 Overview - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.2 Radiator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.3 Overview - Charge Air Cooling Circuit Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.4 Charge Air Cooling Circuit Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 219
4.5 Overview - Fan Shroud and Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.6 Fan Shroud, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.7 Coolant Fan V7 / Coolant Fan 2 V177 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 223
5Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.1 Vacuum Pipe Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.2 Overview - Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.3 Charge Air Pressure Sensor G31 / Charge Air Pressure Sensor 2 G447 , Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.4 Supercharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.5 Overview - Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.6 Supercharger, Securing to Engine/Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.7 Supercharger, Securing to Engine/Transmission Holder for Leakage Test . . . . . . . . . . . . 238
1.8 Charge Air Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.9 Overview - Drive Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Audi Q7 2007 ➤
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Contents iii

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1.10 Drive Head and Decoupling Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 243
1.11 Supercharger, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.1 Overview - Muffler and Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
1.2 Left Catalytic Converter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.3 Right Catalytic Converter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.4 Front Muffler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.5 Center Muffler and Rear Muffler, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
1.6 Tail Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.7 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.8 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.1 Overview - Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2.2 Left Exhaust Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.3 Right Exhaust Manifold, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3Secondary Air Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.1 Overview - Secondary Air Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.2 Secondary Air Injection Combination Valves, Checking for Function and Leaks . . . . . . . . 269
3.3 Secondary Air Injection Left Combination Valve, Removing and Installing . . . . . . . . . . . . 271
3.4 Secondary Air Injection Right Combination Valve, Removing and Installing . . . . . . . . . . . . 272
3.5 Secondary Air Injection Pump Motor V101 , Removing and Installing . . . . . . . . . . . . . . . . 273
3.6 Secondary Air Injection Sensor 1 G609 , Removing and Installing . . . . . . . . . . . . . . . . . . 274
4Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
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iv Contents

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00 – General, Technical Data
1Engine Number
(Edition 01.2016)
Note
The engine number is only visible if the front engine covers are
removed.
♦ Engine number (“engine code” and “serial number”) is located
at front on cylinder block at top -arrow-.
♦ Engine codes beginning with “C” are four-digit.
♦ The first three digits of the engine code stand for displacement
and the mechanical structure of the engine. They are stamped
in the cylinder block, including the serial number.
♦ The 4th digit describes the engine output and torque and de‐
pends on the engine control module.
Note
♦ The four digit engine code is on the type plate, vehicle data
label and Engine Control Module (ECM).
♦ For the location of the type plate and vehicle data label. Refer
to ⇒ Maintenance Procedures; Rep. Gr. 03 .
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1. Engine Number 1

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2Engine Specifications
Engine Specifications. Refer to ⇒ Fluid Capacity Tables; Rep.
Gr. 03 .
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6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
2 Rep. Gr.00 - General, Technical Data

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3Safety Precautions
⇒ “3.1 Safety Precautions when Working on Fuel Supply Sys‐
tem”, page 3
⇒ “3.2 Safety Precautions when Working on Cooling System”,
page 3
⇒ “3.3 Safety Precautions when Working on Vehicles with Start/
Stop System”, page 3
⇒ “3.4 Safety Precautions during Road Test with Testing Equip‐
ment”, page 3
⇒ “3.5 Safety Precautions when Working on Exhaust System”,
page 4
3.1 Safety Precautions when Working on
Fuel Supply System
There Is a Risk of Injury Due to the Fuel Being under Pressure.
The fuel system is under pressure. Injuries are possible from fuel
spraying out.
Before opening the fuel system:
– Wear protective eyewear.
– Wear safety gloves.
– Reduce the pressure: Place clean cloths around the connec‐
tion point and carefully open the connection point.
Risk of a Fire Due to Leaking Fuel.
When the battery is connected, the door contact switch activates
the fuel pump when opening the driver door. Leaking fuel can
ignite and start a fire.
– Before opening the fuel system, interrupt the power supply to
the fuel pump.
3.2 Safety Precautions when Working on
Cooling System
Risk of Scalding Due to Hot Coolant
The cooling system is under pressure when the engine is warm.
Risk of scalding due to hot steam and hot coolant.
– Wear safety gloves.
– Wear protective eyewear.
– Reduce the pressure by covering the coolant expansion tank
cap with a cloth and carefully opening it.
3.3 Safety Precautions when Working on
Vehicles with Start/Stop System
There Is a Risk of Injury Due to the Engine Starting Unexpectedly.
The engine can start unexpectedly on vehicles with an activated
Start/Stop System. A message in the instrument cluster indicates
whether the Start/Stop System is activated.
– Deactivate the Start/Stop System: switch off the ignition.
3.4 Safety Precautions during Road Test
with Testing Equipment
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6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
3. Safety Precautions 3

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There Is a Risk of Injury Caused by Unsecured Testing Equip‐
ment.
If the front passenger airbag deploys during an accident, unse‐
cured testing equipment becomes a dangerous projectile.
– Secure the testing equipment on the rear seat.
Or
– Have a second technician operate the testing equipment on
the rear seat.
3.5 Safety Precautions when Working on
Exhaust System
Caution
Risk of damaging the coupling.
♦ Coupling must not be bent more than 10°.
♦ Do not load the coupling on the cable.
♦ Do not damage the wire mesh on the coupling.
3.6 Safety Precautions when Working on Ig‐
nition System
Risk of Injury Due to Electrocution
When the engine is running the ignition system is under high-
voltage. It is possible to be electrocuted by touching the ignition
system.
– Never touch or remove the ignition wires when the engine is
running or at cranking speed.
Risk of Damaging the Components.
Washing the engine as well as connecting and disconnecting
wires when the engine is running can damage components.
– Switch off the ignition before connecting and disconnecting
wires.
– Switch off the ignition before washing the engine.
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6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
4 Rep. Gr.00 - General, Technical Data

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4General Repair Information
⇒ “4.1 Fuel Supply, Injection System and Charging System,
Clean Working Conditions”, page 5
⇒ “4.2 Fuel System Leak Test”, page 5
⇒ “4.3 Engine Contaminants”, page 5
⇒ “4.4 Contact Corrosion”, page 6
⇒ “4.5 Routing and Securing Lines”, page 6
⇒ “4.6 Cooler and Condenser Assembly”, page 6
⇒ “4.7 Vacuum System, Checking”, page 6
4.1 Fuel Supply, Injection System and
Charging System, Clean Working Con‐
ditions
Even a little contamination can lead to faults. Observe the follow‐
ing guidelines for cleanliness when working on the fuel system,
on the injection system and on the charging system:
♦Before loosening, connections and surrounding areas must be
cleaned thoroughly with engine or brake cleaner, and then
cleaned area must be dried completely.
♦ Seal off any open lines and connections immediately with
plugs, for example, take from Engine Bung Set - VAS6122- .
♦ Place removed parts on a clean surface and cover them with
lint-free cloths.
♦ Carefully cover or seal opened components if repairs are not
performed immediately.
♦ Install only clean parts: remove the replacement parts from
their packaging just before installing them. Do not use parts
that have been stored out of their original packaging (for ex‐
ample, in tool boxes etc.).
♦ If system is open, do not work with compressed air and do not
move the vehicle.
♦ Make sure no fuel gets onto the fuel hoses. If necessary, wipe
off the fuel hoses immediately. Replace any corroded fuel
hoses.
♦ Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
4.2 Fuel System Leak Test
– Let the engine run a few minutes at a moderate speed.
– Turn off the ignition.
– Check the entire fuel system for leaks.
– Replace the part if there are leaks in spite of correct tightening
specifications.
– Perform a road test and press the accelerator pedal all the way
down at least one time.
– Then check the high pressure area again for leaks.
4.3 Engine Contaminants
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4. General Repair Information 5

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♦ To prevent foreign objects from entering when working on the
engine, seal open intake and exhaust channels with suitable
plugs, for example from the Engine Bung Set - VAS6122- .
♦ If mechanical damage to a cylinder bank is found, check the
intake and exhaust tract and the combustion chambers in the
opposite cylinder back for foreign objects to prevent further
damage.
4.4 Contact Corrosion
Contact corrosion can occur if incorrect fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only connecting elements with a special surface
coating are installed.
In addition, rubber or plastic parts and adhesive are made of ma‐
terials that do not conduct electricity.
If there are doubts about whether the parts are suitable, then use
new parts. Refer to the Parts Catalog.
Note
♦ Only original replacement parts are recommended, they are
checked and compatible with aluminum.
♦ It is recommended to use Audi accessories.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
4.5 Routing and Securing Lines
♦Mark the individual fuel, hydraulic and vacuum lines for the
Evaporative Emission (EVAP) canister system as well as the
electrical wires before disconnecting and/or removing them.
This will prevent a mix-up when reconnecting them. If neces‐
sary, draw sketches or take pictures.
♦ Due to the limited space inside the engine compartment, be
especially careful when working near moving or hot parts to
avoid damaging the lines.
4.6 Cooler and Condenser Assembly
The radiator and condenser may have small indentations on the
fins even when installed correctly. It is not damage. Do not replace
the radiator, condenser or turbocharger because of impressions
like that.
4.7 Vacuum System, Checking
Special tools and workshop equipment required
♦Hand Vacuum Pump - VAS6213-
Procedure
– Check all vacuum lines in the vacuum system for:
♦ Cracks
♦ Damage caused by animals
♦ Crimps
♦ Leaks
– Check the vacuum lines leading both to and from the solenoid
valve to the respective component.
Audi Q7 2007 ➤
6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
6 Rep. Gr.00 - General, Technical Data

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– If there is a fault stored in the Diagnostic Trouble Code (DTC)
memory, check the vacuum lines for the named component,
but also check all the vacuum lines.
– If using the Hand Vacuum Pump - VAS6213- does not produce
any vacuum or if the vacuum drops again right away, then
check the hand vacuum pump and the connection hoses for
leaks.
Audi Q7 2007 ➤
6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
4. General Repair Information 7

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5Special Tools
Special tools and workshop equipment required
♦Hand Vacuum Pump - VAS6213-
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6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
8 Rep. Gr.00 - General, Technical Data

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10 – Engine Assembly
1Engine, Removing
Special tools and workshop equipment required
♦Pry Lever - 80-200-
♦ Used Oil Collection and Extraction Unit - SMN372500-
♦ Step ladder such as Step Ladder - VAS5085-
♦ Engine Bung Set - VAS6122-
♦ Scissor Lift Table - VAS6131B- with Scissor Lift Table - Audi
Set - VAS6131/10- , Scissor Lift Table - A8 Set - VAS6131/11- ,
Scissor Lift Table - Q7 Set - VAS6131/13- and Scissor Lift Ta‐
ble - Audi Set - Mounting Pin - VAS6131/10-2- quantity: 3
♦ Shop Crane - Drip Tray - VAS6208-
♦ Hose Clip Pliers - VAS6362-
♦ Locking Pin - T10060A-
♦ Puller - Ball Joint - T10187-
Procedure
Note
♦ With lock carrier installed, engine is removed downward with
transmission and subframe.
♦ During installation, cable ties must be installed at the same
location.
– On vehicles with air suspension, activate vehicle lift mode.
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 43 ; Air
Spring Suspension Settings -Vehicle Diagnostic Tester- , Con‐
necting and Selecting Functions; Vehicle Lift Mode .
Caution
Risk of damaging electronic components when disconnecting
the battery.
♦ Complete the steps for disconnecting the battery.
–Disconnect the Ground (GND) cable -4-. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
– Extract the power steering oil from the reservoir with the Used
Oil Collection and Extraction Unit - SMN372500- .
WARNING
The cooling system is under pressure when the engine is
warm. Risk of scalding due to hot steam and hot coolant.
Scalding the skin and other parts of the body is possible.
• Wear safety gloves.
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1. Engine, Removing 9

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•Wear protective eyewear.
• Reduce the pressure by covering the coolant expansion
tank cap with a cloth and carefully opening it.
– Open the coolant reservoir cap.
– Remove the noise insulation -1 and 2-. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Underbody Trim Panels .
– Remove the left and right front wheel housing liners. Refer to
⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liners .
– Remove the rear driveshaft. Refer to ⇒ Transfer Case 0BU,
Front Final Drive 0BM, 0C1 and 0BN, Rear Final Drive 0BP;
Rep. Gr. 39 ; Rear Driveshaft; Rear Drive Shaft, Removing
and Installing .
Note
Collect escaping coolant in a clean container for disposal or
reuse.
– Place the Shop Crane - Drip Tray - VAS6208- under engine.
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6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
10 Rep. Gr.10 - Engine Assembly

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– Remove the right lower coolant hose -arrow- from the radiator
by lifting the clamp and let the coolant drain out.
– Free up the coolant hose.
– Open the clamps -1 and 2-, drain the coolant and then remove
the coolant hoses from the coolant pipes.
– Open the clamps -arrows-, drain the coolant and remove the
coolant hoses from the coolant pipes on the left longitudinal
member.
– Open the clamp -1-, drain the coolant and remove the coolant
hose from the coolant pipe on the lock carrier.
– Place the Used Oil Collection and Extraction Unit -
SMN372500- under the separating point.
– Open the clamp and remove the hydraulic hose -2-.
– Seal the open lines and connections with clean plugs from the
Engine Bung Set - VAS6122- .
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1. Engine, Removing 11

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– Remove the coolant hose from the engine oil cooler by loos‐
ening the hose clamp -arrow- and letting the coolant drain out.
– Remove the engine covers -1 and 2- upward.
Caution
Danger of defects caused by dirt.
♦ Follow the guidelines for cleanliness when working on the
fuel supply system. Refer to ⇒ “4.1 Fuel Supply, Injection
System and Charging System, Clean Working Condi‐
tions”, page 5 .
–Free up the fuel supply line in the center of the plenum cham‐
ber bulkhead.
WARNING
The fuel system is under pressure.
Risk of injury from fuel spraying out.
• Wear protective eyewear.
• Wear safety gloves.
• Reduce the pressure: Place clean cloths around the con‐
nection point and carefully open the connection point.
– Roll up the protective boot to disconnect the fuel supply line
-1-.
– Push the hose coupling -2- on the fuel line in direction of
-arrow A- and then press the release buttons in direction of
-arrows B-.
– Remove the hose coupling with the release buttons pressed.
– Unlock the brackets -3 and 4-, lay them on the engine and free
up the fuel supply hose.
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– Press the release buttons and disconnect the hose -1- from
the Evaporative Emission (EVAP) canister.
– Disconnect the brake booster vacuum line -2-, free it up and
lay it on the right side of the vehicle.
– Remove the vacuum hose -1- from the air guide pipe connec‐
tion.
– Loosen the clamps -arrows- and remove the air guide pipe.
– Remove coolant hoses by loosening the hose clamps
-1 and 2-.
– Remove the connectors -1 through 4- from the bracket on the
right suspension strut tower, disconnect them and free up the
wires.
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1. Engine, Removing 13

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– Open the clamps -1 and 2- and the clips -3- and then remove
the coolant hoses.
Caution
Risk of damage due to reversed running direction on a used
ribbed belt.
♦ Before removing ribbed belt, marking running direction
with chalk or felt-tip pen for reinstallation later.
–To release the tension on the ribbed belt, swivel the tensioner
clockwise in direction of -arrow- and then lock the tensioner
using a Locking Pin - T10060A- .
– Remove the ribbed belt from the Air Conditioning (A/C) com‐
pressor.
Note
Place a cloth underneath to catch the draining hydraulic fluid.
– Remove the banjo bolt -1-.
– Loosen the hose clamp -2- and remove the power steering
fluid hose.
Audi Q7 2007 ➤
6-Cylinder Direct Injection 3.0L 4V TFSI Supercharged Engine - Edition 01.2016
14 Rep. Gr.10 - Engine Assembly