Service

Repair Manual
Audi A6 2005 ➤
Maintenance Procedures
Edition 10.2011

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.

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
03 - Maintenance, Diagnosis

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.

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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2012 Audi AG, Ingolstadt D3E8026E69D

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Contents

03 - Maintenance, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Type Plate, VIN and Engine Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Suspension Blocks, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Raising Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Tow Starting/Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Vehicle Checks during Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Measured Values Block 32, Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Transport Mode, Deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Battery, Checking Level Using Guided Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Battery, Checking Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 AGM Battery, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Tires, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7 Brake Fluid, Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Brake System, Inspecting Visually for Leaks and Damage . . . . . . . . . . . . . . . . . . . . . . . . 27
2.9 Brake Pads, Checking Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.10 Brake Pads, Checking Thickness (RS6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.11 Brake Fluid, Checking Depending on Brake Pad Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.12 Digital TV Tuner, Programming Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.13 Fuel Injector Cleaner G17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.14 Key, Check Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.15 DTC Memory, Checking Using Vehicle Diagnosis, Testing and Information System VAS
5051/5052 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.16 Noise Insulation, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.17 Front Axle Joints, Checking Play, Security and Joint Boots . . . . . . . . . . . . . . . . . . . . . . . . 32
2.18 Power Steering
Protected System,
by copyright. Copying Checking for Leaks
for private or commercial and inChecking
purposes, Fluid
part or in whole, is notLevel and Filling . . . . . . 33
2.19 Interior Rearview
permitted Mirrorbywith
unless authorised AUDI AG.Compass,
AUDI AG does Calibrating
not guarantee or.accept
. . . .any
. .liability
....................... 34
2.20 Ribbed Belt, Check Tension and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.21 License Plate, Attaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.22 Air Conditioning, Check Function and Setting Temperature . . . . . . . . . . . . . . . . . . . . . . . . 35
2.23 Coolant System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.24 Throttle Valve Control Module Air Guide, Cleaning, RS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.25 Air Filter, Clean Air Filter Housing and Replace Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.26 Engine and Engine Compartment, Inspecting for Leaks and Damage . . . . . . . . . . . . . . . . 47
2.27 Engine Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.28 Engine Oil, Draining and Replacing Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.29 Engine Oil, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.30 Engine Oil, R S6, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.31 Engine, Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.32 Navigation Eject Button, Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.33 Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.34 Wheel Bolts, Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.35 Windshield Washer System, Checking and Adjusting Spray Nozzles . . . . . . . . . . . . . . . . 60
2.36 Headlamp Washer System, Checking Spray Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.37 Headlamps, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.38 Windshield Washer System, Filling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.39 Windshield Wiper Blades, Checking End Position and for Damage . . . . . . . . . . . . . . . . . . 66
2.40 Windshield Wiper Blades, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.41 Sunroof, Cleaning and Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.42 Snow Screen, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.43 Service Display, Resetting or Adapting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Contents i
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.44 Language, Selecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.45 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.46 Transport Protection, Removing Front and Rear Shock Absorber Protectors . . . . . . . . . . 75
2.47 Door Arrester, Hinge, Hood Safety Catches and Lock Cylinder, Lubricating . . . . . . . . . . . . 76
2.48 Underbody, Inspecting for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.49 Transport Mode, Deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.50 Plenum Chamber Cover, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.51 Plenum Chamber Water Drain, Checking and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.52 Factory-Equipped Winter Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.53 Clock, Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.54 Spark Plugs, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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.

ii Contents
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

03 – Maintenance, Diagnosis
1 General Information
⇒ “1.1 Engine Overview“, page 1
⇒ “1.2 Type Plate, VIN and Engine Code“, page 3
⇒ “1.3 Suspension Blocks, Installing“, page 4
⇒ “1.4 Raising Vehicle“, page 8
⇒ “1.5 Tow Starting/Towing“, page 10
⇒ “1.6 Vehicle Checks during Inspection and Maintenance“, page
13

1.1 Engine Overview

Engine code BVJ BXA
Displacement L 4.2 5.2
Number of cylinders/valves per cylin‐ 8/4 10/4
der
Emissions catego‐ EU IV EU IV
ry
Output kW at RPM 257/ 320/
6800 6800
Torque Nm at RPM 440/3500 540/3500
Bore ∅ mm 84.5 84.5
Stroke mm 92.8 92.8
Compression ratio Copying for private or commercial purposes, in part12.5
Protected by copyright. or in whole, is not 12.5
Fuel injection/Ignition FSI FSI
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Minimum ROZ 982) 982)

1) 91 RON standard unleaded gasoline is permissible, however with decreased

power output.
2) 95 RON Super unleaded gasoline is permissible, however with decreased
power output.

Code letters CAJA CCAA

Displace‐ liter 2.968 2.968
ment
Output kW at RPM 213/5500 213/5500
Torque Nm at RPM 420/1600 420/1600
Bore dia. mm 84.5 84.5
Stroke mm 88.2 88.2
Compression ratio 10.5 10.5
RON min. 98 3) 98 3)
Fuel injection and ignition Simos Simos
system
Ignition sequence 1-4-3-6-2-5 1-4-3-6-2-5
Emissions values EU 5 ULEV 2
Exhaust gas recirculation no no
Turbocharger Compressor Compressor
Knock control 2 sensors 2 sensors
Oxygen sensor regulation 4 sensors 4 sensors

1. General Information 1
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Code letters CAJA CCAA

Charge air cooler yes yes
Variable valve timing Intake Intake
Variable intake manifold no no
Secondary Air Injection yes yes
System
Valve per cylinder 4 4

3) Super unleaded RON 95 is permissible, but with reduced power.

Code letters BKH

Displacement liter 3.123
Output kW at RPM 188 at 6500
Torque Nm at RPM 330 at 3250
Bore diameter 84.5
mm
Stroke mm 92.8
Compression ratio 12.5
RON min. 95 4)
Fuel injection and ignition system Simos
Ignition sequence 1-4-3-6-2-5
Exhaust gas recirculation no
Turbocharger, G-Charger no
Knock control yes
Variable valve timing yes
Variable intake manifold no
Secondary air injection system no
Valves per cylinder 4

4) Super unleaded RON 95 is permissible, but with reduced power.

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Code letters BNK by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.
Displacement ltr. 4.163
Output kW at 246 at 6500
RPM
Torque Nm at 410 at 3500
RPM
Bore dia. mm 84.5
Stroke mm 92.8
Compression ratio 11.5
RON 98 5)
Fuel injection and ignition MPI Bosch Motronic
system
Ignition se‐ 1-5-4-8-6-3-7-2
quence
Knock control yes
Exhaust Gas Recirculation no
(EGR)
Variable intake manifold yes
Variable valve timing yes

2 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Code letters BNK

Secondary air injection yes
(AIR)
5) Super unleaded RON 95 is permissible, but with reduced power.

1.2 Type Plate, VIN and Engine Code

A - Type plate
- It is located in the luggage compartment under the floor covering.
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- Vehicles for some countries have no type plate. with respect to the correctness of information in this document. Copyright by AUDI AG.

B - Vehicle Identification Number

- It is stamped into the front wall of the engine compartment.
Decoding VINs
WAU ZZZ 4F0 5 N 000 233
Manufacturer Filler character Model Model year Production loca‐ Serial number
code 2003 tion

Vehicle Data Label

The vehicle data label is in the customer's Maintenance booklet
and in the vehicle in the spare wheel recess or on the luggage
compartment floor.
The label contains the following vehicle data:
1 - Vehicle Identification Number
2 - Model identification number/Production control number
3 - Model explanation
4 - Engine output/Emissions standard/Transmission
5 - Engine and transmission codes (no information for certain
countries)
6 - Paint number/interior equipment identification number
7 - Optional equipment identification numbers
8 - Curb weight/Consumption/CO2 emissions (no information for
certain countries)
Engine Code and Engine Identification

Note

The “engine code“ is on the vehicle data label in the Maintenance

booklet and in the spare wheel recess or on the luggage com‐
partment floor.

– The engine numbers are located on the different types as

shown in the illustrations.

1. General Information 3
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

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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.

♦ V6 gasoline engine
♦ V8-cylinder Gasoline engine
♦ V10-cylinder Gasoline engine
♦ V10-cylinder Turbo gasoline engines (R S6)

1.3 Suspension Blocks, Installing

If pressure is lost in the air suspension shock absorbers, the ve‐
hicle does not have sufficient ground clearance.
The vehicle must not be moved in this condition.
To drive onto a car transporter or a lift, for example, suspension
blocks must be installed.

4 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

This increases the ground clearance.

WARNING

The vehicle must not be loaded.

The vehicle is not in driveable condition when suspensions
blocks are installed.
The vehicle can only be moved.
When moving steering wheel from center position, do not turn
more than 3/4 left or right.
After installing suspension blocks, check body seal around
front axle suspension strut mount and fix if necessary.
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Special tools and workshop equipment required

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.

♦ Drive-On Ramp -T40081-

♦ Suspension Block Set -T40082-

♦ Stand (Commercially Available)

♦ Onboard Vehicle Jack
♦ Floor Jack (Commercially Available)
Installing suspension blocks on front axle
Workshop arrangement
Right side:
Supporting plate: T40082/2 Rubber block T40082/4

Left side:
Supporting plate: T40082/1 Rubber block T40082/3

1. General Information 5
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Bring front wheels into straight position.

– Drive vehicle front axle backwards on the Drive-On Ramps -
T40081- .
– Engage 1st gear or place selector lever in P position and en‐
gage handbrake.

– Lift vehicle with Onboard Vehicle Jack / Floor Jack until wheel
is clear of ground.

Stand

WARNING

Protect vehicle on stand from falling down.

– Remove drive-on ramp.

– Insert supporting plate with open retaining bracket -1- in wheel

bearing housing.
– Close the retaining bracket -1- and secure with screw -2-.
– Place Rubber Block on supporting plate.

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with respect to the correctness of information in this document. Copyright by AUDI AG.

6 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Make sure the writing on rubber block points toward inside of

wheel housing and that it is aligned flush with supporting plate.
– Remove stand.
– Let vehicle down slowly.

Note

♦ Check secure fit of supporting plate after installing.

♦ If there is not enough clearance after inserting rubber block,
push the wheel down.
♦ When lowering vehicle, make sure rubber block is not crooked
and that it lies on the suspension
Protected strut
by copyright. mount.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Installing suspension blocks on rear axle

with respect to the correctness of information in this document. Copyright by AUDI AG.

Workshop arrangement
Upper distance ring: T40082/5 Lower distance ring: T40082/6

– Drive vehicle rear axle onto Drive-On Ramp -T40081- .

– Engage 1st gear or place selector lever in P position and en‐
gage handbrake.

– Lift vehicle with Onboard Vehicle Jack / Floor Jack until wheel
is clear of ground.

1. General Information 7
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Stand

WARNING

Protect vehicle on stand from falling down.

– Remove drive-on ramp.

– Push rubber buffer down -arrow-.

– Insert upper -1- and then lower distance ring -2- until you feel
them engage.
– Remove stand.
– Let vehicle down slowly.

Note

♦ If there is not enough clearance after inserting distance ring,

push the wheel down.
♦ When lowering vehicle, make sure distance ring is not
crooked.

1.4 Raising Vehicle

Vehicle lifting mode on vehicle with air suspension

Note

♦ Before lifting vehicle with vehicle jack or lift, vehicle lifting

mode must be activated so that the automatic air suspension
regulating process does not make lifting with vehicle jack or
lift more difficult.
♦ Vehicle lifting mode automatically switches off when vehicle
speed exceeds 10 mph (15 km/h).
♦ When vehicle lifting mode is activated, the indicator light in the
instrument cluster comes on.

Switching ON
– Switch ignition on.
– Press “CAR“ permitted
function key. Main by menu “adaptive airnot
suspen‐
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unless authorised AUDI AG. AUDI AG does guarantee or accept any liability
sion“ appears. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Press “SETUP“ function key. “adaptive air suspension“ menu
appears.
– Turn control knob to desire mode and select “ON“.
Switching OFF
– Switch ignition on.
– Press “CAR“ function key. Main menu “adaptive air suspen‐
sion“ appears.

8 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Press “SETUP“ function key. “adaptive air suspension“ menu

appears.
– Turn control knob to “Vehicle lifting mode“ and select “OFF“ to
switch of vehicle lifting mode.

WARNING

♦ Before driving on to a hoist ensure there is sufficient clear‐

ance between low lying vehicle components and hoist.
♦ Before driving a vehicle onto a lifting platform it must be
ensured that the vehicle weight does not exceed the per‐
missible lifting capacity of the platform.
♦ Vehicle may only be lifted at points indicated in illustration
in order to avoid damaging vehicle floor pan and to prevent
vehicle from tipping.
♦ Never start engine and engage a gear with vehicle lifted
so long as even one wheel has contact with the floor!
There is a risk of an accident if this is not observed!
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♦ If work is to be performed under vehicle it mustwith
berespect
sup‐ to the correctness of information in this document. Copyright by AUDI AG.
ported by suitable stands.

Floor Jack

Note

On vehicles with air suspension, vehicle lifting mode must be re‐

set before lifting with floor jack to prevent unexpected air suspen‐
sion regulation measures.

Always use a suitable rubber or wooden block between the jack

and the vehicle.
A floor jack must be attached only at the mounting points depicted
in the illustration.
Do not lift the vehicle at the engine oil pan, transmission, or on
front or rear axles as serious damage may result.
Hoist and Floor Jack Lifting Points
Front and rear:
At plastic recesses on vehicle underbody marked in red.

1. General Information 9
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

1.5 Tow Starting/Towing

Note

♦ If air suspension shock absorbers in one axle lose pressure

completely, the vehicle does not have enough ground clear‐
ance. The vehicle must not be moved in this condition. To drive
onto a car transporter or a lift, for example, suspension blocks
must be installed. Refer to
⇒ “1.3 Suspension Blocks, Installing“, page 4
♦ The vehicle cannot be towed when suspensions blocks are
installed.

Front Towing Eyes

– Attach tow rope or bar only at following eye:
– Remove cover from below.
– Remove towing eye from vehicle tool kit.

– Screw in towing eye -arrow- until stop and tighten eye with
wheel bolt wrench.

Note

Remove towing eye after use and return to vehicle tool kit storage
compartment. Towing eye must always be in vehicle.

Rear Towing Eye

Sedan
– Attach tow rope or bar only at following eye:

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10 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove cover from above.

Avant

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1. General Information 11
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove plug.

Note

♦ The tow-rope should be able to stretch to reduce the risk of

damage to both vehicles. Therefore only ropes of synthetic
material or rope from similarly flexible material should be used.
However it is safer to use a tow bar!
♦ Avoid excessive towing effort and do not jerk. During towing
operations on unsurfaced roads there is always a danger that
the attachment points will be overstressed and damaged.
♦ Vehicle towing should only be done if it is not possible to start
the engine with the starting assist cable.

If the vehicle must ever tow or be towed, observe the following:

♦ Legal regulations concerning towing must be observed.
♦ Both drivers must be familiar with towing procedures. Inex‐
perienced drivers should not attempt to tow start or tow.
♦ When using a tow rope the driver of the towing vehicle must
engage the clutch very gently when moving off and changing
gear.
♦ The driver of the vehicle being towed must ensure that the tow
rope is always taut.
♦ Both vehicles must have the emergency flasher switched on -
if necessary observe any other regulations.
♦ The ignition must be switched on, so that the steering wheel
is not locked and the turn signals, horn, windshield wipers, and
windshield washer system can be operated.
♦ Since the brake booster only works with the engine running,
the brake pedal must be stepped on with substantially more
force when the engine is switched off.
♦ With the engine switched off, the power steering also does not
work, increasing the amount of steering effort.
♦ Without lubricants in the manual transmission and/or auto‐
matic transmissions the car may only be towed with raised
drive wheels.
When towing vehicles with manual transmission, observe the fol‐
lowing: 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
– Before tow starting, push in clutch pedal and hold, andwith
select
respect to the correctness of information in this document. Copyright by AUDI AG.
gear 2 or 3.
– Switch ignition on.
– When both vehicles are in motion, release the clutch pedal.
– As soon as the engine is started, push in the clutch and take
the car out of gear to avoid running into the towing vehicle.

Note

♦ Vehicles with catalytic converter (gasoline engine only) must

not be started when the catalytic converter is at operating tem‐
perature and pulling the vehicle over a longer distance of more
than 50 m. Otherwise, the vehicle could be damaged by un‐
burned fuel entering the catalytic converter.
♦ Tow starting of vehicles with automatic transmission is not
possible for technical reasons.

12 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

When towing vehicles with front wheel drive and automatic trans‐
mission, observe the following:
♦ Selector lever must be in the “N“ position.
♦ Do not tow at speeds greater than 30 mph (50 km/h).
♦ The maximum towing distance is 30 miles (50 km).
For longer distances, the front end of the vehicle must be raised.
Reason: With engine switched off, the transmission oil pump does
not work. Therefore the transmission is not sufficiently lubricated
at higher speeds and longer distances.
When towing with a tow truck, the vehicle may only be towed with
raised front wheels.
Reason: With car raised in the back, the driveshafts turn back‐
wards. This would cause the planetary gears in the automatic
transmission to achieve such high RPM that the transmission
would be heavily damaged within a very short time.
When towing vehicles with all wheel drive and manual transmis‐
sion, also observe the following:
♦ Do not tow at speeds greater than 30 mph (50 km/h).
♦ The maximum towing distance is 30 miles (50 km).
The vehicle can be towed with a tow truck with the front or rear
axle raised.

Note

If normal towing of the vehicle is not possible, the vehicle must be

transported with a special transporter or Protected
trailer. byThis alsoCopying
copyright. applies
for private or commercial purposes, in part or in whole, is not
to towing distances of over 50 km. 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.

When towing vehicles with all wheel drive and automatic trans‐
mission, also observe the following:
♦ Selector lever must be in the “N“ position.
♦ Do not tow at speeds greater than 30 mph (50 km/h).
♦ The maximum towing distance is 30 miles (50 km).
The vehicle must not be towed by a tow truck with front or rear
axle raised.

Note

If normal towing of the vehicle is not possible, the vehicle must be

transported with a special transporter or trailer.

1.6 Vehicle Checks during Inspection and

Maintenance
For vehicle checks, we recommend interactive acceptance VAS
5000 and performance test stand V.A.G 1858.
Brakes, Testing
Information for checking brakes on front and all wheel drive ve‐
hicles is in the corresponding brake system repair manual.
Performance Check
Perform performance check on performance test stand recom‐
mended by Audi. The corresponding correction factors for auto‐

1. General Information 13
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

matic transmissions and all wheel drive are provided in these test
stands. Vehicles with all wheel drive may only be tested on a four-
wheel performance test stand. The four-wheel performance test
stand V.A.G 1858 has movable rollers in order to be able to test
vehicles with different axle spacing.
Tachometer Check
With the tachometer test, the vehicle wheels are driven. Vehicles
with all wheel drive may only be tested on a four-wheel test stand.
Shock Absorber Check
Information on testing shock absorbers can be found in the sus‐
pension repair manual.

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.

14 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

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. Maintenance Procedures 15
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2 Maintenance Procedures
⇒ “2.1 Measured Values Block 32, Reading“, page 17
⇒ “2.2 Transport Mode, Deactivating“, page 18
⇒ “2.3 Battery, Checking Level Using Guided Fault Finding“, page
18
⇒ “2.4 Battery, Checking Fluid Level“, page 19
⇒ page 21
⇒ “2.6 Tires, Checking“, page 22
⇒ “2.7 Brake Fluid, Changing“, page 24
⇒ page 27
⇒ “2.9 Brake Pads, Checking Thickness“, page 27
⇒ “2.10 Brake Pads, Checking Thickness (RS6)“, page 28
⇒ “2.11 Brake Fluid, Checking Depending on Brake Pad Wear“,
page 29
⇒ “2.12 Digital TV Tuner, Programming Remote Control“,
page 30
⇒ “2.13 Fuel Injector Cleaner G17“, page 30
⇒ “2.14 Key, Check Functionality“, page 31
⇒ “2.15 DTC Memory, Checking Using Vehicle Diagnosis, Testing
and Information System VAS 5051/5052“, page 31
⇒ “2.16 Noise Insulation, Removing“, page 32
⇒ “2.17 Front Axle Joints, Checking Play, Security and Joint
Boots“, page 32
⇒ “2.18 Power Steering System, Checking for Leaks and Check‐
ing Fluid Level and Filling“, page 33
⇒ “2.19 Interior Rearview Mirror with Compass, Calibrating“, page
34
⇒ “2.20 Ribbed Belt, Check Tension and Condition “, page 34
⇒ page 35
⇒ “2.22 Air Conditioning, Check Function and Setting Tempera‐
ture“, page 35
⇒ “2.23 Coolant System, Checking“, page 36
⇒ “2.24 Throttle Valve Control Module Air Guide, Cleaning, RS
6“, page 38
⇒ “2.25 Air Filter, Clean Air Filter Housing and Replace Filter“,
page 39
⇒ “2.26 Engine and Engine Compartment, Inspecting for Leaks
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
and Damage“, page 47 with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ “2.27 Engine Cover, Removing and Installing“, page 48

⇒ “2.28 Engine Oil, Draining and Replacing Filter“, page 49
⇒ “2.29 Engine Oil, Filling“, page 55
⇒ “2.30 Engine Oil, R S6, Filling“, page 56
⇒ “2.31 Engine, Checking Oil Level“, page 56
⇒ “2.32 Navigation Eject Button, Unlocking“, page 58
⇒ “2.33 Road Test“, page 58
⇒ “2.34 Wheel Bolts, Tightening Specifications“, page 59

16
⇒ “2.35 Windshield Washer System, Checking and Adjusting
Rep. Gr.03 - Maintenance, Diagnosis
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Spray Nozzles“, page 60

⇒ page 62
⇒ “2.37 Headlamps, Checking and Adjusting“, page 62
⇒ “2.38 Windshield Washer System, Filling Fluid“, page 66
⇒ “2.39 Windshield Wiper Blades, Checking End Position and for
Damage“, page 66
⇒ page 68
⇒ page 68
⇒ “2.42 Snow Screen, Cleaning“, page 70
⇒ “2.43 Service Display, Resetting or Adapting“, page 71
⇒ “2.44 Language, Selecting “, page 73
⇒ “2.45 Dust and Pollen Filter, Removing and Installing“,
page 73
⇒ “2.46 Transport Protection, Removing Front and Rear Shock
Absorber Protectors“, page 75
⇒ “2.47 Door Arrester, Hinge, Hood Safety Catches and Lock
Cylinder, Lubricating“, page 76
⇒ “2.48 Underbody, Inspecting for Damage“, page 77
⇒ “2.49 Transport Mode, Deactivating“, page 77
⇒ page 77
⇒ “2.51 Plenum Chamber Water Drain, Checking and Cleaning“,
page 78
⇒ page 78
⇒ “2.53 Clock, Setting“, page 78
⇒ “2.54 Spark Plugs, Removing and Installing“, page 78

2.1 Measured Values Block 32, Reading

Note

Applies to certain countries only. Refer to the Maintenance table.

– Follow these steps in sequential order.

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. Maintenance Procedures 17
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

♦ Connect Vehicle Diagnosis Tester

♦ On Board Diagnostic
♦ Engine electronics
♦ Measured value blocks
♦ Select measured values block 32
♦ Display field 2 (4-cylinder engines)
♦ Display field 2 and 4 (V6 and V8 engines)

Note

If the values deviate by > 15%, then the Fuel Injector Cleaner G17,
refer to ⇒ “2.13 Fuel Injector Cleaner G17“, page 30 must be
increased by a factor of 4.

WARNING

If a deviation of > 15% is repeated, then a repair is necessary.

2.2 Transport Mode, Deactivating

Transport mode is for maintaining a vehicle's startability (battery
charge). Transport mode limits discharging of battery. If transport
mode is activated, many functions are not available or have limi‐
ted function, for example, CD changer is deactivated, radio is
deactivated, etc.
Switch off the transportation mode using Guided Fault Finding or
Guided Functions.
– Follow these steps in sequential order.
♦ Connect Vehicle Diagnosis Tester
♦ Guided Fault Finding or Guided Functions
♦ Go to - function/component selection
♦ Service Work
♦ Transport mode, activating/deactivating
♦ Now follow guided
Protected program
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.

2.3 Battery, Checking Level Using Guided

Fault Finding
– Follow these steps in sequential order.

18 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

♦ Connect Vehicle Diagnosis Tester

♦ Guided Functions
♦ Select brand and model
♦ Service Work
♦ A Battery, Testing
♦ Send the diagnostic protocol online.

Note

If tester display shows charge or replace battery, refer to ⇒ Elec‐

trical Equipment; Rep. Gr. 27 ; Removal and Installation

2.4 Battery, Checking Fluid Level

⇒ “2.4.1 General Information“, page 19
⇒ “2.4.2 Battery without Visual Indicator“, page 20
⇒ “2.4.3 Battery with Visual Indicator“, page 20

2.4.1 General Information

Note

Batteries with or without visual indicator must not be opened.

– Switch ignition off and remove ignition key.

Sedan
– Raise luggage compartment floor covering and secure.
Avant 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
– Remove the luggage compartment floor covering -1- toand
with respect the
the correctness of information in this document. Copyright by AUDI AG.
spare wheel cover -2-.

2. Maintenance Procedures 19
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

All
– If present, open battery retaining band -1-.

– Release retaining clips -arrows- with a screwdriver -2- and re‐

move battery ground cover -1-.

Note

Shown with formed insert removed in illustration.

2.4.2 Battery without Visual Indicator

♦ On batteries with visible min and max markings, electrolyte
level only needs to be checked visually.
♦ The electrolyte level must be above the MIN marking.
♦ Use a flashlight to improve visibility when performing an exte‐
rior visual inspection of the min and max markings.

Caution

Replace the battery if the electrolyte level is below the mini‐

mum marking! Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;
Removal and Installation .

2.4.3 Battery with Visual Indicator

♦ As the “visual indicator“ is only located in a battery cell, only
the battery electrolyte level for this battery cell can be checked.
♦ The “visual indicator“ -arrow- provides information about the
fluid levels and the state of charge for the battery being
checked.
♦ Bubbles can build up under the “visual indicator“ when the
battery is charging and also while driving, causing the color
displayed to be incorrect.

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.

20 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Loosen the bubbles under the “visual indicator“ by lightly and

carefully hitting the “visual indicator“ -arrow- with the handle of
a screwdriver.
Read the battery electrolyte level present in the color display. Two
different displays are possible:
Color display Battery level
Black or green • Battery electrolyte level OK

Colorless or light • Battery electrolyte level too low. Risk of

yellow explosion, do not check or charge the
battery.

WARNING

Risk of explosion by charging the battery with “visual indicator“.

If the “visual indicator“
Protected is Copying
by copyright. colorless or light
for private yellow,
or commercial do not
purposes, check
in part or in whole, is not
or chargepermitted
the battery. Do notbytry
unless authorised AUDItoAG.
jump
AUDIstart
AG does it!not
There is aor risk
guarantee accept any liability
of explosion withwhen
respect checking, charging,
to the correctness orinjumping
of information theCopyright
this document. battery. by AUDI AG.

The battery must be replaced! Refer to ⇒ Electrical Equipment;

Rep. Gr. 27 ; Removal and Installation .

2.5 AGM Battery, Checking

Note

♦ AGM batteries are marked with “AGM“.

♦ The AGM battery is closed, needs no maintenance, and must
not be opened.

Perform a visual inspection of the battery:

1- Corrosion on the battery pole
2- Battery terminal and battery secure
3- Damage to the battery terminals and housing

Caution

The crash safety is reduced if an incorrect battery is installed.

Always replace an AGM battery with another AGM battery if
that is what the vehicle originally had installed. Refer to ⇒
Electrical Equipment; Rep. Gr. 27 ; Removal and Installation .

2. Maintenance Procedures 21
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.6 Tires, Checking

⇒ “2.6.1 Tires, Checking“, page 22
⇒ “2.6.2 Delivery Inspection“, page 22
⇒ “2.6.3 Inspection Service“, page 22
⇒ “2.6.4 Tread Depth, Checking“, page 22
⇒ “2.6.5 Tire Pressure, Correcting“, page 23
⇒ “2.6.6 Spare Tire“, page 23
⇒ “2.6.7 Tire Repair Kit, Checking Expiration Date“, page 23

2.6.1 Tires, Checking

Note

♦ For safety reasons, all tires on the vehicle should be of the

same make and tread design.
♦ On AWD vehicles, always use tires of the same make and
tread design. If not, the center differential can get damaged.

2.6.2 Delivery Inspection

– Check running surfaces and side walls for damage, remove
foreign bodies, if necessary.

2.6.3 Inspection Service

– Check running surfaces and side walls for damage, remove
foreign bodies, if necessary.
– Check tire treads for cupping, feathering, one-sided tread
wear, porous side walls, cracks, cuts, and rim damage.

WARNING

Inform the customer of any damage found.

2.6.4 Tread Depth, Checking

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Minimum tread depth: 1.6 mm with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

♦ This value may vary for individual countries due to different

legislative regulations.
♦ The minimum tread depth is reached when the tires have worn
down level with the 1.6 mm high tread wear indicators
-arrows- positioned at intervals around the tire.
♦ If the tread wear is close to the wear limits, inform customer
and note findings on the repair order.

22 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.6.5 Tire Pressure, Correcting

The tire pressures are listed on a label affixed to the inside of the
fuel tank door.

Note

Observe that the inflation pressure specifications on the sticker

refer to the air pressure of cold tires. Do not reduce tire pressure
when the tires are warm.

2.6.6 Spare Tire

• Spare wheel with standard tireProtected 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
Maintain the highest specified tire pressure for
with respect to thethe tire size
correctness ac‐ in this document. Copyright by AUDI AG.
of information
cording to the tire pressure label.
• Mini spare tire
The tire pressure is on the sidewall.

Note

On vehicles with steel rims and wheel covers, check tire pressure
valve extensions for damage and contamination that can cause
leaks. Replace, if necessary.

2.6.7 Tire Repair Kit, Checking Expiration

Date
On vehicles with a tire repair kit, check the expiration date.
Remove the bottle and check the expiration date -arrow-.

Note

♦ Replace a bottle that has already been used.

♦ If expiration date has passed, replace bottle.

2. Maintenance Procedures 23
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.7 Brake Fluid, Changing

⇒ “2.7.1 General Information“, page 24
⇒ “2.7.2 Manual Transmission“, page 25
⇒ “2.7.3 All Vehicles“, page 25
⇒ “2.7.4 Sequence and Brake Fluid Capacity Table“, page 26

2.7.1 General Information

♦ Brake filling and bleeding tool -VAS 5234-

♦ Brake filling and bleeding tool -V.A.G 1869- with Adapter set
-V.A.G 1869/4-

WARNING

♦ Brake fluid must never come into contact with fluids con‐
taining mineral oils (oil, gas, cleaning solutions). Oils con‐
taining minerals damage seals and sleeves on brake
systems.
♦ Brake fluid is poisonous. Do not let brake fluid come in
contact with the paint.
♦ Brake fluid is hygroscopic, which means that it absorbs
moisture from the air. Always store brake fluid in air-tight
containers.
♦ Wash off any spilled brake fluid with plenty of water.
♦ Observe waste disposal regulations!

Observe operating instructions for -VAS 5234- or for -

V.A.G 1869- !

– Remove brake fluid reservoir cap -1-.

WARNING

♦ Do not remove the strainer inside the brake fluid reservoir.

Note

Use only new Original Audi brake fluid. Refer to Electronic Parts
Catalog. 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.

24 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove brake fluid reservoir plug -arrow-.

– Connect suction hose from -VAS 5234- or -V.A.G 1869- to
tube -2- of brake fluid reservoir.
– With suction hose from -VAS 5234- or from -V.A.G 1869- or
with extractor, extract 2/3 of the brake fluid.
– Disconnect suction hose.
– Install brake fluid reservoir plug.

WARNING

Do not reuse used / extracted brake fluid!

– Install adapter -1- to brake fluid reservoir.

– Connect filler hose -2- from -VAS 5234- or -V.A.G 1869- to
adapter.

2.7.2 Manual Transmission

– Pull cover cap off clutch slave cylinder bleed screw.
– Place extractor bleeder hose -1- on clutch slave cylinder
bleeder screw, open bleeder screw, and let about 100 ml drain
out. Close bleeder screw and install cover cap.
– Operate clutch pedal several times.

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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.

2.7.3 All Vehicles

– Remove caps from the bleeder screws.

2. Maintenance Procedures 25
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Connect extractor bleeder hose -1- to rear right bleeder screw,

open bleeder screw and allow about 200 ml to flow out. Close
bleeder screw.
Repeat procedure on opposite rear.

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.

– Connect extractor bleeder hose -1- to front right bleeder

screw, open bleeder screw and allow about 200 ml to flow out.
Close bleeder screw.
Repeat procedure on opposite front.

2.7.4 Sequence and Brake Fluid Capacity Ta‐

ble
Right rear 200 ml
Left rear 200 ml
Right front 200 ml
Left front 200 ml
Total amount6) 1000 ml
6) Including brake fluid extracted from brake fluid reservoir and quantity from
clutch slave cylinder.

– Install cover caps on brake caliper bleeder screws.

– Move filler lever on -VAS 5234- or -V.A.G 1869- to position
-B- (see operating instructions).
– Remove the filler hose from the adapter.
– Remove the adapter from the brake fluid reservoir.

26 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Check brake fluid level and fill if necessary.

– Install the brake fluid reservoir cap.
– Check pedal pressure and brake pedal free play. Free play:
max 1/3 of pedal travel

2.8 Brake System, Inspecting Visually for

Leaks and Damage
– Check the following components for leaks and damage:
♦ Brake Master Cylinder
♦ Brake Booster
♦ ABS Hydraulic unit
♦ Calipers
– Make sure the brake hoses are not twisted.
– Make sure the brake hoses do not come in contact with any
vehicle components when steering is at full lock.
– Check brake hoses for porosity, bubbles and cracks.
– Check brake hoses and lines for chafing.
– Check the brake line connections for leaks or corrosion and
make sure they are attached securely.

WARNING

Eliminate any malfunctions (repair procedure).

2.9 Brake Pads, Checking Thickness

Front Disc Brake Pads

WARNING

With pad thickness (including backing plate) of 11 mm, the

brake pads have reached their wear limit and must be replaced
(repair procedure). Inform the customer.
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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. Maintenance Procedures 27
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Note

♦ To check lining thickness, remove front wheels.

♦ Before removing, mark the placement of the wheels to each
brake disc and reinstall wheels in same position after check‐
ing.

a - Brake pad thickness including backing plate

- Wear limit: 11 mm
Rear Disc Brake Pads

WARNING

With pad thickness (including backing plate) of 8 mm, the brake

pads have reached their wear limit and must be replaced (re‐
pair procedure). Inform the customer.

Note

Visual inspection without removing wheels

a - Brake pad thickness including backing plate

- Wear limit: 8 mm
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.

2.10 Brake Pads, Checking Thickness (RS6)

Front Disc Brake Pads

WARNING

When the brake pads (including the backing plate) have a

thickness of 8.5 mm (steel brake discs) and 10 mm (ceramic
brake disc), then the brake pads have reached their wear limit
and must be replaced!

28 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Note

♦ To check lining thickness, remove front wheels.

♦ Before removing, mark the placement of the wheels to each
brake disc and reinstall wheels in same position after check‐
ing.

a - Brake pad thickness including backing plate

- Steel brake disc wear: 8.5 mm
- Ceramic brake disc wear: 10 mm
Rear Disc Brake Pads

WARNING

If the pad thickness (including the backing plate) has reached

9 mm (steel and ceramic brake disc), then the brake pads have
reached their wear limit and must be replaced!

Note

Visual inspection without removing wheels

a - Brake pad thickness including backing plate

- Steel brake disc wear: 9 mm
- Ceramic brake disc wear: 9 mm

2.11 Brake Fluid, Checking Depending on

Brake Pad Wear

WARNING

♦ Brake fluid is poisonous. Do not let brake fluid come in

contact with the paint.
♦ Brake fluid is hygroscopic, meaning that it absorbs mois‐
ture from the surrounding air, and must therefore always
be stored in air-tight containers.

Note 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

Use only new Original Audi brake fluid. Refer to Electronic Parts
with respect to the correctness of information in this document. Copyright by AUDI AG.

Catalog.

– Please observe the following:

2. Maintenance Procedures 29
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Delivery Inspection
♦ Fluid level must be at MAX mark

Note

To prevent the brake fluid from overflowing from the reservoir, the
level must not be over the MAX mark.

Inspection Service
When driving, fluid level drops slightly from use and automatic
brake pad adjustment.
– Always check fluid level in conjunction with brake pad wear:
♦ When brake pads are new or if there is still enough brake lining
left, the brake fluid level must be between MIN and MAX
marks.
♦ With brake fluid at MIN mark or slightly above, topping off
brake fluid is not necessary when wear limit of brake pads has
been almost reached.

WARNING

If brake fluid level is below MIN mark, check brake system (re‐
pair procedure), before adding brake fluid.
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

2.12 Digital TV Tuner, Programming Remote

with respect to the correctness of information in this document. Copyright by AUDI AG.

Control
Refer to ⇒ Communication; Rep. Gr. 91 ; Description and Op‐
eration

2.13 Fuel Injector Cleaner G17

Note

Applies to certain countries only. Refer to the Maintenance table.

♦ Add Fuel Injector Cleaner G17 into the fuel tank in a ratio of
10ml of additive for every 10 liters of fuel.
♦ The following table shows the required quantities for each fuel
level shown in the fuel gauge.
Mixture Ratio
Fuel Gauge G17 additive
approximately approximately 20 ml
1/4
approximately approximately 40 ml
1/2
approximately approximately 60 ml
3/4
approximately approximately 80 ml
1/1

30 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Note

♦ The values in the table are based on an 80 liter fuel tank.

♦ If there are other fuel capacities in the fuel tank which are not
mentioned in the table, then add 10 ml of additive for every 10
liters of fuel.
♦ If values 2 and 4 in measured values block 32 deviate, refer
to ⇒ “2.1 Measured Values Block 32, Reading“, page 17 then
increase the amount of Fuel Injector Cleaner G17 by factor 4.
Example: fuel gauge 1/4 fuel additive G17 80 ml

2.14 Key, Check Functionality

– Separate keys so that the function of each key can be checked
individually.
– Mechanically lock and unlock vehicle with keys on driver's
door.
– Insert each key into the ignition and start the engine.
– If engine switches off by itself after about 3 seconds and
“SAFE“ appears in the odometer display, the key has not been
programmed to the immobilizer.
– Repair measure: Guided Fault Finding (Programming vehicle
keys).
– Note in the delivery check list the number of keys checked and
given to the owner.

2.15 DTC Memory, Checking Using Vehicle

Diagnosis, Testing and Information Sys‐
tem VAS 5051/5052
– Follow these steps in sequential order.
♦ Connect Vehicle Diagnosis Tester
♦ Vehicle Self-Diagnosis (OBD)
♦ Gateway device list
♦ Read the control module with the fault stored in the DTC mem‐
ory.
♦ Correct relevant malfunctions with customer's approval.
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. Maintenance Procedures 31
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.16 Noise Insulation, Removing

Removing
– Open the quick-release connectors -1- and -2- and remove the
noise insulation.
Installing
Installation is reverse of removal. On vehicles with auxiliary heat‐
er, note the following:
– After installing noise insulation, check location of exhaust pipe
-A-; a seal -B- must be installed between exhaust pipe and
noise insulation.

– Exhaust pipe must project below seal and the escape of ex‐
haust from the pipe -A- must not be impaired.

2.17 Front Axle Joints, Checking Play, Se‐

curity and Joint Boots
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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.
Note

Perform this test with vehicle on lift (wheels hanging freely).

Tie Rod Ends

– Check play by moving tie rods and wheels.
♦ You should not feel or see any play.

32 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Check all around ball joint boots -arrow- for damage and cor‐
rect seating. Use a mirror, if necessary.
♦ Ball joint boots can usually be recognized by leaking lubrica‐
tion.

All Control Arms

– Check all around ball joint boots -arrows- for damage and cor‐
rect seating. Use a mirror, if necessary.
♦ Ball joint boots can usually be recognized by leaking lubrica‐
tion.
♦ You should not feel or see any play.
Control Arm

– With unloaded wheels, check relative movement of wheel

bearing housing to control arm.
– By raising and lowers the wheels several times by hand
Protected by -arrow- the relative
copyright. Copying movement
for private or commercial between wheel
purposes, in part bearing
or in whole, is not housing
and control arm can be observed.
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.
– If relative movement when lifting or lowering gives evidence of
play that can be felt or seen, control arm must be replaced.
Driveshaft Boot
– Check all around interior and exterior driveshaft boot for dam‐
age and correct seating. Turn wheel, if necessary.
♦ By turning the front wheels, tears can be found in their early
stages.
♦ Driveshaft boot damage can usually be recognized by leaking
lubrication.

2.18 Power Steering System, Checking for

Leaks and Checking Fluid Level and Fill‐
ing
Checking Fluid Level
– With engine not running, move front wheels in straight-ahead
position.

Cold fluid (approximately 68°F [20°C]):

– Remove cover.

2. Maintenance Procedures 33
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Clean dipstick with clean cloth.

– Screw cap on hand-tight and remove again.

Note

Screw cap fully in to get an accurate fluid level reading.

– Check fluid level: Fluid level must be in -A- range.

Fluid at operating temperature (approximately 176°F [80°C]):
– Remove cover.
– Clean dipstick with clean cloth.
– Screw cap on hand-tight and remove again.

Note

Screw cap fully in to get an accurate fluid level reading.

– Check fluid level: Fluid level must be in -B- range

Note

♦ If fluid level is above specified range, fluid must be extracted

off.
♦ If the fluid level is below the specified level, check the power
steering system for leaks. It is not sufficient just to add fluid.
♦ Do not use power steering fluid that has drained out.

2.19 Interior Rearview Mirror with Compass,

Calibrating
Refer to ⇒ Body Interior; Rep. Gr. 68 ; Description and Operation

2.20 Ribbed Belt, Check Tension and Condi‐

tion
V8 4.2L, V10 FSI and V10 TFSI
Checking for:
♦ Sub-surface cracks (cracks, core ruptures, cross sectional
breaks)
♦ Separation (cover layer, belt cords)
♦ Breaks at lower layer
♦ Fraying of cords
♦ Wear at flanks (material wear, frayed flanks, hardening or
glazing of flanks, surface cracks)
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♦ Oil or grease contamination 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.
♦ Check guide rollers and tensioner rollers and replace if nec‐
essary.

34 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Note

Replace the belt if any damage is found. This will prevent any belt
malfunctions. Replacing the belt is a repair procedure.

2.21 License Plate, Attaching

Note

If the PR numbers 2K1 and 2K7 are combined with 6W6, then
attach the license plate as described.

♦ Install the license plate holder using two bolts -arrows- as far
across from each other as possible on the center line -line- of
the license plate holder.

WARNING

If the vehicle is equipped with PR number 2K1 and 2K7 in

combination with 6W6, then the holes for the screw may not
be drilled into the corners of the license plate.

2.22 Air Conditioning, Check Function and

Setting Temperature
Comfort
– Check all climate control functions. Refer to Owner's manual.
– Check whether 72°F (22°C ) is set in both display fields.
– Set temperature as follows, if necessary:
– Press the “AUTO“ button.
– Set temperature on driver's and passenger's side to 72°F (22°
C) with “rotary knobs“.
Base

– Check all climate control functions. Refer to Owner's manual.

– Carry out temperature setting as follows:
– Set rotary knobs -C and D- to -A-.
– Set driver's side and passenger's side temperature adjusters
to 72°F (22°C).
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. Maintenance Procedures 35
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.23 Coolant System, Checking

⇒ “2.23.1 Coolant Additive, Checking and Filling“, page 36
⇒ “2.23.2 Coolant Level, Checking and Filling“, page 37

2.23.1 Coolant Additive, Checking and Filling

Note

♦ Coolant additive prevents freeze and corrosion damage, scal‐

ing, and raises the boiling point. For these reasons, the cooling
system must be filled with radiator freeze and corrosion pro‐
tection fluid all year round.
♦ Use only approved radiator freeze and corrosion protection
fluid for the different engine versions. Refer to the ⇒ Electronic
Parts Catalog . Using other coolant additives can impair the
corrosion protectant. Loss of coolant and cause considerable
damage to the engine.
♦ Especially in countries with tropical climates or when vehicle
is driven under heavy load, the coolant improves the engine
reliability by its increased boiling point.
♦ The coolant portion of the mixture must amount to at least 40%
(freeze protection to -13°F [-25°C]) and should not exceed
60% (freeze protection to -40°F [-40°C]). Otherwise the freeze
protection will be reduced and the cooling efficiency will be
worsened.
♦ The freeze protection must be ensured to approximately -13°
F (-25 °C).
♦ If climate conditions make greater freeze protection necessa‐
ry, the amount of freeze protection can be increased up to
60%. Adding more coolant reduces the freeze
permittedprotection and
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unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
reduces the cooling efficiency. with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Follow all waste disposal regulations!

Special tools and workshop equipment required

♦ Refractometer -T10007-

36 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Check the concentration of the coolant additive using a re‐

fractometer -T10007- .
The scale -1- of the refractometer is designed for coolant addi‐
tives G 12, G12 Plus, G12 Plus Plus and G11.
Scale -2- refers only to coolant additive G 13. (begins L80)
– If the freeze protection is insufficient, fill according to the mix‐
ture ratio and then perform a road test.
– Check the freeze protection after the road test.
Mixture Ratio
Freeze pro‐ Coolant addi‐ Water
tection to tive
-25°C (-13° approximately. approximately. 60 %
F) 40 %
-35°C (-31° approximately. approximately. 50 %
F) 50 %
-40°C (-40° approximately. approximately. 40 %
F) 60 %

2.23.2 Coolant Level, Checking and Filling

– Check the coolant level in the coolant reservoir when the en‐
gine is cold.
♦ Delivery inspection: coolant level above “MIN marking“
-arrow-.
♦ Inspection service: coolant level above “Min. marking“
-arrow-.
– If coolant level is too low, fill with coolant mixture.
Mixture Ratio
Freeze pro‐ Coolant addi‐ Water
tection to tive
-25°C (-13° approximately. approximately. 60 %
F) 40 %
-35°C (-31° approximately. approximately. 50 %
F) 50 %
-40°C (-40° approximately. approximately. 40 %
F) 60 %

Note

Determine causeProtected
of fluidbyloss, which cannot be attributed to nor‐
mal use and repair.
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. Maintenance Procedures 37
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.24 Throttle Valve Control Module Air

Guide, Cleaning, RS 6
To clean the throttle valve control module air guide, both control
modules must be removed.
Removing
Proceed as follows:
Throttle Valve Control Module 2 -J544- (left):
– Remove the screw -1- and disconnect the connector -2- on the
charge air pressure sensor 2 -G447- .
– Remove the left air guide pipe by loosening the hose clamps
-arrows-.
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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.

– Disconnect the connector -1-.

– Remove the screws -arrows- and then remove the throttle
valve control module 2 -J544- .
– Clean the air guide in the throttle valve control module with a
lint-free cloth with an appropriate cleaner.

Throttle valve control module 1 -J338- (right):

– Remove the air guide hose -2- by pressing the release buttons
-arrows-.

Note

Do not pay attention to -1-.

– Remove the screw -2- and disconnect the connector -1- on the
charge air pressure sensor 2 -G31- .
– Remove the right air guide pipe by loosening the hose clamps
-arrows-.

38 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Disconnect the connector -1-.

– Remove the screws -arrows- and then remove the throttle
valve control module -J338- .
– Clean the air guide in the throttle valve control module with a
lint-free cloth with an appropriate cleaner.
Installing
•
Installation is reverse of removal, but note the following:

Note

♦ Replace the seal.

♦ Before installing, make sure the hose connections as well as
air guide pipes and hoses are free of oil and grease.
♦ Secure all hose connections with hose clamps that match cur‐
rent standard production. Refer to Electronic Parts Catalog.
♦ Before installing, spray the screw clamps with rust remover so
that they can be used to secure the air guide hoses onto the
connections.
♦ It is important to maintain the installation position of the hose
clamps on the air guide pipes so that there is sufficient clear‐
ance around the crash sensors. Refer to ⇒ Engine Mechani‐
cal; Rep. Gr. 21 ; Removal and Installation .

– After removing and installing the throttle valve control module,

perform an “adaptation“ in “Guided Functions“.

2.25 Air Filter, Clean Air Filter Housing and

Replace Filter
⇒ “2.25.1 Snow Screen, Cleaning“, page 39
⇒ “2.25.2 6-Cylinder Gasoline Engines“, page 40
⇒ “2.25.3 8-Cylinder Gasoline Engines“, page 40
⇒ “2.25.4 10-Cylinder Gasoline Engines“, page 41
⇒ “2.25.5 10-Cylinder Gasoline Engines, RS 6 Turbo“,
page 44
⇒ “2.25.6 Air Filter, RS 6, Assembly Overview“, page 46

2.25.1 Snow Screen, Cleaning

♦ In countries with cold climates, the snow screen must be
cleaned ( PR -Number: 1C2 / 1C4), refer to
⇒ “2.42 Snow Screen, Cleaning“, page 70 .

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. Maintenance Procedures 39
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.25.2 6-Cylinder Gasoline Engines

– Remove screws -1- and remove air duct upward.
– Unclip lines -2- from retainers.
– Loosen air duct intake hose -3- and connections (crankcase
ventilation, mass airflow sensor).

– Open clamps -1- with screwdriver and remove air duct.

– Release air filter cover -2-, open and remove.
– Remove the screws -3- and the filter.
– Clean the filter housing and insert a new air filter.
– Assembly is reverse of removal.

2.25.3 8-Cylinder Gasoline Engines

– Remove bolts -arrows-.
– Remove air duct -1- and -2-.

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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.

– Unclip fuel hose -1-.

Note

On USA vehicles, fuel hose is behind air duct hose -3-.

– Remove electrical connection -2- from Mass Air Flow Sensor

-G70- .
– Disconnect Mass Air Flow Sensor -G70- from air duct hose
-3-.
– Open tension clamps -arrows- and remove upper part of air
filter housing with Mass Air Flow Sensor -G70- .

40 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove 2 securing screws -arrows- from air filter insert.

– Remove air filter insert.
– Clean the filter housing and insert a new air filter.
– Assembly is reverse of removal.

2.25.4 10-Cylinder Gasoline Engines

Remove Left Air Filter Housing
– Remove bolts -arrows- and remove left air guide.

– Loosen hose clamps -1- and remove bolts -2 through 4-.

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
– Disconnect electrical
with respect to theconnector
correctness of -arrow-
information on Mass
in this AirCopyright
document. Flow by AUDI AG.
(MAF) Sensor 2 -G246- .
– Remove the left upper part of the air filter housing.
– Remove air filter insert.

2. Maintenance Procedures 41
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Remove Right Air Filter Housing

– Remove bolts -arrows- and remove right air guide.

– Disconnect vacuum hoses -4- and -5-.

– Loosen hose clamps -6- and remove bolts -1 through 3-.

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.

42 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Disconnect electrical connector -arrow- on Mass Air Flow

(MAF) Sensor -G70- .
– Remove the right upper part of the air filter housing.
– Remove air filter insert.

Installing

Installation is done in reverse sequence while observing the fol‐

lowing.
For proper mass airflow sensor function, it is important to observe
the following notes and perform the procedure exactly.

Note

♦ If the air filter insert is heavily soiled or soaked, dirt particles

or moisture can reach the Mass Air Flow Sensor and cause an
incorrect airflow reading. This causes lack of performance be‐
cause a lower injection amount is calculated.
♦ Always use an original air filter insert.
♦ The air filter housing must be clean.
♦ Secure all hose connections with hose clamps that match cur‐
rent standard production. Refer to Parts Catalog.
♦ When cleaning the air filter housing using compressed air,
note the following: to avoid malfunctions, cover the critical air
distribution components such as the mass airflow sensor, air
guide tubes etc. with a clean cloth.
♦ Follow all waste disposal regulations!

– Clean water drain (small hole in bottom part of air filter housing
-arrow-), blow out with compressed air if necessary.
– Clean air filter housing (upper and lower parts) of salt residue,
dirt or leaves (clean with vacuum, if necessary).
– Check mass airflow sensor and air guide hose (clean air side)
for salt residue, dirt and leaves.
– Check air duct from lock carrier to air filter housing for dirt and
leaves.
– When
Protected installing
by copyright. Copyingair filter orinsert,
for private ensure
commercial it is
purposes, centered
in part or in whole,in mount
is not
onunless
permitted bottom of air
authorised filter.
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.
– Carefully and gently place upper part of air filter on lower part.
Make sure the air filter housing upper section is not sitting
crooked on air filter (pay attention to the air filter sealing lip).
– Make sure the air guide hose is seated firmly on mass airflow
sensor.

Tightening Specifications
Component Nm
Hose clamps for air guide hoses 2.5

2. Maintenance Procedures 43
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.25.5 10-Cylinder Gasoline Engines, RS 6

Turbo
Removing Left Air Filter Housing
Proceed as follows:
– Remove the screw -1- and disconnect the connector on the
charge air pressure sensor 2 -G447- .
– Remove the left air guide pipe by loosening the hose clamps
-arrows-.

– Remove the air guide hose -1- by pressing the release buttons.
– Remove the hoses -2- and -3- from the upper part of the air
filter housing.

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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.
– Remove the upper part of the air filter housing -arrow- and
remove the air filter insert.
Remove Right Air Filter Housing
Proceed as follows:
– Remove the crankcase ventilation hose -2- by pressing the
release buttons.

Note

Do not pay attention to -1-.

– Remove the screw -2- and disconnect the connector -1- on the
charge air pressure sensor 2 -G31- .

44 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove the right air guide pipe by loosening the hose clamps
-arrows-.
– Remove the ventilation hose -1- from the upper part of the air
filter housing.
– Remove the upper part of the air filter housing -arrow- and
remove the air filter insert.
Installing
• Tightening torque, refer to
⇒ “2.25.6 Air Filter, RS 6, Assembly Overview“, page 46 .

Note

♦ Always use an original air filter insert.

♦ Before installing, make sure there is no oil or grease on the
hose connections and hoses around the intake area. Do not
use any lubricant containing silicone when installing.
♦ The air filter housing must be clean.
♦ Secure all hose connections with hose clamps that match cur‐
rent standard production. Refer to Parts Catalog.
♦ Before installing, spray the screw clamps with rust remover so
that they can be used to secure the air guide hoses onto the
connections.
♦ It is important to maintain the installation position of the hose
clamps on the air guide pipes so that there is sufficient clear‐
ance around the crash sensors.
♦ When cleaning the air filter housing using compressed air,
note the following: to avoid malfunctions, cover the critical air
distribution components such as the air guide tubes etc. with
a clean cloth.
♦ Always follow the instructions for disposal!

– Clean out the water drain (the small hole in the lower part of
the air filter) with compressed air.
– Clean out any salt build-up, dirt or leaves from the the air filter
housing (both upper and lower parts) using a vacuum.
– Check the air guide hose (clean air side) for salt build-up, dirt
and leaves.
– Check the air guideProtected
going by from the Copying
copyright. lock carrier
for privateto
or the air filter
commercial purposes, in part or in whole, is not
housing for dirt and permitted
leaves.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.
– When installing the air filter insert, be sure to center the insert
when installing it into the air filter housing lower section mount.
– Gently place the air filter housing upper section onto the air
filter housing lower section. Make sure the air filter housing
upper section is sitting angled on the air filter insert (note the
sealing lip on the air filter insert).
Installation is the reverse of removal.

2. Maintenance Procedures 45
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.25.6 Air Filter, RS 6, Assembly Overview

Note

The left air filter housing is shown in the illustration.

1 - Screw
❑ 9 Nm
2 - Air guide
❑ To the lock carrier
❑ Clean any dirt, leaves or
salt build-up
3 - Screw
❑ 1.5 Nm
4 - Air guide
❑ To the lock carrier
❑ Clean any dirt, leaves or
salt build-up
5 - Air filter housing lower sec‐
tion
❑ Clean any dirt, leaves or
salt build-up
❑ Check the water drain,
clean if necessary
6 - Screw
❑ 4.5 Nm
7 - Vacuum hose
❑ From the turbocharger
recirculating valve -
N249- to the mechanical
recirculation air valve
8 - Mechanical recirculating air
valve
9 - Hose clamp
❑ For the specified instal‐
lation location refer to ⇒
Engine Mechanical;
Rep. Gr. 21 ; Removal and Installation
10 - AirProtected
guide by hose
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
11 - Hosewith
clamp
respect to the correctness of information in this document. Copyright by AUDI AG.

❑ For the specified installation location refer to ⇒ Engine Mechanical; Rep. Gr. 21 ; Removal and Instal‐
lation
12 - Air guide pipe
13 - Screw
❑ 5 Nm
14 - O-Ring
❑ Replace
15 - Charge air pressure sensor
❑ Charge air pressure sensor -G31- (right), charge air pressure sensor 2 -G447- (left)
❑ Removing and Installing, refer to ⇒ Engine Mechanical; Rep. Gr. 21 ; Removal and Installation

46 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

16 - Screw
❑ 4.5 Nm
17 - Hose clamp
❑ For the specified installation location refer to ⇒ Engine Mechanical; Rep. Gr. 21 - Aufladung
18 - Air guide hose
19 - Hose clamp
❑ For the specified installation location refer to ⇒ Engine Mechanical; Rep. Gr. 21 - Aufladung
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
20 - Air guide hose 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.
21 - Air filter housing upper section
❑ Clean any dirt, leaves or salt build-up
22 - Air filter insert
❑ Use Original Volkswagen air filter insert ⇒ Electronic Parts Catalog
❑ If so equipped, clean the snow screen
23 - Bracket
❑ For the air filter housing
24 - Grommet
25 - Bushing
26 - Screw
❑ 5 Nm
27 - Nut
❑ 5.5 Nm
28 - Grommets
29 - Retaining bolts
❑ For air filter housing lower section
30 - Hose clamp
❑ For the specified installation location refer to ⇒ Engine Mechanical; Rep. Gr. 21 ; Removal and Instal‐
lation
31 - Air guide hose
32 - Hose clamp
❑ For the specified installation location refer to ⇒ Engine Mechanical; Rep. Gr. 21 ; Removal and Instal‐
lation
33 - Intermediate flange
❑ To the turbocharger
34 - Seal
❑ Replace

2.26 Engine and Engine Compartment, In‐

specting for Leaks and Damage
Perform visual check as follows:
– Check engine and engine compartment for leaks and damage.
– Check lines, hoses and connections on following systems for
leaks, chafing, porosity and cracks:
♦ Fuel system
♦ Cooling and heating system

2. Maintenance Procedures 47
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

♦ Brake system
– Perform visual inspection from below using same viewpoints
as when vehicle was on lift and noise insulation removed.

WARNING

Eliminate any malfunctions (repair procedure).

2.27 Engine Cover, Removing and Installing

⇒ “2.27.1 6-Cylinder Common Rail Engine“, page 48
⇒ “2.27.2 6-Cylinder TFSI“, page 48
⇒ “2.27.3 Engine Cover, Installing“, page 48

2.27.1 6-Cylinder Common Rail Engine

– Remove engine cover with both hands at places -1- and then
-2-. (do not remove engine cover abruptly or by one side).
– Install the engine cover.
– To avoid damage, do not hit engine cover with fist or a tool.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Position engine coverpermitted
on engineunless (be careful
authorised of AG.
by AUDI oil AUDI
fillerAGtube
does not guarantee or accept any liability
and oil dipstick). with respect to the correctness of information in this document. Copyright by AUDI AG.

– Push engine cover first with both hands into position -3- in
rubber grommets and then with both hands into position -4-.

2.27.2 6-Cylinder TFSI

– Remove the engine covers -1- and -2-.

2.27.3 Engine Cover, Installing

– To avoid damage, do not hit engine cover with fist or a tool.
– Position engine cover on engine (be careful of oil filler tube
and oil dipstick).
– Push engine cover first with both hands into position -3- in
rubber grommets and then with both hands into position -4-.

48 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.28 Engine Oil, Draining and Replacing Fil‐

ter
⇒ “2.28.1 General Information“, page 49
⇒ “2.28.2 6-Cylinder Gasoline“, page 50
⇒ “2.28.3 8-Cylinder BVJ“, page 51
⇒ “2.28.4 5.2L FSI“, page 52
⇒ “2.28.5 V 10-Cylinder, Gasoline TFSI, RS6“, page 54

2.28.1 General Information

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WARNING 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.

Oil extraction not permitted with various engine types!

Note

Perform oil change at operating temperature.

Special tools and workshop equipment required

♦ Oil extractor -1782-

♦ Tension band -2171-1-

♦ Oil filter wrench -3417-

2. Maintenance Procedures 49
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

♦ Oil drain adapter -T 40057- (2.0 TFSI)

Note

Follow all waste disposal regulations!

2.28.2 6-Cylinder Gasoline

– Remove coolant reservoir -1- and lay aside.
– Remove oil filter cover with socket wrench -SW 36- -2-.
– Clean sealing surfaces oil filter cover and at oil filter housing.
– Replace oil filter insert.

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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.

Sealing Ring on Cap, Replacing

– Remove sealing ring at pull tab -arrow A- from cap -1-.
– Insert new sealing ring -2- with semicircular profile in groove
-arrow B- on cap.
• The pull tab -arrow A- must face upward.
• Smooth side of sealing ring -2- must face toward outside

50 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

O-Ring, Inserting in Oil Filter Housing

– Insert O-ring -2- in groove -arrow- on oil filter housing -1-.

Note

Follow all waste disposal regulations!

– Engage new oil filter insert in oil filter cover.

– Install oil filter cover -3-.
– Install coolant reservoir.
– Remove the noise insulation. Refer to
⇒ “2.16 Noise Insulation, Removing“, page 32 .
– Open oil drain plug on oil pan or extract engine oil.
– Install oil drain plug.

Note

♦ Oil drain plug is installed without seal.

Check
♦ permitted for authorised
cleanliness.
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unless 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.

Tightening Specifications Nm
Oil filter cover 25
Oil drain plug on oil pan 30
– Fill motor oil. Refer to ⇒ “2.29 Engine Oil, Filling“, page 55
For oil specifications and capacities, refer to ⇒ Fluid Capacity
Tables; Rep. Gr. 03

2.28.3 8-Cylinder BVJ

– Remove the oil filter cover with a socket wrench -SW 32-
-arrow-.
– Clean sealing surfaces oil filter cover and at oil filter housing.

2. Maintenance Procedures 51
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Replace O-rings -2- and -4- and filter component -3-.

Note

♦ By removing the filter element, a valve is opened that allows

the oil in the filter housing to flow automatically back into the
crankcase.
♦ Observe installation position of tab on oil filter.
♦ Follow all waste disposal regulations!

– Insert new oil filter in filter housing

– Install new O-ring -2- and lubricate lightly.
– Install oil filter cover -1-.
– Remove the noise insulation. Refer to
⇒ “2.16 Noise Insulation, Removing“, page 32 .
– Open oil drain plug on oil pan or extract engine oil.
– Install oil drain plug.

Note

♦ Install oil drain plug with new gasket.

♦ Check for cleanliness.

Tightening Specifications Nm
Oil filter cover 25
Oil drain plug on oil pan 25
– Fill motor oil. Refer to ⇒ “2.29 Engine Oil, Filling“, page 55 .
For oil specifications and capacities, refer to ⇒ Fluid Capacity
Tables; Rep. Gr. 03

2.28.4 5.2L FSI

– Remove the noise insulation. Refer to
⇒ “2.16 Noise Insulation, Removing“, page 32 .
– Open oil drain plug and drain engine oil.
– Install oil drain plug with new gasket.

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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.

52 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove rear engine cover -2- -arrows-.

– Remove EVAP valve from bracket and lay aside.

– Secure EVAP line, bleed line and sound generator line at front
with cable ties.

– Loosen cover -1- AF 32.

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– Remove
permitted filter component
unless authorised by AUDI AG. AUDI -3-.
AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Replace O-rings -2- and -4- and filter element -3-.
Observe installation position of tab on oil filter.
– Fill with engine oil.
For oil specifications and capacities, refer to ⇒ Fluid Capacity
Tables; Rep. Gr. 03

Note

Follow all waste disposal regulations!

Tightening Specifications Nm
Oil filter cover 25
Oil drain plug 25

2. Maintenance Procedures 53
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.28.5 V 10-Cylinder, Gasoline TFSI, RS6

– Remove rear engine cover -2- toward the rear -arrows-.

– Free up the oil filter housing cover -1-.
– Loosen cover -1- AF 32.
– Remove filter component -3-.
– Replace O-rings -2- and -4- and filter element -3-.
Observe installation
Protected by position of tab
copyright. Copying for on oilorfilter.
private 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.

– Remove the noise insulation. Refer to

⇒ “2.16 Noise Insulation, Removing“, page 32 .

54 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Open the oil drain plugs -2 - 4 - 6 - 8- and drain the oil.

– Open oil drain plug -arrow- and drain engine oil.
– Install the oil drain plug with a new gasket.
– Remove any remaining oil the oil pan using an oil extractor
-1782- .

Note

Depending on the vehicle- and engine equipment, the number of

oil drain plugs may vary between 2 and 5 pieces.

WARNING

Pay attention to the tightening specifications.

Always pay attention to the instructions when filling the engine
oil. Refer to ⇒ “2.30 Engine Oil, R S6, Filling“, page 56 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Tightening Specifications Nmby AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.
Oil filter cover 25
Thermostat housing drain plug 25
Drain plugs on the oil tubes 40
Drain plug on the control housing 12 +/- 0.5
– Fill the engine oil. Refer to
⇒ “2.30 Engine Oil, R S6, Filling“, page 56
For oil specifications and capacities, refer to ⇒ Fluid Capacity
Tables; Rep. Gr. 03

Note

Follow all waste disposal regulations!

2.29 Engine Oil, Filling

Note

For oil specifications and capacities, refer to ⇒ Fluid Capacity

Tables; Rep. Gr. 03

Engines with turbocharger:

– After the engine oil and oil filter have been replaced, observe
the following when first starting the engine:
♦ As long as the oil pressure indicator lamp in the instrument
cluster is on, the engine may only run in idle. Do not touch the
accelerator pedal! Bumping the accelerator pedal can damage
the turbocharger or destroy it completely
♦ Accelerate only after the oil pressure indicator lamp extin‐
guishes
All:
– Check the oil level. Refer to
⇒ “2.31 Engine, Checking Oil Level“, page 56 .

2. Maintenance Procedures 55
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.30 Engine Oil, R S6, Filling

Note

For oil specifications and capacities, refer to ⇒ Fluid Capacity

Tables; Rep. Gr. 03

Perform the following:

♦ Fill the oil pan with 5.0 liters.
♦ Start the engine.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Switch off thepermitted
engineunless
after lettingbyitAUDI
authorised idleAG.
forAUDI
30AGseconds.
does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Add another 1.5 liters of oil.
♦ Check oil level:
⇒ “2.31.2 Engine Oil, RS 6, Checking Level“, page 57
Engines with turbocharger:
– After the engine oil and oil filter have been replaced, observe
the following when first starting the engine:
♦ As long as the oil pressure indicator lamp in the instrument
cluster is on, the engine may only run in idle. Do not touch the
accelerator pedal! Bumping the accelerator pedal can damage
the turbocharger or destroy it completely
♦ Accelerate only after the oil pressure indicator lamp extin‐
guishes.

2.31 Engine, Checking Oil Level

⇒ “2.31.1 Checking“, page 56
⇒ “2.31.2 Engine Oil, RS 6, Checking Level“, page 57

2.31.1 Checking

Note

♦ For oil specifications and capacities, refer to ⇒ Fluid Capacity

Tables; Rep. Gr. 03
♦ Vehicle must be in level position.
♦ After stopping engine, wait a few minutes to allow oil to flow
back into oil pan.

– Pull out oil dipstick and wipe with clean rag. Replace dipstick
and push down to stop.
– Pull out dipstick again and read oil level.

56 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Markings on dipstick:

a - Oil must not be topped off.

b - Add oil. This will cause oil level to be in area -a-.
c - Add oil. It is sufficient when oil level is in area -b- (grooved
field).

Note

Oil level must not exceed -a- mark on dipstick.

2.31.2 Engine Oil, RS 6, Checking Level

– Follow these steps in sequential order.
• Place the vehicle in a horizontal position.
• Let the engine warm at different RPMs less than 2,500 RPM
until the engine oil reachespermitted
a temperature of approximately
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unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
212 to 230 °F (100 to 110 °C) withaccording
respect to the to the instrument
correctness of information in this document. Copyright by AUDI AG.
cluster.
• Let the engine run in idle for 3 minutes.
• Switch off the engine and let the oil drain down for two minutes;
then check the oil level within 10 minutes.
• Add engine oil if necessary.
• Oil level in the "B" range - add oil.
• Filling capacity approximately 1 liter
• The oil level can be within the "A" range.

Note

Add oil until the oil level is 5 mm below the upper edge of the "Do
not Fill" range.

2. Maintenance Procedures 57
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.32 Navigation Eject Button, Unlocking

– Follow these steps in sequential order.
♦ Connect Vehicle Diagnosis Tester
♦ Guided Functions
♦ Go to - function/component selection
♦ Service Work
♦ Navigation, Eject button, locking/unlocking
♦ Now follow guided program

2.33 Road Test

The following checks depend on the vehicle equipment level and
the available testing possibilities (city or rural).
– During the road test, check the following:
♦ Engine: performance, stalling, idle, acceleration
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♦ Clutch: starting, pedal force, smell 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.
♦ Shifting: ease of movement, shift lever position
♦ Automatic transmission: selector lever position, shift lock/ig‐
nition key withdrawal lock, shift behavior, instrument cluster
display
♦ Foot and parking brake: function, free travel and effectiveness,
pulling to one side, rubbing, squeaking
♦ ABS function: when braking with activated ABS, the brake
pedal must pulse noticeably.
♦ Steering: function, steering travel, steering wheel center posi‐
tion when driving straight ahead.
♦ Tilt/slide sunroof: function
♦ Cruise control system: function
♦ MMI function (radio, navigation, etc.)
♦ Driver information system (DIS): functions
♦ A/C system: function
♦ Vehicle: pulling to one side while driving straight ahead (level
road)
♦ Imbalance: wheels, driveshafts
♦ Wheel bearing: noises
♦ Engine: warm starting behavior
♦ Check the horn.

58 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.34 Wheel Bolts, Tightening Specifications

⇒ “2.34.1 Cap“, page 59
⇒ “2.34.2 Wheel Bolts“, page 59
⇒ “2.34.3 Correct Wheel Installation“, page 59

2.34.1 Cap
– The removal hook -A- for removing the center cap is located
in the vehicle's tool kit.

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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.

2.34.2 Wheel Bolts

The adapter to loosen/tighten the anti-theft wheel bolts is located
with the vehicle tool kit.

Note

Be sure to tighten wheel bolts in diagonal sequence to the fol‐

lowing specified torque:

Tightening Specifications Nm
Wheel Bolts 120
– Return the adapter to the vehicle tools.

2.34.3 Correct Wheel Installation

– When installing wheels, you must observe the following points
to ensure wheels fit securely:
• Always tighten wheel bolts to the specified torque so the wheel
bolt seats in rim are not deformed.
• When installing a wheel, do not tighten first wheel bolt imme‐
diately (for example, with an impact wrench). This would pre‐
vent other bolts from centering rim properly when they are
screwed in. Rim could then become loose, even if tightened
to specified torque.
• Before installing wheels, check for rust/corrosion in wheel bolt
seats and contact surfaces between rims and hubs, removing
if necessary. Otherwise, the wheel bolts can lose tension after
installation and the rim can come loose.

2. Maintenance Procedures 59
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

WARNING

♦ If the above points are not observed, wheels can come

loose and the wheel bolt seats in rim can be deformed.
♦ The deformity could be so small that it cannot be seen.
♦ But even small deformities in the wheel bolt seats can
prevent the wheel from fitting securely, so that it becomes
looser and looser.

2.35 Windshield Washer System, Checking

and Adjusting Spray Nozzles
Special tools and workshop equipment required
♦ Windshield Washer Aiming Tool -T10127- equipped with Tip
-3125/5A-

♦ Windshield Washer Aiming Tool -T40187- equipped with Tip

-3125/5A-

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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.
WARNING

Danger of personal injury.

♦ If the wiper spray nozzle adjusting tool -T40187- is not
going to be used, then make sure both sides are covered
and locked with the covers -3- and -4-.
♦ If one side is not locked by the cover, it is possible to get
injured by the needle -3125/5A- -1- or by the adjusting pin
-2-.
♦ When opening a side make sure the opposite side is not
facing the hand.

60 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Unlock the long cover -1- on the wiper spray nozzle adjusting
tool -T40187- -arrow A- and push it toward the rear
-arrow B-.

– Install the adjusting pin -2- on the spray nozzle -arrow- in the
nozzle unit -1- and aim it at the windshield. Adjust it if neces‐
sary.
– If the spray field does not match the specifications, clean un‐
cleaned washer jets.

WARNING

Danger of personal injury.

♦ The cover must cover and lock the adjusting pin after each
use.

Adjusting the windshield spray nozzle for vehicle with 2-hole noz‐
zles

Note

The adjustment dimensions give values for a driving vehicle, that

is, when parked, the spray pattern will shift slightly.

– Mark the 4 points on the windshield with a water-soluble pen:

• Dimension -a- = 255 mm.
• Dimension -b- = 510 mm.
• Dimension -c- = 530 mm.
• Dimension -d- = 430 mm.
– Locate the points using the socket wrench for the wiper spray
nozzle -T10127- .

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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. Maintenance Procedures 61
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Adjusting the windshield spray nozzles for vehicle with 3-hole je‐
nozzlets

Note

The adjustment dimensions give values for a driving vehicle, that

is, when parked, the spray pattern will shift slightly.

– Mark the 6 points on the windshield with a water-soluble pen:

Dimensions in Driver's side Passenger side
mm
-a- = 290 290
-b- = 550 550
-c- = 275 275
-d- = 275 275
-e- = 515 515
-f- = 195 195
– Locate the points using the socket wrench for the wiper spray
nozzle -T10127- .
– If the spray field does not match the specifications, clean un‐
cleaned jets.
Rear Window Spray Jet, Adjusting

– Adjust spray jets with washer jet adjuster -T10127- so fluid

sprays over the wiper onto the rear window at the places
shown. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Dimension -a- = approximately 122

with mm
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Dimension -b- = approximately 330 mm

♦ Dimension -c- = approximately 5 mm

2.36 Headlamp Washer System, Checking

Spray Nozzles
Headlamp cleaner spray nozzles are set at the factory and do not
need to be adjusted.

2.37 Headlamps, Checking and Adjusting

⇒ “2.37.1 Checking and Adjusting Conditions“, page 62
⇒ “2.37.2 Headlamps, Checking Adjustment with new Test
Screen without 15° Setting Line“, page 64
⇒ “2.37.3 Headlamps, Adjusting“, page 65
⇒ “2.37.4 Fog Lamp Inside Headlamp“, page 65
⇒ “2.37.5 Fog Lamps in Bumper“, page 65

2.37.1 Checking and Adjusting Conditions

♦ Tire pressure OK
♦ Lenses must not be damaged or dirty.

62 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

♦ Reflectors and bulbs OK.

♦ Vehicle must be properly loaded.
Load: Vehicle must be loaded with one person on the driver's
seat, weighing 165 lbs (75 kg), otherwise vehicle must be empty
(curb weight).
The curb weight is the weight of the vehicle ready for operation
with completely filled fuel tank (at least 90%), including the weight
of all equipment items carried for operation (e.g. spare wheel,
tool, vehicle jack, fire extinguisher etc.).
If the fuel tank is not at least 90% full, adjust the weight as follows:
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
– Read fuelwith
level from fuel gauge. Calculate additional weight
respect to the correctness of information in this document. Copyright by AUDI AG.

needed using the following table. Place extra weight in lug‐

gage compartment.
Tank Filling Table
Fuel level ac‐ Front wheel drive All wheel drive
cording to fuel Additional weight in Additional weight in lbs
gauge lbs (kg) (kg)
1/4 121 (55) 132 (60)
1/2 77 (35) 88 (40)
3/4 44 (20) 44 (20)
Full 0 0
Example:
If tank is filled halfway on a front wheel drive vehicle, you must
place an additional 77 lbs (35 kg) of weight in the luggage com‐
partment.

Note

For additional weight use containers filled with water. A container

filled with 5 liters of water weighs approximately 11 lbs (5 kg).

Vehicle must be rolled for several meters or the front and rear
suspension must be bounced several times so that the springs
settle.
The parking brake must be released to avoid tension in suspen‐
sion.
♦ Vehicle and headlamp adjuster must be on a level surface.
Refer to operating instructions for headlamp adjuster.
♦ The vehicle must be aligned.
♦ The headlamp setting unit must be aligned.
Make sure the headlamp adjuster is about 30 cm in front of head‐
lamp.
♦ Inclination must be set.
Inclination measurements are stamped in “%“ at top of headlamp.
The headlamps must be adjusted according to these measure‐
ments. Percentage information is based on a projection distance
of 10 meters. For example, with an inclination measurement of
1.0% (on vehicles with headlamp range adjuster), this converts
to 10 cm.
Vehicles with manual headlamp range control:
♦ The headlamp range adjuster rotary knob must be in basic
setting -0-.

2. Maintenance Procedures 63
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Vehicles with automatic Headlamp Range Control:

Note

To check/adjust headlamps, they must always be placed in the

basic setting with the -VAS 5051- .

♦ Perform basic setting with the Vehicle Diagnosis, Testing and

Information System -VAS 5051- :
– Connect Vehicle Diagnosis, Testing and Information System
-VAS 5051- using the adapter cable -VAS 5051/5- with ignition
switched off.
– Switch the ignition on.
– Select “Guided Fault Finding“
Enter vehicle information; all control modules are interrogated.
– Press the following selections in the order shown:
♦ Go To
♦ Function and component selection
♦ Body
♦ Electrical Equipment
♦ 01 - On Board Diagnostic (OBD) capable systems
♦ 55-Dynamic Headlamp Range Control
♦ J 431-Dynamic Headlamp Range Control, Functions
♦ J 431-Headlamp Range Control Module, basic setting
♦ Press the → button
Follow the steps of the tester and confirm the entry until the fol‐
lowing text appears:
J 431-Headlamp Range Control Module, basic setting
♦ Press the → button
♦ Follow test sequence

2.37.2 Headlamps, Checking Adjustment with

new Test Screen without 15° Setting
Line
– Observe the following:
♦ With dipped beam switched on, horizontal light-dark border
must contact hyphenated line -1- of test surface
♦ Break-away point -2-unless
between leftbyhorizontal
AUDI AG. AUDIpart andnotrising
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permitted authorised AG does guarantee or accept any liability
part on right of light-dark
with respect toborder mustof run
the correctness vertically
information through
in this document. Copyright by AUDI AG.
central point -3-. Bright core of light beam must be right of ver‐
tical line

64 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Note

♦ To make it easier to find break-away point -2- cover and un‐

cover left half of headlamp (as viewed when looking forward)
a few times. Check the low beam one more time.
♦ After correct adjustment of dipped beams the center point of
the main beam must lie on the center mark -3-.
♦ For the previous test screens with 15 ° setting line, adjust for
new test screen. To avoid incorrect settings, ignore 15 ° setting
line.

2.37.3 Headlamps, Adjusting

Left headlamp
Left headlamp adjustment screws:
1 - Height adjustment screw
2 - Height/lateral adjustment screw
Placement
Protected on right
by copyright. Copyingheadlamp is similar.
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
–withTo adjust
respect to theheight, turn
correctness adjustment
of information screwsCopyright
in this document. -1- andby-2- with
AUDI AG. same
number of revolutions.
– To adjust laterally, turn only adjustment screw -2-.
Vehicles with automatic Headlamp Range Control:
– Perform function program J431 - headlamp range control
module, basic setting, to end.

2.37.4 Fog Lamp Inside Headlamp

Note

The adjustment of fog lamps is performed automatically when

adjusting headlamps.

2.37.5 Fog Lamps in Bumper

Inclination figures:
♦ Fog lights 20 cm

2. Maintenance Procedures 65
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Unclip retaining tabs -arrows- and remove cover on lower part

of bumper.
– To adjust the lamp range, turn the adjustment screw -arrow-.
Lateral adjustment is not possible.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2.38 Windshield Washer System, Filling Fluid with respect to the correctness of information in this document. Copyright by AUDI AG.

– Fill washer fluid fully.

Note

Always add a neutral pH window cleaner to washer fluid.

2.39 Windshield Wiper Blades, Checking

End Position and for Damage
Front Windshield Work Sequence
– Switch ignition on.
– Activate mist wipe and let windshield wiper arm travel to end
position.
– Switch ignition off and remove ignition key.
– Pry cover off the windshield wiper arm with a screwdriver.
– Loosen hex head nuts -arrows- a few turns.
– Loosen the windshield wiper arm by tilting the windshield wiper
axis slightly, remove the hex head nuts and remove the wind‐
shield wiper arm.
– Switch ignition on.
– Activate mist wipe and let windshield wiper motor travel to end
position.

Note

♦ Every second time it is switched off, the wiper motor runs to

an over-stroke parked position, that ensures that the lip of the
wiper blade is flipped to the other direction.
♦ To do this, windshield wiper motor runs down over end position
and then back up a bit. This under-stroke parked position must
not be used for aligning the windshield wiper lever.
♦ You must use the position where the windshield wiper motor
runs directly to end position without under-stroke. Activate
mist wipe again, if necessary.

– Turn the ignition off.

66 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Position the windshield wiper arm with the windshield wiper

blade attached on windshield wiper axle and adjust the wind‐
shield wiper arm on windshield as follows:
• Dimension -a- = 5 to 15 mm
• Dimension -b- = 30 to 40 mm.

Note

The dimensions give the distance of the wiper blade point to the
black cowl panel trim on the lower edge of the windshield.

– Tighten the windshield wiper arm nuts.

– Switch ignition on.
– Activate mist wipe and let windshield wiper arm travel to end
position.
– Turn the ignition off.
– Check the windshield wiper arm adjustment again, correct if
necessary.
Tightening Specifications
Component Nm
Windshield wiper arm nut 15
Rear window work sequence
– Let the windshield wiper motor run to the end position.
– Switch ignition off and remove ignition key.

– Carefully spread cover -arrows- and lift.

– Carefully remove the window cleaner spray nozzles -2-.

– Loosen hex head nuts -1- a few turns.
– Loosen the windshield wiper arm by tilting the windshield wiper
axis slightly.
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. Maintenance Procedures 67
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Place the windshield wiper blade on the rear window and ad‐
just as follows:
♦ Dimension -a- = 27 mm

Note

Dimension gives distance of wiper blade point to lower edge of

window.

– Tighten the windshield wiper arm nut to 12 Nm.

– Activate wiper.
– Adjust the windshield wiper arm again, if necessary, and tight‐
en nut.
– Checking spray nozzle adjustment. Refer to
⇒ “2.35 Windshield Washer System, Checking and Adjusting
Spray Nozzles“, page 60 .

2.40 Windshield Wiper Blades, Removing

and Installing
Removing
– Bring wiper into service position.
– Lift windshield wiper arm off of windshield.
– Press retaining clips together -arrow 1-.
– Slide the windshield wiper blade off the windshield wiper arm
-arrow 2-.
– Remove the windshield wiper blade.

Installing
Installation is reverse of removal, but note the following:
– Guide the windshield wiper blade -2- parallel onto the wind‐
shield wiper arm -1- -arrow-. Make sure the windshield wiper
arm sits completely in the guide.

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

2.41 Sunroof, Cleaning and Lubricating

with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

♦ Lint-free cloths
♦ Brush
♦ Shop vacuum i.e. Wet and dry vacuum cleaner
♦ Lubricant G 060 751 A2 for the guide rails.
♦ Krytox paste G 052 141 A2 for seals.
♦ Isopropyl alcohol for cleaning the seals.

68 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Note

Paint brush (approximately 15 mm wide) (bend approximately

40°).

Caution

Hold a cloth under the respective places to protect the vehicle

interior from getting dirty.

Clean and Lubricate Glass Cover Seal

– Install the glass sunroof panel.

Note

For opened glass sunroof panel, first coat the front and then install
the rear.

– Remove grease and remaining dirt from the glass sunroof

panel -arrow- with isopropyl alcohol and a lint-free cloth.
– Apply a thin layer of Krytox paste as far as possible on the
glass sunroof panel -arrow- with a commercially available
paint brush.
• After applying, make sure that there is no visible white grease
film remaining.
– Wipe away any excess Krytox paste from the seal with a lint-
free cloth.
Clean and Lubricate Guide Rail
– Open the glass sunroof panel entirely.
– Remove the grease and remaining dirt on the guide rail with a
lint-free cloth. (If necessary, remove sand and fine pollen from
the guide rails with a shop vacuum).

– Apply G 060 751byA2

Protected grease
copyright. on for
Copying the inside
private of the purposes,
or commercial guide rail
in part or in whole, is not
-arrow- with a commercially
permitted unless authorisedavailable paintAGbrush.
by AUDI AG. AUDI does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Maintenance Procedures 69
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Apply G 060 751 A2 grease on the outside of the guide rail

-arrow- with a commercially available paint brush.

– Apply G 060 751 A2 grease on the side of the guide rails for
the sliding headliner -arrow- with a commercially available
paint brush.
– Remove the excess lubricant from the guide rails with a lint-
free cloth.
– Repeat the process for the opening on the opposite side of the
vehicle.

2.42 Snow Screen, Cleaning

– Remove air filter intake duct.
– Remove snow screen -1- and clean with compressed air.
– Remove stubborn dirt with a blunt object.

Note

Replace snow screen if damaged.

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.

70 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.43 Service Display, Resetting or Adapting

⇒ “2.43.1 Service Interval Display, Through MY 2008, Resetting“,
page 71
⇒ “2.43.2 Service Interval Display, From MY 2009, Resetting“,
page 71
⇒ “2.43.3 Oil Quality, Adapting“, page 72
⇒ “2.43.4 Maximum Values, Adapting“, page 72
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2.43.1 Service Interval Display, Through MY
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.
2008, Resetting
– Follow these steps in sequential order.
♦ Connect Vehicle Diagnosis Tester
♦ Guided Fault Finding or Guided Functions
♦ Go to - function/component selection
♦ Service Work
♦ Combination Processor, reset WIV
♦ Now follow guided program

Note

♦ Please follow guided program function description

♦ WIV = Wartungsintervall - Verlängerung (Maintenance Inter‐
val Extension)

2.43.2 Service Interval Display, From MY 2009,

Resetting

Note

From MY 2009, all vehicles are equipped with the new mainte‐
nance concept as in the A5

– Follow these steps in sequential order.

2. Maintenance Procedures 71
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

♦ Connect Vehicle Diagnosis Tester

♦ Guided Functions
♦ Service Work
♦ Now follow guided program

2.43.3 Oil Quality, Adapting

– Follow these steps in sequential order.
♦ Connect Vehicle Diagnosis Tester
♦ Guided Fault Finding or Guided Functions
♦ Go to - function/component selection
♦ Service Work
♦ Combination Processor, changing oil quality
♦ Now follow guided program

Note

♦ It is necessary to change oil quality if changed between in‐

spection or Audi Long Life Service.
♦ Inspection Service = Oil quality 1
♦ WIV = Wartungsintervall - Verlängerung (Maintenance Inter‐
val Extension)
♦ Please follow guided program function description

2.43.4 Maximum Values, Adapting

– Follow these steps in sequential order.
♦ Connect VAS 5051/5052
♦ Guided Fault Finding orbyGuided
Protected copyright. Functions
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
♦ Go to - function/component
with respect toselection
the correctness of information in this document. Copyright by AUDI AG.

♦ Service Work
♦ Combination Processor, adjusting maximum WIV value
♦ Now follow guided program
Maximum Values at Inspection Service
Minimum mileage in miles (Km) 10,000
miles
(15000 Km)

72 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Maximum mileage in miles (Km) 10,000

miles
(15000 Km)
Maximum time interval in days 365

Note

♦ WIV = Wartungsintervall - Verlängerung (Maintenance Inter‐

val Extension)
♦ Please follow guided program function description

2.44 Language, Selecting

– Switch on MMI.
– Follow these menu steps in sequential order.
♦ Car
♦ Setup
♦ Settings
♦ Menu language
– Now select proper language with rotary button.

2.45 Dust and Pollen Filter, Removing and

Installing

Note

♦ The dust and pollen filter consists of two identically construc‐

ted filter elements. When installing, observe correct installa‐
tion position (filter flow-through direction is indicated with
arrows).
♦ Clean plenum chamber after replacing dust and pollen filter.
Pay special attention to area under air intake unit.
♦ Clean the dust and pollen filter installation duct in the air con‐
ditioner before installing the new filter.

♦ There are different versions of the Protected

dust and pollenCopying
by copyright. filter and
for private or commercial purposes, in part or in whole, is not
both filters have different air resistance. Use the correct ver‐
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.
sion. The control curve for controlling Fresh Air Fan -V2- in the
operating and display unit, the Climatronic Control Module -
J255- , is adapted accordingly.
– The filter insert without active charcoal insert (AKF filter insert)
is installed on vehicles with an operating and display unit, Cli‐
matronic Control Module -J255- “base“ version. Refer to Elec‐
tronic Parts Catalog. No Air Quality Sensors -G238- are
installed in these vehicles.
– The filter insert with active charcoal insert (AKF filter insert) is
installed on vehicles with an operating and display unit, Cli‐
matronic Control Module -J255- “comfort“ version. Refer to
Electronic Parts Catalog. Air Quality Sensors -G238- are in‐
stalled in these vehicles.

2. Maintenance Procedures 73
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Removing

Note

♦ Depending on vehicle equipment, it may be necessary on cer‐

tain versions (with certain special features, such as taxis or
police cars) to remove the glove compartment (eventually,
certain other additional control modules installed in this area
will have to be removed.
♦ On vehicles with right side steering, the dust and pollen filter
must be removed towards the left from the air conditioning unit,
in contrast to vehicles with left side steering. However, the rest
of the work procedure is the same.

– Remove lid -A- from lower glove compartment cover -B-.

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
Note with respect to the correctness of information in this document. Copyright by AUDI AG.

The lid -A- is held by 4 latches on bottom glove compartment

cover -B-. These latches may be difficult to release. Therefore, be
careful that you do not damage the bottom glove compartment
cover -B- when removing.

– Cover the floor covering in area under air conditioning unit duct
for dust and pollen filter with paper.

– Loosen catches -B- and remove dust and pollen filter cover
-A- from air conditioning unit.

– Remove first part of dust and pollen filter -A- from air condi‐
tioning unit.

Note

Two identically constructed filter inserts are installed one on top

of the other in the air conditioning unit.

– Grasp inside air conditioning unit duct -C- and pull second part
of dust and pollen filter -B- (at tab) down and then out of duct.
Installing

74 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Clean air conditioning unit installation duct -C- for dust and
pollen filter of leaves, dust and other contaminants with a com‐
mercially available vacuum and the Suction Nozzle with Brush
-VAS 6288.- .

Note

Dust and other contaminants can adhere to the air conditioning

unit. A brush is attached to the Suction Nozzle -VAS 6288.- to
remove these contaminants.

– Place first part -B- of dust and pollen filter in air conditioning
unit duct -C- and slide into upper installation position. Observe
flow-through direction (arrows on filter -D- point to evaporator).
– Hold the first installed part of the dust and pollen filter -B- in
upper installation position if necessary, for example, with a
steel ruler.
– slide second part of dust and pollen filter -A- (under first part
installed -B-) in air conditioning unit duct. Observe flow-
through direction (arrows on filter -D- point to evaporator).

– Check seal position -C- in groove -D-.

– Install cover -A-. Make sure the proper seating in mount -E-
and latch -B-.
– Install the rest of the parts removed in reverse order of remov‐
al.

2.46 Transport Protection, Removing Front

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

and Rear Shock Absorber Protectors

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.

Front Axle Shock Absorber Protectors

– Release front axle (for example, put vehicle on lift)
– Remove protection devices -A-.

Note

♦ It is not necessary to remove the wheels

♦ Remove tag on rearview mirror

Rear Axle Shock Absorber Protectors

– Release rear axle (for example, put vehicle on lift)

2. Maintenance Procedures 75
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove protection devices -1-.

Note

♦ It is not necessary to remove the wheels

♦ Remove tag on rearview mirror

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.

2.47 Door Arrester, Hinge, Hood Safety

Catches and Lock Cylinder, Lubricating
– Perform the following steps in the given sequence:

Note

♦ Vehicle must be at least at room temperature.

♦ Operate the moveable components several times to allow the
universal oil or spray lubricant to seep in.
♦ Remove any excess lubricant with a lint-free cloth.

Door Arrester
– Remove the protective cap -1- in the direction of the arrow.
– Lubricate the door arrester on the marked positions -arrows-.
• Use universal oil spray G 000 115 A2.

Door Hinge
– Lubricate the door hinge on the marked positions -arrows-.
• Use universal oil spray G 000 115 A2.

Hood Safety Catch

– Lubricate the hood safety catch on the marked positions
-arrows-.
• Use universal oil spray G 000 115 A2.
Lock Cylinder
– Lubricate the lock cylinder.
• Use spray lubricant G 052 778 A2.

76 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.48 Underbody, Inspecting for Damage

– When performing visual inspection, check for damage to un‐
derbody, wheel housings and rocker panels.
– Check for loose wires and securing pieces.

WARNING

Eliminate any malfunctions (repair procedure).

2.49 Transport Mode, Deactivating

Note

♦ Car body may lower.

♦ Air suspension transport mode is for loading vehicles, for ex‐
ample (on train, ship, truck, airplane, etc.).

Switch off the transportation mode using Guided Fault Finding or

Guided Functions.
– Follow these steps in sequential order.
♦ Connect Veicle Diagnosis Tester
♦ Guided Fault Finding or Guided Functions
♦ Go to - function/component selection
♦ Service Work
♦ Activate or deactivate air suspension transport mode
♦ Now follow guided program

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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.

2.50 Plenum Chamber Cover, Removing

– Remove plenum chamber cover gasket -1-.
– Remove plenum chamber cover -2- and -3-.

2. Maintenance Procedures 77
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

2.51 Plenum Chamber Water Drain, Check‐

ing and Cleaning
♦ Inspect plenum chamber for contaminants, for example,
leaves.
♦ If there are contaminants: remove the plenum chamber cover
and clean out the water drain and the plenum chamber.

2.52 Factory-Equipped Winter Tires

Note

♦ On vehicles that were delivered from factory with winter tires,

check for correct pressure during delivery inspection.
♦ The excessive speed warning sticker should be placed in driv‐
er field of vision.

2.53 Clock, Setting

Note

See MMI owner's manual

2.54 Spark Plugs, Removing and Installing

⇒ “2.54.1 General Information“, page 78
⇒ “2.54.2 V6 TFSI Gasoline “, page 79
⇒ “2.54.3 V8 and V6“, page 81
⇒ “2.54.4 V10 FSI, Gasoline“, page 82
⇒ “2.54.5 V10 TFSI Gasoline, RS 6, Cylinders 1 through 5“, page
85
⇒ “2.54.6 V10 TFSI Gasoline, RS 6, Cylinders 6 through 9“, page
86
⇒ “2.54.7 V10 TFSI Gasoline, RS 6, Cylinder 10“, page 87

2.54.1 General Information

Special tools and workshop equipment required
♦ Spark plug wrench -3122B-
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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.

78 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

♦ Ignition coil puller -T40039-

WARNING

Place Ignition coil puller -T40039- on top rib -arrow- of ignition

coil and pull this from spark plug. Placing on bottom rib can
cause damage.

Note

♦ Plug designation, refer to ⇒ Fuel Injection and Ignition; Rep.

Gr. 28 ; Specifications
♦ Follow all waste disposal regulations!

2.54.2 V6 TFSI Gasoline

Removing
– Remove the engine covers -1- and -2-.

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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. Maintenance Procedures 79
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove the screws -arrows- and remove the air ducts -1- and
-2-.

– Free up the fuel line -4- and the line -1- from the EVAP canister
on the air filter housing and air duct pipe.
– Remove the vacuum hose -2- from the connection on the air
duct hose.
– Remove the air duct pipe by loosening the hose clamp -3- and
opening the clamps -arrows-.

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.

– Remove the screws -arrows- and disconnect the connectors

on the ignition coils.
– Move the wiring harness slightly down.

Note

Ignore -1 and 2-.

Left Cylinder Bank 2

– Remove the screw -arrow-.
– Disconnect the connector for the Engine Coolant Level (ECL)
Warning Switch -F66- on the bottom of the coolant reservoir
and move the reservoir with the coolant hoses still connected
-1- and -2- to the side.

80 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove the screws -arrows- and disconnect the connectors

on the ignition coils.
– Move the wiring harness slightly down.

Note

Ignore -1, 2 and 3-.

Continuation for Both Sides:

– Remove the ignition coils using the Ignition coil puller -
T40039- .
– Remove spark plugs with spark plug wrench -3122B- .
– Install new spark plugs.
Installing
Installation is the reverse of removal.
Tightening Specifications Nm
Spark plugs in cylinder head 30
Connector screws 5

2.54.3 V8 and V6
– Turn the ignition off.
Right Cylinder Bank
– Remove air filter. Refer to
⇒ “2.25 Air Filter, Clean Air Filter Housing and Replace Filter“,
page 39
– Remove both bolts -1-.
– Push connector -2- toward ignition coil, press on catch with
hand and remove connector.
– Remove ignition coils -3- from spark plugs with ignition coil
puller -T40039- .
– Remove spark plugs with spark plug wrench -3122B- .
– Install new spark plugs.

Note

Push ignition coils by hand into intended resources in cylinder

head cover.
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Left Cylinder Bank 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.
– Remove the coolant reservoir and lay it aside.

2. Maintenance Procedures 81
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove both bolts -1-.

– Push connector -2- toward ignition coil, press on catch with
hand and remove connector.
– Remove ignition coils -3- from spark plugs with ignition coil
puller -T40039- .
– Remove spark plugs with spark plug wrench -3122B- .
– Install new spark plugs.
Tightening Specifications Nm
Spark plugs in cylinder head 30

Note

Push ignition coils by hand into intended resources in cylinder

head cover.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

2.54.4 V10 FSI, Gasoline

with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

♦ Ignition coil puller -T40039-

– Remove rear engine cover -2-.

Right Cylinder Bank 1

82 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove bolts -arrows- and remove left air duct.

– Open hose clamps -arrows- and remove right air guide hose.
– Disconnect electrical connector -1- on Engine Coolant Level
(ECL) Warning Switch -F66- at bottom of coolant reservoir.

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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.

– Remove bolts -2- and -3- and lay aside coolant reservoir with
connected coolant hoses -4- and -5-.

– Remove the screws -1- and -2-.

2. Maintenance Procedures 83
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Pull ignition coils about 30 mm out of spark plug shaft with

ignition coil puller -T40039- .
– Release electrical connectors and remove them evenly from
ignition coils.
– Remove spark plugs using spark plug wrench -3122B- .
– Install new spark plugs.
Left Cylinder Bank 2

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove bolts -arrows- and remove left air duct. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Open hose clamps -arrows- and remove left air guide hose.

– Remove the screws -1- and -3-.

84 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Pull ignition coils about 30 mm out of spark plug shaft with

ignition coil puller -T40039- .
– Release electrical connectors and remove them evenly from
ignition coils.
– Remove spark plugs using spark plug wrench -3122B- .
– Install new spark plugs.
Installing Ignition Coils
– Loosely place all ignition coils in spark plug shaft.
– Align ignition coils to connectors and place all connectors
evenly on ignition coils.
– Press ignition coils evenly by hand onto spark plugs (do not
use a hammer).
Tightening Specifications
Component Nm
Electrical wiring guide for ignition coils to cylin‐ 5
der head cover
Spark plugs in cylinder head 30

2.54.5 V10 TFSI Gasoline, RS 6, Cylinders 1

through 5
Special tools and workshop equipment required
♦ Ignition coil puller -T40039-

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Removing 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.
Proceed as follows:
– Remove the right air filter housing. Refer to
⇒ “2.25.5 10-Cylinder Gasoline Engines, RS 6 Turbo“,
page 44
– Remove the air guide hose -1- by pressing the release buttons.
– Remove the screws -arrows-.
– Remove the pressure regulator valve for the crankcase venti‐
lation from the air guide hose -2-.

2. Maintenance Procedures 85
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove the screws -1- and -2-.

– Disconnect the connectors on the ignition coils -arrows- and
on the Camshaft Position (CMP) Sensor 2 -G163- -item 3-.
– Move the wiring harness to the side.

– Remove the ignition coils using the ignition coil puller -

T40039- .
Installing
Installation is reverse of removal, but note the following:
– Install the right air filter housing. Refer to
⇒ “2.25.5 10-Cylinder Gasoline Engines, RS 6 Turbo“,
page 44 .

Note

Replace the seals and o-rings.

Tightening Specifications:
Component Nm
Electrical wiring guide for ignition coils to cylin‐ 5
der head cover
Spark plugs in cylinder head 30

2.54.6 V10 TFSI Gasoline, RS 6, Cylinders 6

through 9
Special tools and workshop equipment required
♦ Ignition coil puller

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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.

86 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

Removing
Proceed as follows:
– Remove the left air filter housing. Refer to
⇒ “2.25.5 10-Cylinder Gasoline Engines, RS 6 Turbo“,
page 44 .
– Remove the screws -2- and -3-.
– Disconnect the connectors on the ignition coils -arrows- and
on the Camshaft Position (CMP) Sensor 4 -G301- -item 1-.
– Move the wiring harness to the side.

– Remove the ignition coils using the ignition coil puller -

T40039- .
Installing
Installation is reverse of removal, but note the following:
– Install the left air filter housing. Refer to
⇒ “2.25.5 10-Cylinder Gasoline Engines, RS 6 Turbo“,
page 44 .

Note

Replace the seals and o-rings.

Tightening Specifications:
Component Nm
Electrical wiring guide for ignition coils to cylin‐ 5
der head cover
Spark plugs in cylinder head 30

2.54.7 V10 TFSI Gasoline, RS 6, Cylinder 10

Special tools and workshop equipment required
♦ Engine support bridge -10 - 222 A-

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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. Maintenance Procedures 87
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

♦ Ignition coil puller -T40039-

♦ Engine Support Supplement Set -T40093-

Removing
Proceed as follows:

Caution

Danger of destroying electronic components.

♦ Follow the instructions for disconnecting the battery.

– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Removal and Installation .
– Remove the left and right air filter housing. Refer to
⇒ “2.25.5 10-Cylinder Gasoline Engines, RS 6 Turbo“,
page 44 .
– Remove the crankcase ventilation hose -1- by pressing the
release buttons.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note with respect to the correctness of information in this document. Copyright by AUDI AG.

Do not pay attention to -2-.

88 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove the seal -1- and the plenum chamber cover -2-.

– Remove the spacer -1-.

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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.

– Release and open the strap for the wire guide -arrow-.
– Open the cover over the positive terminal -arrow-.
– Remove the nut on the positive terminal -1- “+“ and free up the
cable.

– Remove the negative terminal “–“ -2- and free up the cable.
– Remove the nut -arrow- and move the coolant reservoir with
the coolant hoses still connected -1 through 4- to the side.

2. Maintenance Procedures 89
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove the Evaporative Emission (EVAP) Canister Purge

Regulator Valve -N80- -2- from the bracket and push it to the
side with the wire and vacuum hose still connected -1-.

– Mount the adapter -10 - 222 A /4- and the connections -

T40093/1- and -T40093/2- onto the left and right suspension
strut towers as illustrated.

Note

The connections are identified for the left and right side of the
vehicle.

– Attach the hooks -10 - 222 A /10- to the engine lift eyes.

– Remove the noise insulation -1- and -2-. Refer to

⇒ “2.16 Noise Insulation, Removing“, page 32 .
– Remove the left by
Protected and rightCopying
copyright. nuts for
-1-.
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.

Note

Do not pay attention to -item 2- and -arrows-.

90 Rep. Gr.03 - Maintenance, Diagnosis

 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove the screws -2- and -3-.

– Disconnect the connectors on the ignition coils -arrows- and
on the Camshaft Position (CMP) Sensor 4 -G301- -item 1-.
– Move the wiring harness to the side.

– Disconnect the connector -arrow- on cylinder 10 ignition coil.

– Remove the air guide hose -1-.

– Lift the engine with the spindle to dimension -a-.

• Dimension -a- = 25 mm.

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. Maintenance Procedures 91
 Audi A6 2005 ➤
Maintenance Procedures - Edition 10.2011

– Remove the ignition coil using the Ignition coil puller -T40039- .
Installing
Component Nm
Electrical wiring guide for ignition coils to cylin‐ 5
der head cover
Spark plugs in cylinder head 30
Positive terminal nut “+“ 20
Negative terminal 9 +/- 1
Nut engine mount 40
Installation is reverse of removal, but note the following:

Note

♦ Replace the seals and o-rings.

♦ Always replace self-locking nuts.

– Install the left engine mount. Refer to ⇒ Engine Mechanical;

Rep. Gr. 10 ; Removal and Installation .
– Install the left and right air filter housing. Refer to
⇒ “2.25.5 10-Cylinder Gasoline Engines, RS 6 Turbo“,
page 44 .
– Note the instructions after connecting the batter. Refer to ⇒
Electrical Equipment; Rep. Gr. 27 ; Removal and Installation .

Edition 11142011JY

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.

92 Rep. Gr.03 - Maintenance, Diagnosis

 Cautions & Warnings

Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.

•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in
this manual, we suggest you leave such repairs to an authorized Audi retailer or other qualified
shop. We especially urge you to consult an authorized Audi retailer before beginning repairs on
any vehicle that may still be covered wholly or in part by any of the extensive warranties issued by
Audi.

•= Disconnect the battery negative terminal (ground strap)whenever you work on the fuel system or
the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved
fire extinguisher handy.

•= Audi is constantly improving its vehicles and sometimes these changes, both in parts and
specifications, are made applicable to earlier models. Therefore, part numbers listed in this
manual are for reference only. Always check with your authorized Audi retailer parts department
for the latest information.

•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be
necessary to reestablish Transmission Control Module (TCM) basic settings using the VAG 1551
Scan Tool (ST).

•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose.
Do not support a vehicle on cinder blocks, hollow tiles or other props that may crumble under
continuous load. Never work under a vehicle that is supported solely by a jack. Never work under
the vehicle while the engine is running.

•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before
disconnecting the battery or removing the radio. If the wrong code is entered when the power is
restored, the
Protected radio may
by copyright. lock
Copying up and
for private becomepurposes,
or commercial inoperable,
in part oreven if isthe
in whole, not correct code is used in a later
attempt.
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.

•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block
the wheels to keep the vehicle from rolling. Disconnect the battery negative terminal (ground
strap) to prevent others from starting the vehicle while you are under it.

•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to
yourself and others if you are tired, upset or have taken medicine or any other substances that
may impair you or keep you from being fully alert.

•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.

•= Always observe good workshop practices. Wear goggles when you operate machine tools or work
with acid. Wear goggles, gloves and other protective clothing whenever the job requires working
with harmful substances.

•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when
you work near machine tools or running engines. If your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.

=Page 1 of 3
© 2002 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual
property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be
modified or reposted to other sites, without the prior expressed written permission of the publisher.
Version 1.0
 Cautions & Warnings
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are
designed to be used only once and are unreliable and may fail if used a second time. This
includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the
recommendations in this manual - replace these fasteners with new parts where indicated, and
any other time it is deemed necessary by inspection.

•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or
under the vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.

•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create
dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and
asbestos dust. Breathing asbestos can cause serious diseases such as asbestosis or cancer, and
may result in death.

•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running
machinery, or be crushed by heavy parts.

•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read
all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate to the work
and use only replacement parts meeting Audi specifications. Makeshift tools, parts and
procedures will not make good repairs.

•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage
containers that might mislead someone into drinking from them. Store flammable fluids away from
fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn
spontaneously.

•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these
tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque listed.

•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping
hydrogen gas is ignited, it will ignite gas trapped in the cells and cause the battery to explode.

•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper
way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or
lake. Consult local ordinances that govern the disposal of wastes.

•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C
system should be serviced only by trained automotive service technicians using approved
refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with
regulations governing the discharging and disposal ofbyautomotive
Protected chemical
copyright. Copying for private refrigerants.
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.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect
the battery negative terminal (ground strap) and the ABS control module connector.

•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive
heat will increase system pressure and may cause the system to burst.

=Page 2 of 3
© 2002 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual
property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be
modified or reposted to other sites, without the prior expressed written permission of the publisher.
Version 1.0
 Cautions & Warnings
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the
Transmission Control Module (TCM), the ABS control module, and the trip computer. In cases
where one or more of these components is not separately fused, disconnect the control module
connector(s).

•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system
(SRS), that automatically deploys an airbag in the event of a frontal impact. The airbag is operated
by an explosive device. Handled improperly or without adequate safeguards, it can be accidentally
activated and cause serious personal injury. To guard against personal injury or airbag system
failure, only trained Audi Service technicians should test, disassemble or service the airbag
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
system. 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.
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed
16.5 volts at the battery with the boosting cables attached. Wait at least one minute before
boosting the battery a second time.

•= Never use a test light to conduct electrical tests of the airbag system. The system must only be
tested by trained Audi Service technicians using the VAG 1551 Scan Tool (ST) or an approved
equivalent. The airbag unit must never be electrically tested while it is not installed in the vehicle.

•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that
may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of
ignition away from the tire repair area. Inflate and deflate the tire at least four times before
breaking the bead from the rim. Completely remove the tire from the rim before attempting any
repair.

•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or
lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of
injury in an accident.

I have read and I understand these Cautions and Warnings.

=Page 3 of 3
© 2002 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual
property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be
modified or reposted to other sites, without the prior expressed written permission of the publisher.
Version 1.0