Audi Q7

Service
Workshop Manual
Audi Q7 2007 ➤
6-cylinder direct injection engine with supercharger
(3.0 ltr. 4-valve TFSI), mechanics
CJTB CJTC CNA
Engine ID
CJW CJW CJW CTW CTW
A B C E A B
Edition 01.2016
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 Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
26 - Exhaust system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 Audi AG, Ingolstadt D3E8028E5C0

Audi Q7 2007 ➤
6-cylinder direct injection engine with supercharger (3.0 ltr. 4-valve TFSI), mechanics - Edition 01.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 3
3.4 Safety precautions when using testers and measuring instruments during a road test . . . . 4
3.5 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.6 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger/
supercharger . . . . . permitted
. . . . . .unless
. . . authorised
. . . . . . by. .AUDI
. . .AG.
. . AUDI
. . . AG
. . does
. . . not
. .guarantee
. . . . . .or.accept
. . . .any
. .liability
.......... 6
4.2 Checking fuel system for withleaks

respect to.the
. .correctness
. . . . . . of. information
. . . . . . in. .this
. .document.
. . . . . .Copyright
. . . . .by. AUDI
. . . AG.
........... 6
4.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Contact corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.6 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.7 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Removing and installing engine cross member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.1 Exploded view - poly V-belt drive for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.2 Removing and installing poly V-belt for supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.3 Removing and installing poly V-belt tensioner for supercharger . . . . . . . . . . . . . . . . . . . . 51
1.4 Exploded view - poly V-belt drive for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.5 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.6 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.7 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.8 Renewing sealing flange (pulley end) with crankshaft oil seal . . . . . . . . . . . . . . . . . . . . . . 58
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Exploded view - drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.4 Checking sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.5 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contents i
Audi Q7 2007 ➤
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.3 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Exploded view - timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.2 Removing and installing timing chain covers (left and right) . . . . . . . . . . . . . . . . . . . . . . . . 82
1.3 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.4 Exploded view - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Removing timing chains from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.6 Removing and installing camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.7 Exploded view - drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.9 Exploded view - drive chain for auxiliary drives . . . .to.the
with respect . .correctness
. . . . . . of. .information
. . . . . .in.this
. .document.
. . . . . .Copyright
. . . . 109
by AUDI AG.
1.10 Removing and installing drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.11 Exploded view - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.12 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.2 Removing and installing cylinder head cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.3 Removing and installing cylinder head cover (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.4 Removing and installing cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.2 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.5 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.6 Renewing valve stem oil seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . 145
3.7 Renewing valve stem oil seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . 148
3.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.9 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.10 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1 Sump (bottom section), sump (top section), oil pump, engine oil cooler . . . . . . . . . . . . . . 154
1.1 Exploded view - sump (bottom section), sump (top section), oil pump, engine oil cooler . . 154
1.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.3 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 158
1.4 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.6 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2 Oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.1 Exploded view - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.3 Checking oil pressure switch F22 / oil pressure switch for reduced oil pressure F378 . . . . 169
2.4 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.5 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 170
2.6 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 171
2.7 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3 Oil separator, crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
ii Contents
Audi Q7 2007 ➤
3.1 Exploded view - oil separator, crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . 173

3.2 Removing and installing crankcase breather hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.3 Removing and installing cover with oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.4 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.5 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2 Coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.1 Exploded view - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.3 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3 Coolant pipes and continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . 192
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.2 Fitting coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.3 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 196
3.4 Removing and installing coolant pipe (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.5 Removing and installing coolant pipes (front left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.6 Removing and installing coolant pipes (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3.7 Removing and installing coolant pipes (rear left) on gearbox . . . . . . . . . . . . . . . . . . . . . . 202
3.8 Removing and installing coolant pipe (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.9 Removing and installing coolant pipe (right-side) on gearbox . . . . . . . . . . . . . . . . . . . . . . 205
3.10 Removing and installing coolant pipes on supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.11 Removing and installing charge air cooling pump V188 . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.12 Exploded view - continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.13 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 212
4 Radiator, radiator cowl and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.1 Exploded view - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.3 by copyright.
Protected ExplodedCopyingview- water
for private radiator
or commercial for charge
purposes, airwhole,
in part or in cooling
is not circuit . . . . . . . . . . . . . . . . . . . . . . . . 219
4.4respect Removing
with and
to the correctness installing
of information water
in this radiator
document. Copyrightfor charge
by AUDI AG. air cooling circuit . . . . . . . . . . . . . . . . . . 220
4.5 Exploded view - radiator cowl and radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.6 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.7 Removing and installing radiator fans V7 / V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1 Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.1 Connection diagram - vacuum lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.2 Exploded view - supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
1.3 Removing and installing charge pressure sender G31 / G447 . . . . . . . . . . . . . . . . . . . . . . 228
1.4 Removing and installing supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.5 Exploded view - charge air coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
1.6 Securing supercharger to engine and gearbox support for assembly work . . . . . . . . . . . . 236
1.7 Securing supercharger to engine and gearbox support for leak test . . . . . . . . . . . . . . . . . . 237
1.8 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.9 Exploded view - drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
1.10 Removing and installing drive unit and damper spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.11 Checking supercharger for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

1 Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.1 Exploded view - silencers, catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Contents iii
Audi Q7 2007 ➤
1.2 Removing and installing catalytic converter (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

1.3 Removing and installing catalytic converter (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
1.4 Removing and installing front silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.5 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.6 Renewing tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.7 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.8 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2 Exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
2.2 Removing and installing exhaust manifold (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.3 Removing and installing exhaust manifold (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.1 Exploded view - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3.2 Checking combination valves for secondary air system for correct operation and leakage
........................................................................ 265
3.3 Removing and installing
Protected by copyright. combination
Copying for private or commercialvalve forin part
purposes, secondary air
or in whole, is notsystem (left-side) . . . . . . . . 267
3.4 Removing and installing combination valve for secondary air system (right-side) . . . . . . . .
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 268
3.5 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 269
3.6 Removing and installing sender 1 for secondary air pressure G609 . . . . . . . . . . . . . . . . . . 270
iv Contents
Audi Q7 2007 ➤
00 – Technical data
1 Engine number
(ARL004580; Edition 01.2016)
Note
Pull off engine cover panels to make the engine number visible.
♦ The engine number (“engine code” and “serial number”) can

be found on top of the cylinder block at the front -arrow-.
♦ Starting with the letter “C”, the engine codes consist of 4 let‐
ters.
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
arepermitted
stamped unlesson the cylinder block, together with the serial
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
number.
♦ The 4th character indicates the power output and torque of the
engine, and is determined by the engine control unit.
Note
♦ The 4-character engine code can be found on the type plate

(in versions for some countries only) and on the vehicle data
sticker and the engine control unit.
♦ Fitting locations of the type plate (certain countries only) and
the vehicle data sticker ⇒ Maintenance ; Booklet 406 .
1. Engine number 1
Audi Q7 2007 ➤
2 Engine data
For engine data refer to ⇒ Technical data for engines; Rep. gr.
00 ; Overview of engines .
2 Rep. gr.00 - Technical data

Audi Q7 2007 ➤
3 Safety precautions
⇒ “3.1 Safety precautions when working on the fuel supply sys‐
tem”, page 3
⇒ “3.2 Safety precautions when working on the cooling system”,
page 3
⇒ “3.3 Safety precautions when working on vehicles with start/
stop system”, page 3
⇒ “3.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
⇒ “3.5 Safety precautions when working on the exhaust system”,
page 4
⇒ “3.6 Safety precautions when working on the ignition system”,
page 4
3.1 Safety precautions when working on the fuel supply system

Risk of injury - fuel system operates under high pressure
The fuel system is pressurised. There is a risk of injury as fuel
may spray out.
Before opening the fuel system:
– Put on safety goggles.
– Put on protective gloves.
– Release pressure (wrap clean cloth around connection and
open connection carefully).
Risk of fire due to escaping fuel
If the battery is connected, the door contact switch activates the
fuel pump when the driver's door is opened. Escaping fuel may
ignite, causing a fire.
– Before opening the fuel system, disconnect power supply to
fuel pump.
3.2 Safety precautions when working on the cooling system

Risk of scalding as hot coolant can escape
The cooling system is under pressure when the engine is hot. Hot
steam/hot coolant can escape - risk of scalding.
– Put on protective gloves.
– Put on safety goggles.
– Release pressure (cover filler cap on coolant expansion tank
with a cloth and open carefully).
3.3 Safety precautions when working on vehicles with start/stop system

Risk of injury - engine may start unexpectedly
3. Safety precautions 3
Audi Q7 2007 ➤
On vehicles with the start/stop system activated, the engine may

start unexpectedly. If the start/stop system is activated, this is in‐
dicated by a message on the dash panel insert.
– Deactivate start/stop system by switching off ignition.
3.4 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapult‐
ed through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or
– Have a second mechanic operate test equipment on the rear
seat.
3.5 Safety precautions when working on the

exhaust system
Caution
Risk of damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.
3.6 Safety precautions when working on the ignition system

Risk of injury caused by electric shock
When the engine is running, there are high voltage levels in the
ignition system. There is a risk of electric shock when touching
the ignition system!
– Never touch or disconnect ignition wiring when the engine is
running or being turned at cranking speed.
Risk of damage to components

Washing the engine or connecting/disconnecting electrical wiring
may result in components being damaged if the engine is running.
– Switch off ignition before connecting/disconnecting electrical
wiring.
– Switch off ignition before cleaning engine.

Audi Q7 2007 ➤
3. Safety precautions 5
Audi Q7 2007 ➤
4 General repair instructions

⇒ “4.1 Rules for cleanliness when working on fuel supply system,
injection system and turbocharger/supercharger”, page 6
⇒ “4.2 Checking fuel system for leaks”, page 6
⇒ “4.3 Foreign particles in engine”, page 6
⇒ “4.4 Contact corrosion!”, page 7
⇒ “4.5 Routing and attachment of pipes, hoses and wiring”, page
7
⇒ “4.6 Installing radiators and condensers”, page 7
⇒ “4.7 Checking vacuum system”, page 7
4.1 Rules for cleanliness when working on

fuel supply system, injection system and
turbocharger/supercharger
Even small amounts of dirt can
Protected by copyright. Copyingcause malfunctions.
for private For this
or commercial purposes, rea‐
in part or in whole, is not
son, please observe theauthorised
permitted unless following rules
by AUDI AG.when
AUDI AGworking on theorfuel
does not guarantee accept any liability
supply system,withinjection system and turbocharger/supercharger:
respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Carefully clean connection points and the surrounding area

with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections immediately with
clean plugs, e.g. from engine bung set - VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have not been stored in their packing (e.g. in tool boxes
etc.).
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately. Re‐
new fuel hoses if damaged.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
4.2 Checking fuel system for leaks

– Allow engine to run for several minutes at moderate rpm.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section of fuel system again for
leaks.
4.3 Foreign particles in engine

Audi Q7 2007 ➤
♦ When working on the engine, all open inlet and exhaust ports
must be sealed with suitable plugs (e.g. from engine bung set
- VAS 6122- ) to prevent foreign particles from entering the
engine.
♦ In the event of mechanical damage to one of the cylinder
banks, the intake and exhaust systems and combustion cham‐
bers of the opposite cylinder bank must always be examined
for foreign particles to prevent further damage occurring later.
4.4 Contact corrosion!

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.
4.5 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activat‐
ed charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.
♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐
cient clearance from all moving or hot components in engine
compartment (little space in engine compartment).
4.6 Installing radiators and condensers

Even when the radiator and condenser are correctly installed,
slight impressions may be visible on the fins of these components.
This does not mean that the components are damaged. If the fins
are only very slightly distorted, this does not justify renewal of the
radiator, charge air cooler or condenser.
4.7 Checking vacuum system

Special tools and workshop equipment required
♦ Hand vacuum pump - VAS 6213-
4. General repair instructions 7

Audi Q7 2007 ➤
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Porous or leaking lines
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check the vacuum lines
leading to the relevant component and also check the remain‐
ing vacuum lines in the system.
– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

Audi Q7 2007 ➤
10 – Removing and installing engine

1 Removing engine
Special tools and workshop

equipment required
♦ Removal lever - 80 - 200-

♦ Used oil collection and extraction unit - V.A.G 1782-
♦ Stepladder - VAS 5085-
♦ Engine bung set - VAS 6122-
♦ Scissor-type assembly platform - VAS 6131 A- with support
set for Audi - VAS 6131/10- and support set -VAS 6131/11- ,
-VAS 6131/13- and 3x -VAS 6131/10-2-
♦ Drip tray for workshop hoist - VAS 6208-
1. Removing engine 9
Audi Q7 2007 ➤
♦ Hose clip pliers - VAS 6362-
♦ Locking pin - T10060 A-
♦ Ball joint puller - T10187-
Procedure
Note
♦ The engine is removed from underneath together with the

gearbox and subframe (with lock carrier installed).
♦ Fit cable ties in the original positions when installing.
– Activate jacking mode on vehicles with air suspension ⇒ Rep.

gr. 43 .
10 Rep. gr.10 - Removing and installing engine

Audi Q7 2007 ➤
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Disconnect earth cable -4- ⇒ Electrical system; Rep. gr. 27 .

– Extract hydraulic fluid for power steering from reservoir using
used oil collection and extraction unit - V.A.G 1782- .
WARNING
The cooling system is under pressure when the engine is hot.

Hot steam/hot coolant can escape - risk of scalding.
Danger of scalding skin and other parts of the body.
• Put on protective gloves.
• Put on safety goggles.
• Release pressure (cover filler cap on coolant expansion
tank with a cloth and open carefully).
– Open filler cap on coolant expansion tank.

– Remove noise insulation panels -1- and -2- ⇒ Rep. gr. 66 .
Audi Q7 2007 ➤
– Remove front left and front right wheel housing liner ⇒ Rep.
gr. 66 .
– Remove rear propshaft ⇒ Transfer box 0BU, front final drive

0BM, 0C1 and rear final drive 0BN, 0BP; Rep. gr. 39 .
Note
Collect drained coolant in a clean container for re-use or disposal.
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– Lift retaining clip, disconnect coolant hose (bottom right)
-arrow- from radiator and drain off coolant.
– Move coolant hose clear.
– Release hose clips -1 and 2-, disconnect coolant hoses from

coolant pipes and drain off coolant.

Audi Q7 2007 ➤
– Release hose clips -arrows-, disconnect coolant hoses from

coolant pipes on longitudinal member (left-side) and drain off
coolant.
– Release hose clip -1-, disconnect coolant hose from coolant

pipe on lock carrier and drain off coolant.
– Position used oil collection and extraction unit - V.A.G 1782-
below connection point.
– Release hose clip and disconnect hydraulic hose -2-.
– Seal off open pipes/lines and connections with clean plugs
from engine bung set - VAS 6122- .
– Release hose clip -arrow-, disconnect coolant hose from en‐

gine oil cooler and drain off coolant.
– Lift off engine cover panels -1- and -2-.
Caution
Risk of damage caused by particles of dirt.

♦ Observe rules for cleanliness when working on the unless
permitted fuel authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
supply system ⇒ page 6 . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Move clear fuel supply line at centre of plenum chamber par‐

tition panel.
Audi Q7 2007 ➤
WARNING
The fuel system is pressurised.

Risk of injury as fuel may spray out.
• Release pressure (wrap clean cloth around connection
and open connection carefully).
– Push back protective sleeve -1- and disconnect fuel supply

line.
– First press hose connector -2- towards fuel line -arrow A-, then
press down release tabs -arrows B-.
– Pull off hose connector, keeping release tabs depressed.
– Release brackets -3 and 4-, move fuel supply hose clear and
place hose on engine.
– Press release tabs and disconnect hose -1- at activated char‐

coal filter.
– Disconnect vacuum line -2- for brake servo, release vacuum
line and move to right side of vehicle.
– Detach vacuum hose -1- from connection on air pipe.

– Release hose clips -arrows- and remove air pipe.

Audi Q7 2007 ➤
– Release hose clips -1, 2- and disconnect coolant hoses.
– Detach electrical connectors -1 … 4- from bracket on suspen‐

sion turret (right-side), unplug connectors and move electrical
wiring clear.
– Release hose clips -1 and 2-, lift retaining clip -3- and detach
coolant hoses.
Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
with chalk or felt-tip pen for re-installation.
– To slacken poly V-belt, turn tensioner clockwise -arrow- and

lock with locking pin - T10060 A- .
– Detach poly V-belt from air conditioner compressor.
Audi Q7 2007 ➤
Note
Lay a cloth underneath vehicle to catch escaping hydraulic fluid.
– Remove banjo bolt -1-.

– Release hose clip -2- and detach hydraulic hose from power
steering pump.
– Release retainer -4- and open cover -5- as indicated by

-arrow-.
– Unscrew nut -3- and move B+ wire clear at plenum chamber
partition panel.
Note
Disregard -items 1, 2-.
– Remove wiper arms -1- and -3- ⇒ Rep. gr. 92 .

– Remove seal -5-.
Caution
Risk of damage to plenum chamber cover.

♦ To avoid cracking the plenum chamber cover -2- during
removal, apply a small amount of soap solution to the joint
between the windscreen and the plenum chamber cover
and pull the plenum chamber cover vertically up out of the
fastening strip, starting from the edge of the windscreen.
– Detach plenum chamber cover -2- by pulling it carefully off re‐

tainer at windscreen.

Audi Q7 2007 ➤
– Remove bolts -arrows- and detach cover for electronics box in

plenum chamber.
– Unplug electrical connectors -1 ... 3- at connector point in

electronics box in plenum chamber.
– Move electrical wiring harness clear.
– Remove nut -2- and detach earth wire.

– Remove engine control unit -1- ⇒ Rep. gr. 24 .
– Move clear electrical wiring harness leading to engine.
– Loosen nut for upper link several turns and use ball joint puller
- T10187- to press off joint.
– Remove nut for upper link completely.
– Perform the same work steps on the other side of the vehicle.
Audi Q7 2007 ➤
– Unplug electrical connector -arrow- at front wheel speed sen‐

sor on both sides.
– Remove bolts -arrows- for wiring retainer.

– Remove bolts -1- for brake caliper.
Note
Do not attempt to bend brake lines to a Protected

different shape.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tie up brake caliper in wheel housing using wire (brake line
remains attached).
Caution
Risk of damage to brake pistons.

♦ Do not operate brake pedal with brake caliper removed.
– Perform the same work steps on the other side of the vehicle.
– Unfasten bottom bolted connection -2- on anti-roll bar (left and

right).
– Unscrew nut from bolt -1- on suspension strut (left and right).
Note
The bolts are removed at a later stage.
– Unscrew bolts -arrows- and remove bracket for noise insula‐

tion.

Audi Q7 2007 ➤
– Unscrew nut -2- on longitudinal member (right-side) and de‐

tach earth wire.
– Press release tabs and disconnect hose -1- from secondary
air pump motor - V101- .
– Remove bolts -1- and -arrows- and detach bracket -2- for cat‐
alytic converter (left-side).
Note
Bolt -1- is accessible from above.
– Pry ball head -1- of selector lever cable off gearbox selector
lever using removal lever - 80 - 200- .
– Remove bolt -2- and detach selector lever cable with cable
support bracket from gearbox.
Note
Take care not to bend or kink selector lever cable.
– Unplug electrical connector -arrow- on steering rack.
Audi Q7 2007 ➤
– Unscrew 2 bolts and remove heat shield -A- from steering

rack.
Caution
Risk of damage to coil connector for airbag.

♦ Make sure that front wheels are in straight-ahead position
before removing universal joint from steering rack.
♦ Do not alter position of steering wheel and steering rack
(locate steering wheel with adhesive tape if necessary).
– Remove bolt -B- for universal joint ⇒ Rep. gr. 48 .

– Press off universal joint from steering rack.
Note
Observe rules for cleanliness when working on automatic gear‐

box ⇒ Rep. gr. 00 .
– Remove bolt -arrow- and detach ATF lines from ATF temper‐
ature regulator.
– Unplug electrical connectors -1, 2, 3- on gearbox.

Audi Q7 2007 ➤
Set up the scissor-type assembly platform as follows:

– Set up scissor-type assembly platform - VAS 6131 A- with
support set for Audi - VAS 6131/10- , support set -VAS
6131/11- and supplementary set -VAS 6131/13- as follows:
Platform Parts of support set for Audi - VAS 6131/10- , sup‐
coordinates port set -VAS 6131/11- and supplementary set -
VAS 6131/13-
B3 /10-1 /10-2 /10-5 /11-1
G3 /10-1 /10-2 /10-5 /11-1
A4 and C4 /13-5 – – /13-2
F4 and H4 /13-6 – – /13-2
B5 /13-4 /10-2 /10-5 /13-1
G5 /13-4 /10-2 /10-5 /13-1
C7 /10-1 /10-2 /10-5 /10-8
F7 /10-1 /10-2 /10-5 /10-8
B13 /10-1 /10-3 /10-5 /10-7
G13 /10-1 /10-3 /10-5 /10-7
– Initially hand-tighten the support elements on the scissor-type
assembly platform.
– Place scissor-type assembly platform in horizontal position.
• Take note of spirit level (bubble gauge).
– Position scissor-type assembly platform - VAS 6131 A- below

engine/gearbox assembly.
– Position support elements from -VAS 6131/10- and -VAS
6131/11- at front left and right of subframe as shown.
– Make sure that threaded spindles are screwed in completely.
– Position support elements from -VAS 6131/10- and -

VAS 6131/13- at engine cross member, as shown in illustra‐
tion.
Audi Q7 2007 ➤
– Position the support elements from -VAS 6131/13- at suspen‐

sion struts, as shown in the illustration.
– Position the support elements from -VAS 6131/10- at rear of

subframe, as shown in the illustration.
– Position support elements from -VAS 6131/10- at left and right

of gearbox carrier, as shown in illustration.
– Turn all spindles for support elements upwards until all locat‐
ing lugs make contact with mounting points.
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform - VAS 6131 A- .
– Remove bolt -1- on left and right.
Note
Bolted connection -2- has already been unscrewed.

Audi Q7 2007 ➤
– Mark installation position of subframe, engine cross member

and gearbox carrier on longitudinal members with felt-tip pen.
– Remove bolts -1 ... 4- in diagonal sequence and in stages.
Caution
Danger of damage to hose and wiring connections and to en‐

gine compartment.
♦ Check that all hoses and electrical connections between
engine, gearbox, subframe and body have been de‐
tached.
♦ Carefully guide out engine/gearbox assembly with sub‐
frame from engine compartment when lowering.
♦ Carefully guide suspension struts
Protected by past
copyright. longitudinal
Copying mem‐ purposes, in part or in whole, is not
for private or commercial
bers. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Lower engine/gearbox assembly using scissor-type assembly

platform - VAS 6131 A- initially only as far as distance -a-.
• Dimension -a- = 180 mm (maximum).
– Unplug electrical connector -1- for air conditioner compressor

regulating valve - N280- .
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
– Remove bolts -arrows- for air conditioner compressor.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Detach air conditioner compressor from bracket and tie up on

longitudinal member (left-side) with refrigerant lines connect‐
ed.
– Lower engine/gearbox assembly further.
– Pull out scissor-type assembly platform - VAS 6131 A- with
engine/gearbox assembly from underneath vehicle.
Audi Q7 2007 ➤
2 Separating engine and gearbox

♦ Support bridge - 30 - 211 A-
♦ Support set for Audi - VAS 6131/10- , supplementary set -

VAS 6131/12- , -VAS 6131/13- and gearbox support - VAS
6131/14-
♦ 2x M10x35 bolts with washers, ∅ 30 mm
♦ Adapter - T40058-
Procedure
• Engine/gearbox assembly removed and secured to scissor-
type assembly platform - VAS 6131 A-
Note
Fit cable ties in the original positions when installing.
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

Audi Q7 2007 ➤
– Set up scissor-type assembly platform - VAS 6131 A- with

support set for Audi - VAS 6131/10- , supplementary set -
6131/14- as follows:
Note
The other support elements remain unchanged.
Platform Parts of support set for Audi - VAS 6131/10- , sup‐

coordinates plementary set -VAS 6131/12- , -VAS 6131/13-
and gearbox support - VAS 6131/14-
E1 /10-1 /13-7
B10 /10-1 /10-2 /10-5 /14
G10 /10-1 /10-2 /10-5 /14
G10 /10-1 /12-2 /10-5 /13-3
– Secure support -VAS 6131/13-7- in threaded holes at front of
engine.
– Additionally secure support -VAS 6131/13-7- to scissor-type

assembly platform with -VAS 6131/10-1- and M10x35 bolt
-arrow- with washer.
– Position support elements from -VAS 6131/10- , -

6131/14- at front of gearbox, as illustrated.
– Prepare support elements from -VAS 6131/12- and -
VAS 6131/13- to support propshaft, as shown in illustration.
– Secure -VAS 6131/12-2- with M10x35 bolt -arrow- and washer
(∅ 30 mm).
2. Separating engine and gearbox 25

Audi Q7 2007 ➤
– Remove nuts -arrows- for catalytic converter (left-side).
– Remove bolt -1- and nuts -arrows- for catalytic converter

(right-side). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew bolt -3- and detach catalytic converter (left-side) with

front silencer.
– Unscrew bolt -1- and detach catalytic converter (right-side)
with front silencer.
Note
– Move breather hose -4- clear.

– Remove bolts -arrows-.
Note
Disregard -items 1, 2, 3-.

Audi Q7 2007 ➤
– Remove bolts -1 and 2-.
Note
Disregard -item 3-.
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der gearbox.
Note
Observe rules for cleanliness when working on automatic gear‐

box ⇒ Rep. gr. 00 .
– Remove bolts -1 and 2- and detach ATF lines from gearbox.

– Remove bolt -1-.

Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Disregard -item 2-.
– Remove nut -1- and bolts -arrows- at engine mounting (right-

side).

Audi Q7 2007 ➤
– Raise engine with support -VAS 6131/13-7- until engine

mounting (right-side) can be taken out.
Note
Disregard -arrow-.
– Remove bolts -arrows- and detach engine support (right-side)

-1-.
– Unplug electrical connector -4-.

– Remove nuts -1 and 3- and move B+ wire clear.
– Unscrew bolts -2 and 5- and remove starter.
– Reinstall engine support and engine mounting ⇒ page 39
for the following steps.
– Insert guide pin of adapter -T40058- as follows:

• The larger-diameter section -arrow 1- faces towards the en‐
gine.
• The smaller-diameter section -arrow 2- faces the adapter.

Audi Q7 2007 ➤
– Counterhold crankshaft using adapter - T40058- and angled

ring spanner when loosening bolts for torque converter.
Note
When performing the next step, turn the crankshaft only in the
normal direction of rotation -arrow-.
– Detach cover -2- towards front.

– Working through aperture of removed starter motor, remove
6 bolts -1- for torque converter (turn crankshaft 120° in direc‐
tion of engine rotation each time).
– Remove bolts -arrows- securing front propshaft to transfer box

⇒ Transfer box 0BU, front final drive 0BM, 0C1 and rear final
drive 0BN, 0BP; Rep. gr. 39 .
– Remove bolts -3 ... 11- securing gearbox to engine.

Audi Q7 2007 ➤
– Loosen clamping bolts -1- on sides of scissor-type assembly

platform - VAS 6131 A- and pull rear section of platform to‐
gether with gearbox slightly towards rear -arrow-.
– At the same time, reach through aperture for removed starter
motor and press torque converter off drive plate.
– Secure the torque converter in the gearbox using support

bridge - 30 - 211 A- to prevent it falling out.

Audi Q7 2007 ➤
3 Securing engine to engine and gearbox support

equipment required
♦ Lifting tackle - 2024 A-

♦ Engine and gearbox support - VAS 6095- with universal
mounting - VAS 6095/1- and bracket for V6 FSI engine,
Audi A6 - VAS 6095/1-5-
♦ Workshop hoist - VAS 6100-
♦ Lift arm extension (workshop hoist) - VAS 6101-
Procedure permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Engine/gearbox assembly removed and secured to scissor-
type assembly platform - VAS 6131 A- (with engine detached
from gearbox) ⇒ page 24 .
• Engine secured with support -VAS 6131/13-7- .
3. Securing engine to engine and gearbox support 31

Audi Q7 2007 ➤
– Remove bolts -arrows- on engine mounting (left-side).
Note
Disregard -item 1-.
WARNING
Risk of accident.
♦ The engine can only be transported with the gearbox re‐
moved using the method described.
• Engine separated from gearbox ⇒ page 24 .

– Attach lifting tackle - 2024 A- to engine lifting eyes and work‐
shop hoist - VAS 6100- with lift arm extension (workshop hoist)
- VAS 6101- as shown in illustration.
Note
To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.
WARNING
Risk of accident.
♦ The support hooks and retaining pins on the lifting tackle
must be secured with locking pins -arrows-.
– Remove support -VAS 6131/13-7- from engine -arrow-.

– Lift engine off engine cross member.

Audi Q7 2007 ➤

-1- and engine support (left-side).
– Secure engine with universal mounting - VAS 6095/1- and

support bracket for V6 FSI engine, Audi A6 - VAS 6095/1-5-
to engine and gearbox support - VAS 6095- as shown in illus‐
tration and tighten to 40 Nm.
3. Securing engine to engine and gearbox support 33

Audi Q7 2007 ➤
4 Installing engine
Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled, phos‐

phated or black-finished nuts and bolts.
♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques: ± 15 %.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10
Protected 40 Copying for private or commercial purposes, in part or in whole, is not
by copyright.
M12 65
Assembly mountings ⇒ “5.1 Exploded view - assembly mount‐

ings”, page 39
Earth connection on longitudinal member (right-side)
– Tighten nut -2- to 15 Nm.
Engine to gearbox
Item Bolt 1) Nm
1 M10x95 15 +90°
2…5 M12x75 30 +90°
6, 7 M12x140 30 +90°
8, 9, 10 M10x60 15 +90°
11 M10x45 15 +90°
A Dowel sleeves for centralising
• 1)Aluminium bolts must not be used more often than twice
⇒ page 35 .

Audi Q7 2007 ➤
♦ The aluminium bolts -1 … 11- must not be used more often

than twice. After first use, bolts must therefore be identified
with an “X” made by two chisel marks -arrow-.
♦ To avoid damaging the bolts when making this mark, do not
clamp them directly in a vice. Clamp a 14 mm socket with 1/
2" drive in a vice and insert the bolt as shown.
♦ Bolts already marked with an “X” must not be used again.
Procedure
Note
♦ Renew the bolts tightened with specified tightening angle.

♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings.
♦ Do not remove plugs or protective caps until you are ready to
fit the relevant line.
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ To secure the air hoses at their connections, spray rust re‐
mover onto the worm thread of the used hose clips before
installing.
♦ Fit all cable ties in the original positions when installing.
– Install engine supports (left and right) ⇒ page 39 .
– Check whether dowel sleeves -A- for centring engine and

gearbox are fitted in cylinder block and in timing chain cover
(bottom); install missing dowel sleeves.
Caution
Risk of damage to drive lug of ATF pump if torque converter is

installed incorrectly.
♦ Check installation depth of torque converter.
• If the torque converter is correctly installed, the depth -a- be‐

tween the bottom contact surfaces at the threaded holes on
the torque converter and the contact surface of the torque
converter bell housing is about 23 mm.
Note
4. Installing engine 35
Audi Q7 2007 ➤
If the torque converter has not been fully inserted, this distance
will be approx. 11 mm.
– Before bringing engine and gearbox together, turn torque con‐

verter and drive plate on engine so that holes for bolts -1- are
in line with aperture for starter motor.
Caution
Risk of damage to automatic gearbox.

♦ Before and during tightening of bolts on engine/gearbox
assembly, continually check that the torque converter be‐
hind the drive plate can be turned. If the torque converter
cannot be turned, it must be assumed that it has not been
installed correctly.
♦ Use only new bolts of the correct type (same as original
equipment) to secure torque converter on drive plate.
– Install alternator ⇒ Electrical system; Rep. gr. 27 .

– Secure gearbox to engine.
– Secure torque converter ⇒ Rep. gr. 37 .
Installation is carried out in the reverse order; note the following:
– Install starter ⇒ Electrical system; Rep. gr. 27 .
– Install coolant pipe (right-side) on gearbox ⇒ page 205 .
– Install coolant pipes (rear left) on gearbox ⇒ page 202 .
– Installpermitted
ATF linesunless ⇒ Rep.bygr.
authorised AUDI37
AG.. AUDI AG does not guarantee or accept any liability
– Secure front propshaft to transfer box ⇒ Transfer box 0BU,
front final drive 0BM, 0C1 and rear final drive 0BN, 0BP; Rep.
gr. 39 .
– Raise engine/gearbox assembly using scissor-type assembly
platform - VAS 6131 A- .
– Install air conditioner compressor ⇒ Rep. gr. 87 .
– Adjust the subframe, engine cross member and gearbox car‐

rier according to the markings made on the longitudinal mem‐
bers during removal.
– Tighten bolts for subframe, engine cross member and gearbox
carrier only to specified torque (do not turn further); the bolts
are only fully tightened after performing the wheel alignment
check ⇒ Rep. gr. 40 .
WARNING
Risk of accident because of loose bolted connections.

♦ Do NOT drive the vehicle unless the subframe bolts have
been tightened to their final torque.
– Secure universal joint on steering rack ⇒ Rep. gr. 48 .

– Install and if necessary adjust selector lever cable ⇒ Rep. gr.
37 .

Audi Q7 2007 ➤
– Install catalytic converter: left-side ⇒ page 251 ; right-side

⇒ page 252 .
– Align the exhaust system so it is free of stress ⇒ page
256 .
– Secure rear propshaft to transfer box ⇒ Transfer box 0BU,
front final drive 0BM, 0C1 and rear final drive 0BN, 0BP; Rep.
gr. 39 .
– Install anti-roll bar ⇒ Rep. gr. 40 .
– Install brake calipers ⇒ Rep. gr. 46 .
– Install suspension struts and suspension links ⇒ Rep. gr. 40 .
– Install engine control unit ⇒ Rep. gr. 24 .
– Install cover for electronics box in plenum chamber ⇒ Elec‐
trical system; Rep. gr. 97 .
– Secure electrical wire at jump start socket - U6- ⇒ Electrical
system; Rep. gr. 27 .
– Tighten earth connection on longitudinal member (right-
side) ⇒ page 34 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.

– Observe notes on procedure for connecting the battery ⇒
Electrical system; Rep. gr. 27 .
Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– Install hydraulic line ⇒ Rep. gr. 48 .

– Install and adjust wiper arms ⇒ Electrical system; Rep. gr.
92 .
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
406 .
– Before starting engine, top up hydraulic fluid in power steering
reservoir ⇒ Rep. gr. 48 .
Note
The power steering pump must not be run when dry.
– Connect coolant hoses with plug-in connector ⇒ page 217 .

– Fill up with coolant ⇒ page 181 .
Note
♦ Drained-off coolant may only be used again if the original

cylinder head and cylinder block are re-installed.
♦ Contaminated or dirty coolant must not be used again.
– Align subframe and engine cross member ⇒ Rep. gr. 40 .
4. Installing engine 37
Audi Q7 2007 ➤
– Align gearbox carrier and secure ⇒ Rep. gr. 37 .

– Install front wheel housing liners ⇒ Rep. gr. 66 .
– Perform wheel alignment check ⇒ Rep. gr. 44 .
WARNING
Risk of accident because of loose bolted connections.

♦ Tighten bolts for subframe to final setting after performing
wheel alignment check.
– Install bracket for noise insulation and noise insulation panels

⇒ Rep. gr. 66 .
– Deactivate jacking mode on vehicles with air suspension ⇒
Rep. gr. 43 .

Audi Q7 2007 ➤
5 Assembly mountings
⇒ “5.1 Exploded view - assembly mountings”, page 39
⇒ “5.2 Removing and installing engine mountings”, page 39
⇒ “5.3 Removing and installing engine cross member”, page
42
5.1 Exploded view - assembly mountings
1 - Engine cross member

❑ Removing and installing
⇒ “5.3 Removing and in‐
stalling engine cross
member”, page 42
2 - Bolt
❑ Renew
❑ 120 Nm +180°
3 - Engine mounting (right-
side)
stalling engine mount‐
ings”, page 39
4 - Bolt
❑ 50 Nm
5 - Bolt
❑ 40 Nm
6 - Nut
❑ 75 Nm
7 - Engine support (right-side)
❑ Version fitted in vehicle
may differ from illustra‐
tion
8 - Engine support (left-side)
9 - Bolt
❑ 50 Nm
10 - Nut
❑ 75 Nm
11 - Bolt
❑ 60 Nm
12 - Engine mounting (left-side)
❑ Removing
permitted andby installing
unless authorised AUDI AG. AUDI ⇒ AG
“5.2 Removing
does and
not guarantee or installing
accept any liability engine mountings”, page 39
13 - Bolt
❑ Renew
❑ 120 Nm +180°
5.2 Removing and installing engine mountings
5. Assembly mountings 39
Audi Q7 2007 ➤

equipment required
♦ Support bracket - 10 - 222 A-

♦ 2x Hook - 10 - 222 A /10-
♦ Adapters - 10 - 222 A /19-
♦ Adapters - 10 - 222 A /22-
♦ Engine support bracket (basic set) - T40091-
♦ Engine support bracket (supplementary set) - T40093-
Removing
gr. 43 .
– Remove air cleaner housing ⇒ Rep. gr. 24 .

Audi Q7 2007 ➤
– Position support bracket - 10 - 222 A- with adapters - 10 - 222

A /22- and -T40091/3- on bolted flanges of wing panels as
shown in illustration.
– Attach further components as shown in illustration. Position

adapters - 10 - 222 A /19- on flanges of longitudinal members.
– Engage hooks - 10 - 222 A /10- at rear engine lifting eyes.
– Push support -T40091/2- with two sliding supports -T40093/5-

into the two connecting pieces -T40093/4- .
– Fit long spindles from support bracket - 10 - 222 A- and engage
hooks on front engine lifting eyes.
WARNING
Risk of accident.
♦ Secure support -T40091/2- with pins and split pins of con‐
necting pieces -T40093/4- .
Audi Q7 2007 ➤
– Lift engine until engine supports are positioned above studs of

engine mountings (take up weight at all spindles evenly).
Engine mounting (right-side):

– Remove bolts -1- and detach heat shield for steering rack bel‐
lows.
Both sides (continued):

– Remove nut -1- and bolts -arrows-.
– Raise engine with threaded spindles until relevant engine sup‐
port is positioned above stud of engine mounting.
– Detach engine mounting.
Note
When removing the engine mounting on the right side of the ve‐
hicle, turn the steering onto full right lock. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installing
• Tightening torques ⇒ “5.1 Exploded view - assembly mount‐
ings”, page 39
– Install heat shield for steering rack bellows ⇒ Rep. gr. 48 .
– Install noise insulation panels ⇒ Rep. gr. 66 .
– Install air cleaner housing ⇒ Rep. gr. 24 .
Rep. gr. 43 .
5.3 Removing and installing engine cross member

Audi Q7 2007 ➤

equipment required
♦ Support bracket - 10 - 222 A-

♦ permitted
2x Hook - 10 - 222byAAUDI
/10-
unless authorised AG. AUDI AG does not guarantee or accept any liability
♦ Adapters - 10 - 222 A /19-
♦ Adapters - 10 - 222 A /22-
♦ Engine support bracket (basic set) - T40091-
♦ Engine support bracket (supplementary set) - T40093-
Removing
gr. 43 .
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
– Disconnect earth cable -4- ⇒ Electrical system; Rep. gr. 27 .
Audi Q7 2007 ➤
– Remove front left and front right wheel housing liner ⇒ Rep.
gr. 66 .

Audi Q7 2007 ➤
– Remove anti-roll bar ⇒ Rep. gr. 40 .
– Set up support bracket - 10 - 222 A- with adapters - 10 - 222

A /22- and connecting pieces -T40091/3- on bolted flanges of
wing panels.
– Attach further components as shown in illustration. Position

adapters - 10 - 222 A /19- on flanges of longitudinal members.
– Engage hooks - 10 - 222 A /10- at rear engine lifting eyes.
– Push support -T40091/2- with two sliding supports -T40093/5-

into the two connecting pieces -T40093/4- .
– Fit long spindles from support bracket - 10 - 222 A- and engage
hooks on front engine lifting eyes.
WARNING
Risk of accident.
♦ Secure support -T40091/2- with pins and split pins of con‐
necting pieces -T40093/4- .
– Partly take up weight of engine, but do not lift engine.
Audi Q7 2007 ➤
– Remove bolts -arrows- for engine mountings on both sides.
Note
Disregard -item 1-.
– Unscrew 2 bolts and remove heat shield -A- from steering

rack.
Caution
Risk of damage to coil connector for airbag.

♦ Make sure that front wheels are in straight-ahead position
before removing universal joint from steering rack.
♦ Do not alter position of steering wheel and steering rack
(locate steering wheel with adhesive tape if necessary).
– Remove bolt -B- for universal joint ⇒ Rep. gr. 48 .

– Press off universal joint from steering rack.
– Move coolant hoses clear -arrow-.

– Detach power steering hydraulic line from brackets on left of
subframe.

– Press release tabs and disconnect secondary air hoses -1-.
– Remove nuts -2- and loosen nut -5-.
– Detach secondary air pump motor - V101- with bracket.
Note
Disregard -item 4-.

Audi Q7 2007 ➤
– Mark installation position of subframe and engine cross mem‐

ber on longitudinal members with felt-tip pen.
WARNING
Accident risk if subframe mountings are detached.

♦ Subframe bolts -2- and gearbox carrier bolts -1- must not
be loosened.
– Remove bolts -3- and -4- and lower front part of subframe with
engine cross member.
– Take out engine cross member to front.
Installing
• Tightening torques ⇒ “5.1 Exploded view - assembly mount‐
ings”, page 39
Note
(same asbyoriginal
Protected equipment)
copyright. Copying for private⇒or commercial
Electronic partsin catalogue
purposes, part or in whole,.is not
– Secure subframe ⇒ Rep. gr. 40 .
– Install secondary air pump motor - V101- ⇒ page 269 .
– Secure universal joint on steering rack ⇒ Rep. gr. 48 .
– Install engine mountings ⇒ page 39 .
– Install anti-roll bar ⇒ Rep. gr. 40 .
– Install wheel housing liners (front) and noise insulation panels
⇒ Rep. gr. 66 .
– Observe notes on procedure for connecting the battery ⇒
Electrical system; Rep. gr. 27 .
Rep. gr. 43 .
Audi Q7 2007 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - poly V-belt drive for supercharger”,
page 48
⇒ “1.2 Removing and installing poly V-belt for supercharger”,
page 49
⇒ “1.3 Removing and installing poly V-belt tensioner for super‐
charger”, page 51
⇒ “1.4 Exploded view - poly V-belt drive for ancillaries”, page
51
⇒ “1.5 Removing and installing poly V-belt”, page 54
⇒ “1.6 Removing and installing tensioner for poly V-belt”, page
55
⇒ “1.7 Removing and installing vibration damper”, page 57
⇒ “1.8 Renewing sealing flange (pulley end) with crankshaft oil
seal”, page 58
1.1 Exploded view - poly V-belt drive for supercharger
48 Rep. gr.13 - Crankshaft group

Audi Q7 2007 ➤
1 - Poly V-belt
❑ For supercharger
❑ Check for wear
stalling poly V-belt for
supercharger”, page
49
❑ When installing, make
sure it is properly seated
on pulleys
2 - Bolt
❑ 40 Nm
3 - Washer
4 - Cover
5 - Supercharger
❑ Exploded view ⇒
“1.2 Exploded view - su‐
percharger”, page
226
6 - Idler roller
❑ For poly V-belt
7 - Vibration damper
❑ With poly V-belt pulley
❑ Can only be installed in
one position (holes are
off-set).
⇒ “1.7 Removing andauthorised
in‐
permitted unless by AUDI AG. AUDI AG does not guarantee or accept any liability
stalling vibration
damper”, page 57
8 - Bolt
❑ Tightening torque ⇒ Item 2 (page 52)
9 - Tensioner
❑ For poly V-belt
❑ Removing and installing ⇒ “1.3 Removing and installing poly V-belt tensioner for supercharger”, page
51
10 - Bolt
❑ 40 Nm
1.2 Removing and installing poly V-belt for

supercharger
1. Cylinder block (pulley end) 49

Audi Q7 2007 ➤
Removing
WARNING
Risk of injury as the radiator fans may start up automatically.

♦ Even when the ignition is switched off, the radiator fans
can start up without warning due to accumulated heat in
the engine
Protected compartment,
by copyright. etc.or commercial purposes, in part or in whole, is not
Copying for private
– Lift off engine cover panel (front) -1-.
Caution

– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.
– Detach poly V-belt and lock tensioner with locking pin - T10060
A- .

Audi Q7 2007 ➤
Installing
– Fit poly V-belt on pulleys as shown in illustration:
1- Tensioner
2- Supercharger
3- Idler roller
4- Vibration damper
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Start engine and check that belt runs properly.
1.3 Removing and installing poly V-belt ten‐

sioner for supercharger
Removing
– Remove poly V-belt for supercharger ⇒ page 49 .
– Remove bolt -1- and take off poly V-belt tensioner -2-.
Note
Ignore -T10060 A- .
Installing
• Tightening torque ⇒ “1.1 Exploded view - poly V-belt drive for
supercharger”, page 48
– Install poly V-belt for supercharger ⇒ page 49 .
1.4 Exploded view - poly V-belt drive for ancillaries

Audi Q7 2007 ➤
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
stalling poly V-belt”,
page 54
❑ Do not kink
❑ When installing, make
sure it is properly seated
on pulleys
2 - Bolt
❑ Renew
❑ 20 Nm +90°
3 - Vibration damper
❑ With double-sided poly
V-belt pulley
stalling vibration
damper”, page 57
4 - Cover
❑ For idler roller
5 - Idler roller Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For poly V-belt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 40 Nm
6 - Bolt
❑ Tightening torque ⇒
Electrical system; Rep.
gr. 27
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27
8 - Bolt
❑ 20 Nm
9 - Bracket
❑ For alternator
10 - Bolt
11 - Poly V-belt pulley
❑ For coolant pump
❑ Removing and installing ⇒ page 190
12 - Bolt
13 - Coolant pump
❑ Removing and installing ⇒ “2.2 Removing and installing coolant pump”, page 190
14 - Bolt
❑ Tightening torque and sequence ⇒ Fig. ““Sealing flange (pulley end) - tightening torque and sequence”“ ,
page 54

Audi Q7 2007 ➤
15 - Bolt
❑ Tightening torque ⇒ Rep. gr. 48
16 - Bracket
❑ For power steering pump
17 - Sliding bush
18 - Bolt
19 - Bolt
20 - Power steering pump
❑ Removing and installing ⇒ Rep. gr. 48
21 - Poly V-belt pulley
❑ For power steering pump
22 - Bolt
23 - Tensioner
❑ For poly V-belt
❑ Removing and installing ⇒ “1.6 Removing and installing tensioner for poly V-belt”, page 55
❑ 40 Nm
24 - Bracket
❑ For air conditioner compressor
25 - Bolt
26 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
27 - Bolt
28Protected
- Dowel sleeveCopying for private or commercial purposes, in part or in whole, is not
by copyright.
❑with 2x
29 - Cover
❑ For tensioner
30 - Sealing flange (pulley end)
❑ Renewing ⇒ “1.8 Renewing sealing flange (pulley end) with crankshaft oil seal”, page 58

Audi Q7 2007 ➤
Sealing flange (pulley end) - tightening torque and sequence

– Tighten bolts -arrows- in stages and in diagonal sequence; fi‐
nal torque 9 Nm.
1.5 Removing and installing poly V-belt

Removing
– Remove bolt -arrow- and detach together with idler roller.

Audi Q7 2007 ➤
Caution


– Take off poly V-belt.
Installing

• Tightening torque ⇒ “1.1 Exploded view - poly V-belt drive for
supercharger”, page 48
– Fit poly V-belt on pulleys as shown in illustration.
1- Alternator
2- Idler roller
3- Coolant pump
4- Power steering pump
5- Air conditioner compressor
6- Tensioner for poly V-belt
7- Vibration damper
Note
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Start engine and check that belt runs properly.

– Install poly V-belt for supercharger ⇒ “1.2 Removing and in‐
stalling poly V-belt for supercharger”, page 49 .
1.6 Removing and installing tensioner for

poly V-belt

Audi Q7 2007 ➤
Removing
WARNING

the engine compartment, etc.
– Remove bolt -2- for coolant pipes (front left).
Note
♦ For illustration purposes, the installation position is shown with

the engine removed.
♦ Disregard -items 1, 3-.
– Remove bolts -arrows- for coolant pipes (front left).
Note
♦ For illustration purposes, the installation position is shown with

the engine removed.
♦ Disregard -item 1-.
– To slacken poly V-belt turn tensioner in clockwise direction

-arrow-.
– Remove polyunless
permitted V-belt from bytensioner
authorised and
AUDI AG. AUDI AGrelease tensioner.
does not guarantee or accept any liability
Note
Ignore -T10060 A- .

Audi Q7 2007 ➤
– Detach cover from tensioner.

– Remove bolt -1- and detach poly V-belt tensioner -2- from
cylinder block.
Installing
• Tightening torques ⇒ “1.4 Exploded view - poly V-belt drive for
ancillaries”, page 51
– Install poly V-belt ⇒ “1.5 Removing and installing poly V-belt”,
page 54 .
– Install coolant pipes (front left) ⇒ “3.5 Removing and installing
coolant pipes (front left)”, page 198 .
1.7 Removing and installing vibration

damper
♦ Counterhold tool - 3036-
Removing
– Remove poly V-belt for supercharger ⇒ page 49 .Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi Q7 2007 ➤
– Loosen bolts -1- for vibration damper using counterhold tool -

3036- .
– Remove bolts and take off vibration damper.
Installing
• Tightening torques ⇒ “1.4 Exploded view - poly V-belt drive for
ancillaries”, page 51
Note

♦ Can only be installed in one position (holes are off-set)
– Observe dowel sleeve when installing vibration damper.

– Install poly V-belt ⇒ “1.5 Removing and installing poly V-belt”,
page 54 .
1.8 Renewing sealing flange (pulley end)

with crankshaft oil seal
♦ Pin wrench - 3212-
♦ Assembly tool - T40048-
♦ Electric drill with plastic brush

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue

Audi Q7 2007 ➤
Procedure
– Remove poly V-belt ⇒ page 54 .
– Remove vibration damper ⇒ page 57 .
– Loosen bolts -arrows- for coolant pump pulley (counterhold
with pin wrench - 3212- ).
– Remove bolts and take off poly V-belt pulley.
– Loosen bolts -arrows- in diagonal sequence and remove.

– Release sealing flange (pulley end) from bonded joint and take
off sealing flange.
Note
Renew sealing flange (pulley end).
Caution
Protect lubrication system against contamination.

♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury due to sealant residue.

– Remove sealant residue from cylinder block and sump (top

section) using rotating plastic brush or similar.
– Clean sealing surfaces; they must be free of oil and grease.

Audi Q7 2007 ➤
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5

mm).
Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.
– Apply bead of sealant -arrow- onto sealing surface of new

sealing flange (pulley end) as shown in illustration.
• The groove on the sealing surface must be completely filled
with sealant.
• The bead of sealant must project 1.5 … 2.0 mm above the
sealing surface.
Note
The sealing flange (pulley end) must be installed within 5 minutes

after applying the sealant.
– Fit assembly aid -T40048/1- onto assembly sleeve -T40048/2-

and slide sealing flange -1- onto assembly sleeve.
– Detach assembly aid.

Audi Q7 2007 ➤
– First position sealing flange (with assembly sleeve -T40048/2-

inserted) on crankshaft.
– Keep sealing flange straight while pushing it onto engine seal‐
ing surface. Then bolt on ⇒ Fig. ““Sealing flange (pulley end)
- tightening torque and sequence”“ , page 54 .
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install poly V-belt pulley for coolant pump ⇒ “2.1 Exploded
view - coolant pump/thermostat”, page 189 .
– Install vibration damper ⇒ “1.7 Removing and installing vibra‐
tion damper”, page 57 .

Audi Q7 2007 ➤
2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - drive plate”, page 62
⇒ “2.2 Removing and installing drive plate”, page 62
⇒ “2.3 Removing and installing sender wheel”, page 63
⇒ “2.4 Checking sender wheel”, page 64
⇒ “2.5 Renewing crankshaft oil seal (gearbox end)”, page 65
2.1 Exploded view - drive plate
Note
When performing assembly work, secure engine to engine and gearbox support - VAS 6095- ⇒ page 31 .
1 - Drive plate
❑ Check holes for torque
converter for cracks and
scoring
stalling drive plate”,
page 62
2 - Bolt
❑ Renew
❑ 60 Nm +90°
3 - Sender wheel
❑ For engine speed
sender - G28-
4 - Oil seal
❑ For crankshaft (gearbox
end)
❑ Renewing ⇒ “2.5 Re‐
newing crankshaft oil
seal (gearbox end)”, Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
page 65 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 - Dowel pin
6 - Crankshaft
2.2 Removing and installing drive plate


Audi Q7 2007 ➤
♦ Counterhold tool - 10-201-
Removing
• Gearbox removed ⇒ Rep. gr. 37 .
– Insert counterhold tool - 10 - 201- to slacken bolts.
– Remove bolts and take off drive plate and sender wheel.
Installing
• Tightening torques ⇒ “2.1 Exploded view - drive plate”, page
62
Note
Renew the bolts tightened with specified tightening angle.
– Pay attention to dowel pin when installing drive plate.

– Fit counterhold tool - 10 - 201- the other way round to tighten
bolts.
2.3 Removing and installing sender wheel

Removing
– Remove drive plate ⇒ page 62 .
Caution
Risk of magnetic fields causing irreparable damage to sender

wheel.
♦ Protected
The sender wheel
by copyright. must
Copying be kept
for private away from
or commercial magnets
purposes, in part or in(e.g.
whole, is not
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation ⇒ page 64 .
2. Cylinder block (gearbox end) 63

Audi Q7 2007 ➤
– Detach sender wheel -arrow-.

Installing
– Install drive plate ⇒ “2.2 Removing and installing drive plate”,
page 62 .
2.4 Checking sender wheel

♦ Sensor gauge - T10473-
Procedure
• Sender wheel removed ⇒ page 63 .
Caution
Risk of magnetic fields causing irreparable damage to sender

wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation.
– Check entire circumference of sender wheel using sensor

gauge - T10473- , as shown in illustration.

Audi Q7 2007 ➤
Inspection image of sender wheel

A - Sender wheel OK
B - Sender wheel defective
2.5 Renewing crankshaft oil seal (gearbox

end)
♦ Guide piece - T10122/6-
♦ Fitting tool - T10122 A-
♦ Extractor tool - T20143/2-
2. Cylinder block (gearbox end) 65

Audi Q7 2007 ➤
Procedure
– Remove drive plate ⇒ page 62 .
– Pry out oil seal using extractor tool -T20143/2- .
– Clean contact surface and sealing surface.
– Fit assembly aid -T10122/1- onto guide piece - T10122/6- and

slide oil seal -A- onto guide piece.
– Detach assembly aid -T10122/1- .
– Fit guide piece - T10122/6- onto crankshaft.

– Bolt guide piece to crankshaft through securing points -A- us‐
ing bolts -arrows-.
Caution
Risk of leaks if installed incorrectly.

♦ Slide oil seal onto crankshaft by hand to prevent sealing
lip on oil seal from folding over.
– Slide oil seal over guide piece - T10122/6- onto crankshaft by

hand.
– Press in oil seal evenly all round using thrust piece -

T10122/5- .
– Remove guide piece - T10122/6- .
–Protected
Check that oil seal and its sealing lip are correctly seated. If
sealing
permitted lipauthorised
unless is partially folded
by AUDI AG. AUDIover, repeat
AG does procedure
not guarantee or accept with a new
any liability
oil respect
with seal. to the correctness of information in this document. Copyright by AUDI AG.
– Install drive plate ⇒ “2.2 Removing and installing drive plate”,
page 62 .

Audi Q7 2007 ➤
3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 67
⇒ “3.2 Crankshaft dimensions”, page 70
⇒ “3.3 Measuring axial clearance of crankshaft”, page 71
⇒ “3.4 Measuring radial clearance of crankshaft”, page 71
3.1 Exploded view - crankshaft
Note
When performing assembly work, secure engine to engine and gearbox support - VAS 6095- ⇒ page 31 .
1 - Sealing
permitted flange (pulley
unless authorised by AUDI AG.end)
AUDI AG does not guarantee or accept any liability
newing sealing flange

(pulley end) with
crankshaft oil seal”,
page 58
2 - Bolt
❑ Tightening torque and
sequence ⇒ Fig. ““Seal‐
ing flange (pulley end) -
tightening torque and
sequence”“ , page 54
3 - Crankshaft
❑ Measuring axial clear‐
ance ⇒ “3.3 Measuring
axial clearance of
crankshaft”, page
71
❑ Measuring radial clear‐
ance ⇒ “3.4 Measuring
radial clearance of
crankshaft”, page
71
❑ Crankshaft dimensions
⇒ “3.2 Crankshaft di‐
mensions”, page 70
4 - Dowel sleeve
❑ 4x
❑ Inserting in retaining
frame ⇒ Fig. ““Applying
sealant to retaining
frame, position of dowel
sleeves”“ , page 69
5 - Seal
❑ Renew
6 - Bolt
❑ For sealing surfaces: retaining frame to cylinder block
❑ Differing bolt lengths and bolt heads
❑ Tightening torque and sequence ⇒ Fig. ““Installing retaining frame”“ , page 70
7 - Bolt
3. Crankshaft 67
Audi Q7 2007 ➤
❑ Long, large collar

❑ For retaining frame (inner row)
❑ Renew
❑ Use old bolts when measuring radial clearance
8 - Bolt
❑ Short, small collar
❑ For retaining frame (outer row)
9 - Retaining frame
❑ With valve for oil pressure control - N428- ⇒ Fig. ““ Valve for oil pressure control -N428- ”“ , page
166
❑ To remove, detach guide rail ⇒ Item 1 (page 107) for drive chain for valve gear
❑ Applying sealant ⇒ Fig. ““Applying sealant to retaining frame, position of dowel sleeves”“ , page 69
❑ Removing and installing valve for oil pressure control - N428- ⇒ “2.6 Removing and installing valve for
oil pressure control N428 ”, page 171
10 - Seal
❑ Renew
11 - Thrust washer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil groove faces outwards
❑ Make sure it engages in retaining frame
12 - Bearing shell
❑ For retaining frame (without oil groove)
❑ Renew used bearing shells
❑ Note installation position
❑ Install new bearing shells for retaining frame with correct coloured markings ⇒ Fig. ““Matching crankshaft
bearing shells to bearings in retaining frame”“ , page 70
13 - Thrust washer
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil groove faces outwards
❑ Make sure it engages in cylinder block
14 - Bearing shell
❑ For cylinder block (with oil groove)
❑ Renew used bearing shells
❑ Note installation position
❑ Install new bearing shells for the cylinder block with the correct coloured markings ⇒ Fig. ““Matching
crankshaft bearing shells to bearings in cylinder block”“ , page 70
15 - Cylinder block

Audi Q7 2007 ➤
Plug for “TDC” marking - tightening torque
Note
Fit new O-ring.
– Tighten plug -arrow- to 14 Nm.
Valve for oil pressure control - N428-

1- Electrical connector
2- O-ring - renew
3- Bolt, 9 Nm
4- Valve for oil pressure control - N428-
Applying sealant to retaining frame, position of dowel sleeves

– Apply beads of sealant -arrows- onto clean sealing surfaces
of retaining frame as shown in illustration.
with sealant.
• The beads of sealant must project 1.5 … 2.0 mm above the
sealing surface.
– Fit seals -1- and -2-.
– Check that dowel sleeves -3 ... 6- are inserted in retaining
frame at positions shown in illustration.
3. Crankshaft 69
Audi Q7 2007 ➤
Installing retaining frame
Note
– Install long bolts in inner row on retaining frame.

– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. -1 … 16- 50 Nm
2. -1 … 16- Turn 90° further
3. -17 … 31- 20 Nm
4. -17 … 31- Turn 90° further
Matching
with respectcrankshaft bearing shells todocument.
bearings in cylinder block
to the correctness of information in this Copyright by AUDI AG.
♦ Bearing shells of the correct thickness are matched to the

bearings in the cylinder block at the factory. Coloured dots on
the side of the bearing shells are used to identify the bearing
shell thickness.
♦ The allocation of the bearing shells to the bearing positions in
the cylinder block is indicated by a code letter at the relevant
bearing on the retaining frame.
Code letter on retaining frame Colour coding of bearing
R = Red
G = Yellow
B = Blue
S = Black
Matching crankshaft bearing shells to bearings in retaining frame

♦ Bearing shells of the correct thickness are matched to the
bearings in the retaining frame at the factory. Coloured dots
on the side of the bearing shells are used to identify the bear‐
ing shell thickness.
♦ The allocation of the bearing shells to the bearing positions in
the retaining frame is indicated by a sequence of letters on the
gearbox flange on the crankshaft. The first letter in the se‐
quence stands for bearing “1”, the second letter for bearing
“2”, etc.
Letter on crankshaft Colour coding of bearing
R = Red
G = Yellow
B = Blue
S = Black
3.2 Crankshaft dimensions

Audi Q7 2007 ➤
Honing dimension Crankshaft bearing journal ∅ Crankshaft conrod journal ∅

mm mm
Basic dimension 65.00 – 0.022 56.00 – 0.022
– 0.042 – 0.042
3.3 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
– Secure dial gauge - VAS 6079- with universal dial gauge
bracket - VW 387- to cylinder block as shown in illustration.
– Apply dial gauge to crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
• Axial clearance: 0.15 ... 0.25 mm
3.4 Measuring radial clearance of

crankshaft
♦ Plastigage
Procedure
– Remove retaining frame and clean bearing journals.
3. Crankshaft 71
Audi Q7 2007 ➤
– Place a length of Plastigage corresponding to the width of the

bearing on the bearing journal or in the bearing shell.
• The Plastigage must be positioned in the centre of the bearing
shell.
– Fit retaining frame, secure with old bolts and tighten to final
torque ⇒ Item 7 (page 67) without rotating crankshaft.
– Remove retaining frame again.
– Compare width of Plastigage with measurement scale.
Radial clearance:
• New: 0.015 ... 0.055 mm.
• Wear limit: 0.080 mm.
– Renew bolts for retaining frame which are tightened by turning
through specified angle.

Audi Q7 2007 ➤
4 Pistons and conrods

⇒ “4.1 Exploded view - pistons and conrods”, page 73
⇒ “4.2 Measuring radial clearance of conrods”, page 75
⇒ “4.3 Removing and installing pistons”, page 75
⇒ “4.4 Checking pistons and cylinder bores”, page 77
4.1 Exploded view - pistons and conrods
Note
♦ All bearing and running surfaces must be oiled before assembling.

♦ Oil spray jet for piston cooling ⇒ Fig. ““Oil spray jet for piston cooling”“ , page 75 .
1 - Bolts
❑ Renew
❑ Lubricate threads and
contact surface
❑ 50 Nm +90°
❑ Use old bolts when
measuring radial clear‐
ance
2 - Conrod bearing cap
❑ Mark installation posi‐
tion for re-installation
❑ Mark cylinder allocation
in colour ⇒ Fig. ““Mark‐
ing conrods”“ , page
74
❑ Installation position of
conrod pairs ⇒ Fig.
““Conrod installation po‐
sition”“ , page 75
3 - Bearing shells
❑ Ensure that retaining Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
lugs are securely seat‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ed.
❑ Renew used bearing
shells
❑ Oversized bearings are
available for machined
crankshaft conrod jour‐
nals ⇒ Electronic parts
catalogue
❑ Lugs on conrod bear‐
ings must be on the
same side
4 - Conrod
❑ Only renew as a complete set
❑ Mark cylinder allocation in colour ⇒ Fig. ““Marking conrods”“ , page 74
❑ Installation position of conrod pairs ⇒ Fig. ““Conrod installation position”“ , page 75
❑ Axial clearance for each conrod pair (when new): 0.20 … 0.45 mm
❑ Measuring radial clearance ⇒ “4.2 Measuring radial clearance of conrods”, page 75
4. Pistons and conrods 73

Audi Q7 2007 ➤
5 - Circlip
❑ Renew
6 - Piston pin
❑ Removing and installing ⇒ “4.3 Removing and installing pistons”, page 75
7 - Piston
❑ Mark installation position and cylinder number ⇒ Fig. ““Installation position of pistons”“ , page 74
❑ Renew piston if cracking is visible on piston crown or piston skirt
❑ Removing and installing ⇒ “4.3 Removing and installing pistons”, page 75
❑ Checking ⇒ Fig. ““Checking piston”“ , page 77
❑ Piston and cylinder dimensions ⇒ “4.4 Checking pistons and cylinder bores”, page 77
❑ Measuring cylinder bore ⇒ Fig. ““Measuring cylinder bore”“ , page 77
❑ Install using piston ring clamp
8 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Measuring ring gap ⇒ Fig. ““Measuring piston ring gap”“ , page 77
❑ Measuring ring-to-groove clearance ⇒ Fig. ““Measuring ring-to-groove clearance”“ , page 78
Installation position of pistons
Caution
Do not damage the coating of the piston crown.

♦ If you intend to re-install used pistons, mark the cylinder
number on the piston crown using paint. Do not attempt
to mark the piston crown with a centre punch or by making
a notch or similar.
Installation position:
• Arrows on piston crowns point to pulley end.
Marking conrods permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
♦ Only renew conrods as a complete set.

♦ Do not interchange conrod bearings.
– Use a coloured pen to mark matching conrods and conrod

bearing caps with cylinder numbers -arrow- for re-installation.

Audi Q7 2007 ➤
Conrod installation position

• The cast lugs -arrows- on the ground surfaces of the conrod
pairs “1 and 2”, “3 and 4”, and “5 and 6” must face each other.
Oil spray jet for piston cooling

1- Apply locking fluid to bolt and tighten to 9 Nm; for locking
fluid refer to ⇒ Electronic parts catalogue .
2- Oil spray jet with spray nozzle valve (opening pressure:
2 ... 2.4 bar)
Caution
Risk of damage to oil spray jets due to deformation.

• Never bend oil spray jets.
4.2 Measuring radial clearance of conrods

♦ Plastigage
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap, secure with old bolts and tighten to
final torque ⇒ Item 1 (page 73) without rotating crankshaft.
– Remove conrod bearing cap again.
Radial clearance:
• New: 0.010 ... 0.052 mm.
– Renew conrod bolts.
4.3 Removing and installing pistons


Audi Q7 2007 ➤
♦ Drift - VW 222 A-
♦ Piston ring clamp, commercially available

Removing
• Engine secured to engine and gearbox support - VAS 6095-
⇒ page 31 .
– Remove cylinder head ⇒ page 122 .
– Remove upper section of sump ⇒ page 161 .
– Mark installation position and matching of conrod bearing caps
to cylinder and to conrods for re-installation ⇒ Fig. ““Marking
conrods”“ , page 74 .
– Unbolt conrod bearing caps.
– Pull out pistons upwards with conrods.
Note
If piston pin is difficult to remove, heat piston to approx. 60 °C.

– Take circlip out of piston pin boss.
– Use drift - VW 222 A- to drive out piston pin.

Installing
• Tightening torques ⇒ “4.1 Exploded view - pistons and con‐
rods”, page 73
Note
– Oil running surfaces of bearing shells.

– Install pistons using piston ring clamp.
Installation position:
• Pistons ⇒ Fig. ““Installation position of pistons”“ , page 74
• Conrods ⇒ Fig. ““Conrod installation position”“ , page 75
– Install conrod bearing caps according to markings.
– Install sump (upper section) ⇒ “1.6 Removing and installing
sump (top section)”, page 161 .
– Install cylinder head ⇒ “2.4 Removing and installing cylinder
heads”, page 122 .

Audi Q7 2007 ➤
4.4 Checking pistons and cylinder bores

Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.03 mm.
Piston ∅ mm
Nominal dimension 84.49 1)
• 1) Dimensions including coating (thickness approx. 0.02 mm).
The coating will wear down in service.
Measuring cylinder bore

– Use a cylinder gauge - VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal
direction -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore ∅ mm
Nominal dimension 84.51 1)
• 1) Measure at 50 mm into cylinder bore.
Measuring piston ring gap

– Insert ring atpermitted
right angle to cylinder wall fromAGabove
does notand push
unless authorised by AUDI AG. AUDI guarantee or accept any liability
down into lower withcylinder opening
respect to the correctnessapprox. 15inmm
of information from bottom
this document. Copyright by AUDI AG.
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
1st compression ring 0.20 … 0.30 0.80
2nd compression ring 0.50 … 0.70 0.80
Oil scraper ring 0.25 … 0.50 – 1)
• 1) Specification not yet available.

Audi Q7 2007 ➤
Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring new Wear limit
mm mm
1st compression ring 0.04 … 0.08 0.20
2nd compression ring 0.03 … 0.07 0.20
Oil scraper ring 0.02 … 0.06 0.15

Audi Q7 2007 ➤
15 – Cylinder head, valve gear

1 Chain drive
⇒ “1.1 Exploded view - timing chain covers”, page 79
⇒ “1.2 Removing and installing timing chain covers (left and
right)”, page 82
⇒ “1.3 Removing and installing timing chain cover (bottom)”, page
85
⇒ “1.4 Exploded view - camshaft timing chains”, page 90
⇒ “1.5 Removing timing chains from camshafts”, page 93
⇒ “1.6 Removing and installing camshaft timing chains”, page
104
⇒ “1.7 Exploded view - drive chain for valve gear”, page 106
⇒ “1.8 Removing and installing drive chain for valve gear”,
page 108
⇒ “1.9 Exploded view - drive chain for auxiliary drives”, page
109
⇒ “1.10 Removing and installing drive chain for auxiliary drives”,
page 110
⇒ “1.11 Exploded view - balance shaft”, page 113
⇒ “1.12 Removing and installing balance shaft”, page 114
1.1 Exploded view - timing chain covers

1. Chain drive 79
Audi Q7 2007 ➤
1 - Bolt
sequence ⇒ Fig. ““Tim‐
ing chain cover (bottom)
- tightening torque and
sequence”“ , page
82
2 - Oil seal
❑ For crankshaft (gearbox
end)
newing crankshaft oil
seal (gearbox end)”,
page 65
3 - Bolt
sequence ⇒ Fig. ““Tim‐
ing chain cover (bottom)
- tightening torque and
82
4 - Dowel sleeve
❑ 2x
5 - Timing chain cover (bottom)
❑ Installation instructions
for sleeve ⇒ page
89
stalling timing chain
cover (bottom)”, page
85
6 - Threaded pin
Item 13 (page 166)
7 - Cylinder head gasket (left-side)
8 - Bolt
❑ Renew
Tightening torque and sequence ⇒ Fig. ““Timing chain cover (left-side) - tightening torque and sequence”“ ,
page 81
9 - Bracket Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For wiring harness with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Bracket
❑ For wiring harness
11 - Bolt
❑ Renew
Tightening torque and sequence ⇒ Fig. ““Timing chain cover (left-side) - tightening torque and sequence”“ ,
page 81
12 - Timing chain cover (left-side)

❑ Removing and installing ⇒ “1.2 Removing and installing timing chain covers (left and right)”, page
82
13 - Seal
❑ Renew
80 Rep. gr.15 - Cylinder head, valve gear

Audi Q7 2007 ➤
14 - Seal
❑ Renew
15 - Cylinder head gasket (right-side)
16 - Timing chain cover (right-side)
❑ Removing and installing ⇒ “1.2 Removing and installing timing chain covers (left and right)”, page
82
17 - Nut
❑ 9 Nm
18 - Bracket
❑ For electrical wiring
19 - Threaded pin
❑ Tightening torque and sequence ⇒ Fig. ““Timing chain cover (right-side) - tightening torque and se‐
quence”“ , page 82
20 - Bracket
❑ For heat shield
21 - Bolt
❑ Renew
22 - Dowel sleeve
❑ 2x
23 - Bolt
❑ Renew
24 - Cover
❑ For starter aperture
25 - Engine speed sender - G28-
26 - Bolt
❑ Tightening torque
by AUDI⇒ AG.Rep. gr.does
28not guarantee or accept any liability
permitted unless authorised AUDI AG
27 - Cover
❑ For engine speed sender - G28-
Timing chain cover (left-side) - tightening torque and sequence
Note

♦ The brackets -arrows A and B- are secured together with the
timing chain cover (left-side).
– Tighten bolts in 2 stages in the sequence shown:

1. -1 … 8- 5 Nm
2. -1 … 8- Turn 90° further
1. Chain drive 81
Audi Q7 2007 ➤
Timing chain cover (right-side) - tightening torque and sequence
Note

♦ The bracket -arrow- is secured together with the timing chain
cover (right-side).

1. -1 … 8- 5 Nm
Timing chain cover (bottom) - tightening torque and sequence
Note

Securing with aluminium bolts: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Tighten aluminium bolts in stages as follows:
1. -arrows- 3 Nm
2. -1 … 10- 3 Nm in diagonal sequence
3. -1, 2, 4, 5, 7- Turn 90° further
4. -arrows- 9 Nm
5. -8, 9, 10- 8 Nm
6. -8, 9, 10- Turn 90° further
7. -3- 16 Nm
8. -6- 20 Nm
9. -6- Turn 180° further
Securing with steel bolts:
– Tighten steel bolts in stages as follows:
1. -arrows- 3 Nm
2. -1 … 10- 3 Nm in diagonal sequence
3. -1, 2, 4, 5, 7- and 9 Nm
-arrows-
4. -8, 9, 10- 20 Nm
5. -3- 16 Nm
6. -6- 70 Nm
1.2 Removing and installing timing chain

covers (left and right)
♦ Electric drill with plastic brush attachment
♦ Safety goggles

Audi Q7 2007 ➤

Removing
Note
Fit all cable ties in the original positions when installing.
– Lift off engine cover panel (rear) -2-.

– Remove corresponding combination valve for secondary air
system: left-side ⇒ page 267 , right-side ⇒ page 268 .
Timing chain cover (left-side):

– Unscrew bolts -1 ... 8- and detach brackets -arrows A, B-.
– Carefully release timing chain cover (left-side) from bonded
joint and detach.
Timing chain cover (right-side):

– Remove nutsunless
permitted -arrows-
authorisedand push
by AUDI AG. bracket
AUDI AG does -1-notwith electrical
guarantee or accept any liability
wiring harness
with respectto one
to the side. of information in this document. Copyright by AUDI AG.
correctness
– Remove bolts -1 ... 8-.

– Carefully release timing chain cover (right-side) from bonded
joint and detach.
Installing
Tightening torques
• ⇒ “1.1 Exploded view - timing chain covers”, page 79 .
• ⇒ Fig. ““Timing chain cover (left-side) - tightening torque and
sequence”“ , page 81 .
• ⇒ Fig. ““Timing chain cover (right-side) - tightening torque and
1. Chain drive 83
Audi Q7 2007 ➤
Note
Fit new O-rings.
– Remove old sealant from sealing surfaces.
Caution

WARNING

– Remove remaining sealant on timing chain cover and cylinder

head using rotating plastic brush or similar.
Note
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2

mm).
Caution

– Apply sealant bead -arrow- onto clean sealing surfaces of tim‐

ing chain cover as illustrated.
• Width of sealant bead: 2.5 mm.
Note
The timing chain cover must be installed within 5 minuteswithafter
applying the sealant.

Audi Q7 2007 ➤
– Install timing chain cover (left-side) and tighten bolts ⇒ Fig.

““Timing chain cover (left-side) - tightening torque and se‐
quence”“ , page 81 .
– Install timing chain cover (right-side) and tighten bolts ⇒ Fig.

““Timing chain cover (right-side) - tightening torque and se‐
note the following:
– Install combination valve for secondary air system: left-side ⇒
page 267 , right-side ⇒ page 268 .
1.3 Removing and installing timing chain

cover (bottom)
♦ Safety goggles
Removing
– Remove coolant pipe (top) ⇒ page 203 .
• Engine oil drained ⇒ Maintenance ; Booklet 406
Note
– Remove oil filter housing ⇒ page 167

Protected .
– Remove drive plate ⇒ page 62with
. respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove timing chain covers (left and right) ⇒ page 82 .
1. Chain drive 85
Audi Q7 2007 ➤
– Unplug electrical connector -3- for engine speed sender -

G28- .
Note
– Remove bolts -3- on timing chain cover (left-side) and detach

bracket.
Note
– Remove bolts -1- on timing chain cover (right-side) and detach

bracket.
Note

– Slacken bolts -1 ... 10- in diagonal sequence and remove.
– Carefully release timing chain cover (bottom) from bonded
joint and remove cover.
– Press crankshaft oil seal (gearbox end) out of timing chain
cover (bottom).

Audi Q7 2007 ➤
Installing
• Tightening torques ⇒ Fig. ““Timing chain cover (bottom) - tight‐
ening torque and sequence”“ , page 82
Note
– Pull dowel sleeve at top right out of cylinder block.

– Bevel the dowel sleeve with a file, as illustrated.
• Dimension -x- = 6.5 mm.
• Dimension -y- = 8 mm.
– Fit dowel sleeve on cylinder block in such a way that the bev‐
elled side points upwards.
Note
Bevelling the dowel sleeve makes it easier to fit the timing chain
cover (bottom) with the cylinder head installed.
Caution

WARNING

– Remove remaining sealant on timing chain cover (bottom),

cylinder block and cylinder head using rotating plastic brush
or similar.
– Before installing gearbox, remove residue from threaded holes
for engine/gearbox bolts in cylinder block using a thread tap.
1. Chain drive 87
Audi Q7 2007 ➤
– Clean old sealant from holes -arrow- in cylinder head gaskets.
Note
With the cylinder head installed the holes in the cylinder head
gasket are only half visible.
Caution
Avoid damage to cylinder head gasket.

♦ Only bend the ends of the cylinder head gaskets slightly
and do not kink.
Note
If the cylinder head gasket has been bent and kinked it must be
renewed.
– Carefully bend the ends of the cylinder head gaskets down

very slightly -arrows-, just far enough to be able to clean the
upper sealing surface on the cylinder head gasket and cylinder
head.
– Clean cylinder head gaskets (top and bottom); they must be
free of oil and grease.
Note

– Cut off nozzle of tube at front marking with

(nozzle
respect∅ approx. 2 of information in this document. Copyright by AUDI AG.
to the correctness
mm).

Audi Q7 2007 ➤
– Apply a small amount of sealant to sealing surfaces of cylinder

head gaskets (top and bottom). To do so, you again have to
bend cylinder head gaskets down very slightly -arrows-.
– Use a flat object (e.g. a feeler gauge) to apply sealant to the
area between cylinder head and gasket.
– Clean holes -arrow- in cylinder head gaskets and fill them with
sealant.
Note
Depending on version, a second sleeve -2- may be fitted between

sealing flange and cylinder block on left side of engine.
Caution
Risk of sealant entering hole for gearbox bolt.

♦ Appropriate sleeve -1- ⇒ Electronic parts catalogue must
be fitted before installing timing chain cover (bottom).
♦ Projection of sleeve -a- = 3 mm above the sealing surface.
Note
Sleeves -1- and -2- have different diameters and are not inter‐
changeable.
1. Chain drive 89
Audi Q7 2007 ➤
Caution

♦ The beads of sealant must not be thicker than specified.
– Apply sealant beads -1 ... 4- onto the clean sealing surfaces

of the timing chain cover (bottom) as illustrated.
with sealant.
• The beads of sealant must project 1.5 … 2.0 mm above the
sealing surface.
• Apply sealant -3- in a continuous bead as shown in illustration
(although groove is not continuous).
Note
The timing chain cover must be installed within 5 minutes after

– Insert seals -arrows- in grooves on timing chain cover (bot‐

tom).
– Fit timing chain cover (bottom), guiding it towards the sealing

surface on cylinder block and cylinder head at an angle and
from below.
– Take care not to damage the cylinder head gaskets when fit‐
ting the cover.
– Tighten bolts ⇒ Fig. ““Timing chain cover (bottom) - tightening
torque and sequence”“ , page 82 .
note the following:
– Install crankshaft oil seal (gearbox end) ⇒ page 65 .
– Install timing chain covers (left and right) ⇒ page 82 .
– Install drive plate ⇒ page 62 .
– Install coolant pipe (top) ⇒ page 203 .
– Install oil filter housing ⇒ page 167 .
– Install supercharger ⇒ page 230 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
406 .
1.4 Exploded view - camshaft timing chains

Camshaft timing chain (left-side)

Audi Q7 2007 ➤
1 - Bolt
❑ Renew
❑ 80 Nm +90°
2 - Bolt
❑ Renew
❑ 80 Nm +90°
3 - Camshaft chain sprocket
❑ For exhaust camshaft
⇒ “1.5 Removing timing
chains from camshafts”,
page 93
4 - Camshaft adjuster
❑ For inlet camshaft
❑ Identification “Intake”
page 93
Note
Depending on the version, the

camshaft adjuster may have three
or four recesses. The illustration
shows a camshaft adjuster with four
recesses.
5 - Camshaft timing chain (left-

side) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Mark direction of rota‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with a paint marker

❑ Removing from
camshafts ⇒ “1.5 Removing timing chains from camshafts”, page 93
❑ Removing and installing ⇒ “1.6 Removing and installing camshaft timing chains”, page 104
6 - Bolt
❑ 9 Nm
7 - Slide
8 - Chain tensioner
❑ For camshaft timing chain (left-side)
❑ Removing and installing ⇒ “1.5 Removing timing chains from camshafts”, page 93
9 - Bearing plate
❑ For drive chain sprocket
10 - Bolt
11 - Drive chain sprocket
❑ For camshaft timing chain (left-side)
12 - Bearing mounting
❑ For drive chain sprocket for camshaft timing chain (left-side)
13 - Bolts
1. Chain drive 91
Audi Q7 2007 ➤
Camshaft timing chain (right-side)
1 - Bolt
❑ Renew
❑ 80 Nm +90°
2 - Camshaft chain sprocket
❑ For exhaust camshaft
page 93
3 - Bolt
❑ Renew
❑ 80 Nm +90°
4 - Camshaft adjuster
❑ For inlet camshaft
❑ Identification “Intake”
page 93
Note
Depending on the version, the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
camshaft adjuster may have three permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
or four recesses. The illustration

shows a camshaft adjuster with four

recesses.
5 - Bolt
Item 15 (page 107)
for camshaft timing chain (right-side)
❑ Asymmetric version
❑ Installation position ⇒ Fig. ““Installation position: bearing mounting for drive sprocket for camshaft timing
chain (right-side)”“ , page 108
❑ For camshaft timing chain (right-side)
8 - Camshaft timing chain (right-side)
❑ Mark direction of rotation for re-installation with a paint marker
❑ Removing from camshafts ⇒ “1.5 Removing timing chains from camshafts”, page 93
❑ Removing and installing ⇒ “1.6 Removing and installing camshaft timing chains”, page 104
9 - Thrust washer
❑ For drive chain sprocket for camshaft timing chain (right-side)
10 - Chain tensioner

Audi Q7 2007 ➤
❑ For camshaft timing chain (right-side)

❑ Removing and installing ⇒ “1.5 Removing timing chains from camshafts”, page 93
11 - Slide
12 - Bolt
❑ 9 Nm
1.5 Removing timing chains from camshafts

equipment required

♦ Special wrench - T10035-
♦ Counterhold tool - T10172-
♦ Locking pin - T40069-
♦ 2x Locking pin - T40071-
♦ Adapter - T10172/10-
1. Chain drive 93
Audi Q7 2007 ➤
♦ 2x Camshaft clamp - T40133-
♦ Special wrench - T40269- for camshaft adjuster with three re‐

cesses
♦ Special wrench - T40079- for camshaft adjuster with 4 recess‐
es with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
WARNING

Note
♦ In the following procedure the camshaft timing chains remain

on the engine.
♦ Even when working on one cylinder head only, the procedure
must still be carried out on both cylinder banks.
– Remove timing chain covers (left and right) ⇒ page 82 .

Audi Q7 2007 ➤
– Remove cylinder head cover: left-side ⇒ page 119 ; right-

side ⇒ page 120 .
– Remove front noise insulation -1- ⇒ Rep. gr. 66 .
– Insert guide pin of adapter -T40058- as follows:

gine.
– Use adapter - T40058- and angled ring spanner to turn

crankshaft in direction of engine rotation -arrow- to “TDC”.
• The threaded holes -arrows- in the camshafts must face up‐

wards.
1. Chain drive 95
Audi Q7 2007 ➤
– Fit camshaft clamps - T40133- onto both cylinder heads and

tighten bolts -arrows- to 25 Nm.
Note
Illustration shows the cylinder head for cylinder bank 2 (left-side).
– Remove plug -arrow- for crankshaft “TDC” marking from cylin‐

der block.
– Screw locking pin - T40069- into hole (20 Nm); if necessary,

turn crankshaft -1- backwards and forwards slightly to fully
centralise locking pin.
Note
Chain tensioners for camshaft timing chain are oil-damped and

can only be compressed slowly by applying constant pressure.
– Press guide rail of chain tensioner for camshaft timing chain

(left-side) inwards as far as the stop using a screwdriver -1-.
Then lock chain tensioner by inserting locking pin - T40071- .

Audi Q7 2007 ➤
– Press guide rail of chain tensioner for camshaft timing chain

(right-side) inwards as far as the stop using a screwdriver
-1-. Then lock chain tensioner by inserting locking pin -
T40071- .
Camshaft adjusters with three recesses:
Caution
Risk of damage to camshaft if handled incorrectly.

• Never use camshaft clamp as a counterhold tool.
– Counterhold at corresponding camshaft adjuster by applying

special wrench - T40269- with torque wrench - V.A.G 1332-
and open ring spanner insert - V.A.G 1332/9- , and loosen bolt
-2-.
Notepermitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Disregard -item 1- and -arrow-.
• Perform the same procedure on the opposite cylinder bank.
Camshaft adjusters with four recesses:
Caution
Risk of damage to camshaft if handled incorrectly.

• Never use camshaft clamp as a counterhold tool.
– Counterhold at corresponding camshaft adjuster by applying

special wrench - T40079- with torque wrench - V.A.G 1332-
and open ring spanner insert - V.A.G 1332/9- , and loosen bolt
-2-.
Note
1. Chain drive 97
Audi Q7 2007 ➤
All vehicles (continued):

– Counterhold at corresponding camshaft sprocket by applying
counterhold tool - T10172A- with adapter - T10172/10- and
loosen bolt with special wrench - T10035- .
Note
Disregard -arrow-.
Caution
Risk of irreparable damage to engine.

♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine.
– Use paint to mark allocation of camshaft adjuster and

camshaft sprocket to corresponding cylinder head for re-in‐
stallation.
– Unscrew bolts -1- and -2- on cylinder head (left-side) and re‐
move camshaft adjuster and camshaft sprocket.
– Unscrew bolts -1- and -2- on cylinder head (right-side) and
remove camshaft adjuster and camshaft sprocket.
Installing
• Tightening torques ⇒ “1.4 Exploded view - camshaft timing
chains”, page 90
Note
Caution
Risk of damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshafts are turned.

Audi Q7 2007 ➤
• Drive chain for valve gear installed ⇒ “1.8 Removing and in‐
stalling drive chain for valve gear”, page 108
• Crankshaft -1- locked in “TDC” position with locking pin -
T40069- .
• Camshafts on both cylinder heads locked in “TDC” position

-arrows- with camshaft clamp - T40133- (25 Nm).
Note
When assembling, note the following:
Caution
Risk of damage to engine.

♦ The camshaft sprockets MUST be installed as described
in the following work steps:
• Fit camshaft sprockets according to marks applied when re‐

moving. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• When fitting camshaft sprockets, make sure that the lugs on
the camshaft sprockets engage in the slots on the
camshafts -arrows-.
Note
1. Chain drive 99
Audi Q7 2007 ➤
• Turn camshaft sprocket on camshaft anti-clockwise onto stop

-arrow-.
Note
• Dot -1- should align with adjustment window -2-.
Note
♦ Illustration shows the cylinder head for cylinder bank 2 (left-

side).
♦ Disregard the camshaft timing chain in the illustration.
Caution
Risk of damage to engine.

♦ The camshaft adjusters MUST be installed as described
in the following work steps:
• Fit camshaft adjusters according to marks applied during re‐

moval.
• Groove -1- on camshaft adjuster should align with adjustment
window -2-.
Noteby copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
♦ Illustration
with respect shows the cylinder
to the correctness head
of information for
in this cylinder
document. bank
Copyright by 1 (right-
AUDI AG.
side).
♦ Disregard the camshaft timing chain in the illustration.

Audi Q7 2007 ➤
Installation (continued)
– Re-install camshaft adjusters on cylinder head (left-side) in the
same position as before (pay attention to marks applied when
removing).
– Fit camshaft timing chain (left-side) onto drive sprocket,
camshaft adjuster and camshaft sprocket and fit bolts -1- and
-2- without tightening.
• It should just be possible to turn the camshaft adjuster and
camshaft sprocket on the camshaft without axial movement.
– Remove locking pin - T40071- .
– Re-install camshaft adjuster on cylinder head (right-side) in

the same position as before (pay attention to marks applied
when removing).
– Fit camshaft timing chain (right-side) onto drive sprocket,
camshaft adjuster and camshaft sprocket and fit bolts -1- and
-2- without tightening.
• It should just be possible to turn the camshaft adjuster and
camshaft sprocket on the camshaft without axial movement.
– Apply counterhold tool - T10172A- with adapter - T10172/10-

to camshaft sprocket of exhaust camshaft (right-side).
– Have a 2nd mechanic apply tension to camshaft timing chain
by pressing camshaft sprocket in direction of -arrow-.
– Tighten bolts as follows while keeping camshaft sprocket un‐
der tension:
Stage Bolt Tightening torque
1. On exhaust 80 Nm
camshaft
1. On inlet 80 Nm
camshaft
Camshaft adjusters with three recesses:

– Fit special wrench - T40269- onto camshaft adjuster of inlet
camshaft (left-side).
– Apply torque wrench - V.A.G 1332- with open ring spanner
insert - V.A.G 1332/9- to special wrench - T40269- .
– Have a second mechanic apply approx. 40 Nm of tension to
camshaft timing chain by pressing torque wrench - V.A.G
1332- in direction of -arrow-.
1. Chain drive 101

Audi Q7 2007 ➤
Camshaft adjusters with four recesses:

– Fit key - T40079- onto camshaft adjuster of inlet camshaft (left-
side).
– Apply torque wrench - V.A.G 1332- with open ring spanner
insert - V.A.G 1332/9- to key - T40079- .
– Have a second mechanic apply approx. 40 Nm of tension to
camshaft timing chain by pressing torque wrench - V.A.G
1332- in direction of -arrow-.
– Tighten bolts as follows while keeping camshaft adjuster un‐
der tension:
1. -1- on exhaust camshaft: 80 Nm
1. -2- on inlet camshaft: 80 Nm
– Tighten bolts securing camshaft adjuster and camshaft

sprocket on cylinder head (left-side) as follows:
2. -1- Tighten on exhaust camshaft to final
tightening torque ⇒ Item 2 (page 91)
2. -2- Tighten on inlet camshaft to final tight‐
ening torque ⇒ Item 1 (page 91)
– Tighten bolts securing camshaft adjuster and camshaft

sprocket on cylinder head (right-side) as follows:
2. -1- Tighten on inlet camshaft to final tight‐
ening torque ⇒ Item 3 (page 92)
2. -2- by copyright.
Protected Tighten
Copyingon exhaust
for private camshaft
or commercial to final
purposes, in part or in whole, is not
tightening
permitted unless authorised torque
by AUDI AG. AUDI⇒ AG
Item
does1not
(page 92)or accept any liability
guarantee
– Remove camshaft clamps - T40133- from both cylinder heads

-arrows-.
Note

Audi Q7 2007 ➤
– Using adapter - T40058- and angled ring spanner, turn

crankshaft
Protected by copyright. Copying2for
revolutions in normal
private or commercial direction
purposes, in part or in of rotation
whole, is not
-arrow-
permitted unless until
authorised crankshaft
by AUDI AG. AUDI AG isdoes
at “TDC” again.
not guarantee or accept any liability
Note
If you turn the crankshaft beyond “TDC” by mistake, turn it back

approx. 30° and set to “TDC” again.
• The threaded holes -arrows- in the camshafts must face up‐

wards.

tighten bolts -arrows- to 25 Nm.
1. Chain drive 103

Audi Q7 2007 ➤
– Screw the locking pin - T40069- directly into the hole.

• The locking pin - T40069- must engage in the locating hole in
crankshaft -1-. If it does not, reset valve timing.
– Remove camshaft clamps from both cylinder heads.
– Remove locking pin.
note the following:
– Install plug for crankshaft “TDC” mark ⇒ page 69 .
– Install cylinder head cover: left-side ⇒ page 119 ; right-side
⇒ page 120 .
– Install timing chain covers (left and right) ⇒ page 82 .
– Install front noise insulation ⇒ Rep. gr. 66 .
1.6 Removing and installing camshaft tim‐

ing chains
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Gearbox removed ⇒ Rep. gr.
with37 . to the correctness of information in this document. Copyright by AUDI AG.
respect
– Remove timing chain cover (bottom) ⇒ page 85 .

– Remove timing chain from camshafts on relevant side ⇒ page
93 .
Caution
If a used timing chain rotates in the opposite direction when it

is refitted, this can cause breakage.
♦ Mark running direction of timing chains (left and right) with
paint for re-installation. Do not attempt to mark the timing
chain with a centre punch or by making a notch or similar.
– Remove locking pin - T40071- and detach camshaft timing

chain (left-side).
– Remove bolts -1- and -2- and take off chain tensioner (right-
side).

Audi Q7 2007 ➤
– Press guide rail of chain tensioner for drive chain for valve gear
in direction of -arrow- and lock chain tensioner by inserting
locking pin - T40071- .
– Remove bolt -1- securing bearing mounting for drive chain
sprocket.
– Pull off drive sprocket with bearing mounting and lift off
camshaft timing chain (right-side).
Installing
• Tightening torques ⇒ “1.4 Exploded view - camshaft timing
chains”, page 90
Note
♦ Note the correct installation position if the tensioning element

has been removed from the chain tensioner: drilling in base of
housing faces chain tensioner and piston faces tensioner rail.
Caution
Risk of damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshafts are turned.
– Fit camshaft timing chain (left-side) on drive chain sprocket

according to marks made upon removal and guide chain up‐
wards to cylinder head.
– Press down guide rail of chain tensioner for timing chain (left-
side) and lock chain tensioner by inserting locking pin -
T40071- .
1. Chain drive 105

Audi Q7 2007 ➤
– Fit camshaft timing chain (right-side) on drive chain sprocket

according to marks made upon removal and guide chain up‐
wards to cylinder head.
– Install drive sprocket ⇒ page 108 .
– Tighten bolt -1- securing bearing mounting for drive chain
sprocket.
Note
Disregard -arrow-.
– Fit chain tensioner on cylinder head (right-side).

– Tighten bolts -1- and -2-.
note the following:
– Fit timing chains on camshafts ⇒ page 98 .
– Install timing chain cover (bottom) ⇒ page 85 .
1.7 Exploded view - drive chain for valve gear

Audi Q7 2007 ➤
1 - Guide rail
2 - Bolt
❑ Renew
❑ 10 Nm +90°
3 - Bolts
❑ Renew
❑ 5 Nm +60°
❑ For timing chain (left-
side)
6 - Bolt
❑ Renew
❑ 10 Nm +90°
7 - Drive chain
❑ For timing drive
❑ Mark direction of rota‐
with a paint marker
stalling drive chain for
valve gear”, page
108
8 - Bolt
❑ Renew
❑ 10 Nm +90°
9 - Guide rail
10 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 8 Nm +45°
11 - Bearing plate
❑ For drive chain sprocket for camshaft timing chain (right-side)
❑ For timing chain (right-side)
13 - Thrust washer
15 - Bolt
1. Chain drive 107

Audi Q7 2007 ➤
❑ Renew
❑ 30 Nm +90°
16 - Seal
❑ Renew
17 - Chain tensioner
❑ Removing and installing ⇒ “1.8 Removing and installing drive chain for valve gear”, page 108
18 - Bolt
❑ 9 Nm
19 - Crankshaft
20 - Bolt
❑ Renew
❑ 10 Nm +90°
Installation position: bearing mounting for drive sprocket for

camshaft timing chain (right-side)
• Dowel pins in bearing mounting -3- for drive sprocket for
camshaft timing chain (right-side) must engage in drillings in
thrust washer -1- and in cylinder block drillings.
2 - Drive sprocket for camshaft timing chain (right-side)
4 - Bolt
1.8 Removing and installing drive chain for

valve gear

Audi Q7 2007 ➤
Removing
– Remove timing chains from camshafts ⇒ page 93 .
– Remove drive chain for auxiliary drives ⇒ page 110 .
– Press guide rail of chain tensioner for drive chain in direction
of -arrow- and lock chain tensioner by inserting locking pin -
T40071- .
Caution
If a used drive chain rotates in the opposite direction when it is

refitted, this can cause breakage.
♦ Mark running direction of drive chain with paint for re-in‐
stallation. Do not attempt to mark the drive chain with a
centre punch or by making a notch or similar.
– Unscrew bolts -1- and remove guide rail.

– Remove bolts -2- and take off chain tensioner.
– Detach drive chain for valve gear.
Installing
Installation
permitted is carried
unless authorised by AUDIout
AG. in the
AUDI AGreverse order;ornote
does not guarantee acceptthe following:
any liability
• Tightening torques ⇒ “1.7 Exploded view - drive chain for valve
gear”, page 106
Note
– Position drive chain for valve gear onto drive chain sprockets
(according to marks applied during removal).
– Install guide rail and tighten bolts -1-.

– Install chain tensioner and tighten bolts -2-.
– Press guide rail of chain tensioner for drive chain in direction
of -arrow- and pull locking pin - T40071- out of chain tensioner.
– Install drive chain for auxiliary drives ⇒ page 110 .
1.9 Exploded view - drive chain for auxiliary drives
1. Chain drive 109

Audi Q7 2007 ➤
1 - Crankshaft
2 - Drive chain
❑ For auxiliary drives
❑ Mark direction of rota‐
with a paint marker
⇒ “1.10 Removing and
installing drive chain for
auxiliary drives”, page
110
❑ For oil pump
❑ Installation position:
Side with lettering faces
engine
4 - Bolt
❑ Renew
❑ 30 Nm +90°
5 - Compression spring
6 - Bolt
❑ Renew
❑ 15 Nm +90°
7 - Chain sprocket for balance
shaft
Side with lettering faces
gearbox
8 - Chain tensioner
❑ With guide rail
9 - Bolt
❑ Renew
❑ 10 Nm +45°
1.10 Removing and installing drive chain for

auxiliary drives
♦ Special wrench - T40049-

Audi Q7 2007 ➤
♦ Locating pins - T40116-
Removing
Caution with respect to the correctness of information in this document. Copyright by AUDI AG.
Risk of damage to drive chain if thread of bolt exceeds speci‐

fied length.
♦ Use bolts with a maximum thread length -a- of 22 mm to
attach special wrench -T40049- .
♦ If no suitable bolts are available, position suitable washer
(s) under bolt head so that remaining thread length does
not exceed 22 mm.
1. Chain drive 111

Audi Q7 2007 ➤
– Attach special wrench - T40049- at rear end of crankshaft us‐

ing 2 bolts -arrows-.
– Remove plug -arrow- for crankshaft “TDC” marking from cylin‐

der block.
– Rotate crankshaft in normal direction of rotation to “TDC”.
– Screw locking pin - T40069- into hole (20 Nm); if necessary,

turn crankshaft -1- backwards and forwards slightly to fully
centralise locking pin.
– Press guide rail of chain tensioner in direction of -arrow- and

lock chain tensioner by inserting locking pin - T40071- .
Caution
If a used drive chain rotates in the opposite direction when it is

refitted, this by
Protected can cause
copyright. breakage.
Copying for private or commercial purposes, in part or in whole, is not
♦ Markwithrunning direction
respect to the correctnessof
of drive chain
information in thiswith paint
document. for re-in‐
Copyright by AUDI AG.
stallation. Do not attempt to mark the drive chain with a
centre punch or by making a notch or similar.
– Unscrew bolts -3- and detach chain sprocket from balance

shaft.
– Remove bolts -1- and -2- and take off chain tensioner with
chain.

Audi Q7 2007 ➤
Installing
• Tightening torques ⇒ “1.9 Exploded view - drive chain for aux‐
iliary drives”, page 109
T40069- .
Note
– Install chain tensioner with chain and balance shaft sprocket.

– Lock balance shaft in “TDC” position using locating pin -
T40116- .
• The elongated holes in the balance shaft sprocket must be
aligned centrally over the threaded holes in the balance shaft.
If necessary move chain one tooth further.
– Tighten bolts for chain tensioner.
– Fit bolts -1- for chain sprocket without tightening.
• It should just be possible to turn the sprocket on the balance
shaft without axial movement.
– Pull out locking pin - T40071- to release chain tensioner.
– Press against guide rail of chain tensioner -arrow- using a
screwdriver, and at the same time tighten bolts -1- securing
chain sprocket.
– Pull locating pin -T40116- out of balance shaft.
note the following:
– Install plug for crankshaft “TDC” mark ⇒ page 69 .
1.11 Exploded view - balance shaft
1. Chain drive 113

Audi Q7 2007 ➤
1 - Balance shaft
installing balance shaft”,
page 114
2 - Bolt
❑ 60 Nm
❑ Use locating pin -
T40116- as counterhold
when loosening and
tightening
3 - Balance weight (gearbox
end)
❑ Can only be fitted on
balance shaft in one po‐
sition.
4 - Bearing plate
5 - Bolt
❑ 13 Nm
6 - Balance weight (pulley end)
❑ Can only be fitted on
balance shaft in one po‐
sition.
7 - Bolt
❑ 60 Nm
❑ Use locating pin -
T40116- as counterhold
when loosening and
tightening
1.12 Removing and installing balance shaft

Removing
• Gearbox removed
– Remove sealing flange (pulley end) ⇒ page 58 .
– Remove drive chain for auxiliary drives ⇒ page 110 .

Audi Q7 2007 ➤
– Use locating pin -T40116- to lock balance weight -1- in position

at rear of engine.
– Unscrew bolt -2- and detach balance weight from balance
shaft.
– Unscrew bolt -2- (counterhold balance weight -1- with a suit‐

able pin) and detach balance weight at front of engine from
balance shaft.
– Unscrew bolts -arrows- and detach bearing plate for balance

shaft at rear of engine. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull balance shaft to rear out of cylinder block.
Installing
• Tightening torques ⇒ “1.11 Exploded view - balance shaft”,
page 113
T40069- .
Note
Balance weights can only be fitted on balance shaft in one posi‐

tion.
– Install drive chain for auxiliary drives ⇒ page 110 .

– Install sealing flange (pulley end) ⇒ page 58 .
1. Chain drive 115

Audi Q7 2007 ➤
2 Cylinder head
⇒ “2.1 Exploded view - cylinder head”, page 116
⇒ “2.2 Removing and installing cylinder head cover (left-side)”,
page 119
⇒ “2.3 Removing and installing cylinder head cover (right-side)”,
page 120
⇒ “2.4 Removing and installing cylinder heads”, page 122
⇒ “2.5 Checking compression”, page 130
2.1 Exploded view - cylinder head
Note
1 - Cylinder head gasket

moving and installing
cylinder heads”, page
122
part number withmust
respect face
to the correctness of information in this document. Copyright by AUDI AG.
cylinder head
❑ If renewed, change
coolant and engine oil
2 - Cylinder head
stalling cylinder heads”,
page 122
❑ Checking for distortion
⇒ Fig. ““Checking cylin‐
der head for distortion”“ ,
page 118
❑ Machining limit ⇒ Fig.
““Cylinder head machin‐
ing limit”“ , page 119
❑ If renewed, change
coolant and engine oil
3 - O-ring
❑ Renew
4 - Hall sender
❑ Cylinder bank 1 (right-
side): Hall sender - G40-
❑ Cylinder bank 2 (left-
side): Hall sender 2 -
G163-
5 - Bolt
Rep. gr. 28
6 - Bolt
❑ Renew

Audi Q7 2007 ➤
❑ Note correct sequence when loosening ⇒ page 127

❑ Tightening torque and sequence ⇒ Fig. ““Cylinder head - tightening torque and sequence”“ , page
118
7 - Ignition coil
8 - Cylinder head cover
❑ Removing and installing: left-side ⇒ page 119 , right-side ⇒ page 120
9 - Seal
❑ Renew if damaged or leaking
10 - Filler cap
11 - Hose
❑ For crankcase breather
❑ Removing and installing ⇒ “3.2 Removing and installing crankcase breather hoses”, page 174
Caution
Risk of violating emis‐
sion legislation applying
to USA models.
Do
♦ NOT open hose con‐
nection.
12 - O-ring
❑ Renew
13 - Bolt
❑ Renew if seal is damaged
❑ ⇒ Fig. ““Cylinder head cover (left-side) - tightening torque and sequence”“ , page 118 , ⇒ Fig. ““Cylinder
head cover (right-side) - tightening torque and sequence”“ , page 118
14 - Bolt
15 - Connector rail
❑ For ignition coils
16 - Gasket
❑ For cylinder head cover
❑ Renew if damaged or leaking
17 - Camshaft control valve
❑ Cylinder bank 1 (right-side): camshaft control valve 1 - N205-
❑ Cylinder bank 2 (left-side): camshaft control valve 2 - N208-
18 - Bolt
❑ 5 Nm
19 - O-ring
❑ Renew
2. Cylinder head 117

Audi Q7 2007 ➤
Cylinder head cover (left-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 12- to 9 Nm.
Cylinder head cover (right-side) - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 12- to 9 Nm.
Cylinder head - tightening torque and sequence
Note

Stage Bolts TighteningProtected
torque/angle
by copyright.specification
1. -1 … 8- Screw in by hand until
with respect contact
to the is made
correctness of information in this document. Copyright by AUDI AG.
2. -1 … 8- 40 Nm
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. distortion: 0.05 mm.

Audi Q7 2007 ➤
Cylinder head machining limit

Machining of the cylinder head (surface grinding) is only permis‐
sible down to the minimum dimension -a-.
• Minimum dimension: -a- = 139.20 mm
Guide tube for oil dipstick - tightening torque

– Tighten bolt -arrow- to 9 Nm.
2.2 Removing and installing cylinder head

cover (left-side)
Removing
– Remove ignition coils ⇒ Rep. gr. 28 .
Rest-of-world vehicles:
– Disconnect crankcase breather hose -arrow- by pressing re‐
lease tabs.
– Remove bolts in the sequence -12 ... 1- and remove cylinder
head cover (left-side).
USA models:
Caution
Risk of violating emission legislation applying to USA models.

♦ Do NOT open hose connection -arrow-.
– Remove bolts in the sequence -12 ... 1- and move cylinder

head cover (left-side) clear to one side with crankcase
breather hose -arrow- still connected.

Audi Q7 2007 ➤
Installing
• Tightening torques ⇒ Fig. ““Cylinder head cover (left-side) -
tightening torque and sequence”“ , page 118
Note
♦ Fit new O-ring.

♦ Renew gasket for cylinder head cover if damaged.
♦ Renew bolts for cylinder head cover if seals on bolts are dam‐
aged.

– Tighten bolts for cylinder head cover (left-side) ⇒ page 118 .
– Install ignition coils ⇒ Rep. gr. 28 .
2.3 Removing and installing cylinder head

cover (right-side)
Removing
– Remove ignition coils ⇒ Rep. gr. 28 .

Audi Q7 2007 ➤
– Lift off cover -arrow-.
ProtectedCaution
♦ Observe rules for cleanliness when working on the fuel
supply system ⇒ page 6 .
WARNING


– Loosen union nut -2- and pivot fuel supply line to one side.
Rest-of-world vehicles:
– Disconnect crankcase breather hose -arrow- by pressing re‐
lease tabs.
– Remove bolts in the sequence -12 ... 1- and remove cylinder
head cover (right-side).
USA models:
Caution

♦ Do NOT open hose connection -arrow-.
– Remove bolts in the sequence -12 ... 1- and move cylinder

head cover (right-side) clear to one side with crankcase
breather hose -arrow- still connected.
Installing

Audi Q7 2007 ➤

• Tightening torques ⇒ Fig. ““Cylinder head cover (right-side) -
tightening torque and sequence”“ , page 118
Note
♦ Fit new O-ring.

♦ Renew gasket for cylinder head cover if damaged.
♦ Renew bolts for cylinder head cover if seals on bolts are dam‐
aged.

– Tighten bolts for cylinder head cover (right-side) ⇒ Fig. ““Cylin‐
der head cover (right-side) - tightening torque and se‐
– Install fuel supply line ⇒ Rep. gr. 24 .
2.4 Removing and installing cylinder heads

♦ Special wrench, long reach - T10070- for vehicles up to ► July

2011

Audi Q7 2007 ➤
♦ Bit XZN 12 - T40270- , for vehicles from July 2011 ► onwards
Removing
Note
♦ The following chapter describes how to remove both cylinder

heads together.
♦ If only one of the cylinder heads is to be removed, refer to the
corresponding procedure described in this chapter.
♦ Fit all cable ties in the original positions when installing.
– To remove cylinder head (right-side), first remove coolant pipe

(top) ⇒ page 203 .
– Remove intake manifold bottom sections ⇒ Rep. gr. 24 .
– Remove catalytic converter: left-side ⇒ page 251 ; right-side
⇒ page 252 .
– Unplug electrical connectors -1, 2, 3- from injectors on both
sides.
Note
Disregard -item 4-. by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
– Remove timing chain from camshafts on relevant side ⇒ page

93 .
– Remove locking pin - T40071- from cylinder head (left-side).

Audi Q7 2007 ➤
– Remove bolts -1- and -2- and detach chain tensioner from
cylinder head (right-side).
Note
Locking pin - T40071- remains in place.
– Remove bolts for power steering pump pulley (counterhold

– Remove bolts -1 and 2- and move power steering pump to one

side.
Note
– Unplug electrical connector -1- for air conditioner compressor

regulating valve - N280- .
– Remove bolt -2- for earth connection.

Audi Q7 2007 ➤
– Unplug electrical connectors on cylinder head (left-side):

1 - For Hall sender 2 - G163-
3 - For camshaft control valve 2 - N208-
– Move electrical wiring harness clear to side.
Note
Ignore items marked -2- and -arrows-.
– Unplug electrical connector -1- for coolant temperature sender

- G62- .
– Remove bolts -arrows- at coolant pipe (front).

– Unplug electrical connectors
permitted on cylinder
unless authorised by AUDI AG.head (right-side):
AUDI AG does not guarantee or accept any liability
1- Camshaft control valve 1 - N205-
2- Hall sender - G40-
– Move electrical wiring harness clear to side.
Note
Disregard -arrows-.

Audi Q7 2007 ➤
– Remove bolt -arrow- and pull out guide tube for oil dipstick.
– Unplug electrical connectors:

1 - For Lambda probe - G39- (right-side)
2 - For Lambda probe 2 - G108- (left-side)
Note
– Release hose clip -1-, detach vacuum hose from vacuum

pump and move vacuum hose clear.
Note
Disregard -arrows-.
For cylinder head (right-side) only

All vehicles (continued)

– Remove bolts -arrows- at rear of cylinder head.
♦ Cylinder head (left-side): 3 bolts
♦ Cylinder head (right-side): 4 bolts

Audi Q7 2007 ➤
Note
♦ Depending on the version, different camshafts (with or without

recesses) and cylinder head bolts (with or without collar) are
fitted.
♦ Distinguishing features:
♦ Cylinder head bolts without a collar have a Polydrive head.
♦ Cylinder head bolts with a collar have a multi-point socket
head.
♦ Camshafts with assembly clearance feature have tool recess‐
es -arrows-; the cylinder head bolts without a collar can be
removed without any further preparation. Those with a collar
cannot be removed without further preparation (camshafts
must be removed ⇒ page 136 before cylinder head bolts can
be unscrewed).
♦ Camshafts without tool recesses must be removed ⇒ page
136 before the cylinder head bolts can be removed.
– Use special wrench, long reach - T10070-
permitted / bit XZN
unless authorised 12 AG.
by AUDI - AUDI AG does not guarantee or accept any liability
T40270- to slacken cylinder head bolts in the sequence
-1 ... 8-.
– Unscrew bolts, detach cylinder head and set it down on a soft
surface (foam plastic).
Installing
• Tightening torques ⇒ “2.1 Exploded view - cylinder head”,
page 116
Caution
Risk of damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Risk of damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Ensure that cylinder head gasket seals properly:
♦ Carefully remove any remaining emery and abrasive ma‐
terial.
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Risk of damage to open valves.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Risk of damage to valves and piston crowns after working on
valve gear.

Audi Q7 2007 ➤
♦ Turn the engine carefully at least 2 rotations to ensure that

none of the valves make contact when the starter is op‐
erated.
Note

♦ Renew self-locking nuts as well as seals, gaskets and O-rings.
♦ Note the different sealants for sealing surfaces and cylinder
head bolts ⇒ Electronic parts catalogue .
♦ When installing an exchange cylinder head, the contact sur‐
faces between the hydraulic compensation elements, roller
rocker fingers and cams must be oiled before installing the
cylinder head cover.
♦ After renewing the cylinder head or cylinder head gasket,
change the coolant and engine oil.
Cylinder head with camshafts installed

• Camshafts on both cylinder heads locked in “TDC” position
-arrows- with camshaft clamp - T40133- (25 Nm).
• The camshaft clamp - T40133- is positioned correctly if the
holes for the cylinder head bolts remain free.

T40069- .

Audi Q7 2007 ➤
– Fit new seals for coolant pipe (front).

– Place cylinder head gasket in position.
• Installation position: the word “oben” (top) or the Part No.
should be visible.
• Pay attention to dowel sleeves -arrows- in cylinder block.
– Fit cylinder head.
– Tighten cylinder head bolts ⇒ Fig. ““Cylinder head - tightening

torque and sequence”“ , page 118 .
Cylinder head with camshafts removed
– Install camshafts ⇒ page 136 .

– Tighten bolts -arrows- for timing chain cover (bottom) ⇒ Fig.
““Timing chain cover (bottom) - tightening torque and se‐
♦ Cylinder head (left-side): 3 bolts
♦ Cylinder head (right-side): 4 bolts
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Cylinder head bolts do not have to be torqued down again later

after repair work.

note the following:
– Install dipstick guide tube ⇒ Fig. ““Guide tube for oil dipstick -
tightening torque”“ , page 119 .
– Install coolant pipe (front) ⇒ page 197 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install power steering pump ⇒ Rep. gr. 48 .
– Install camshaft timing chains ⇒ page 104 .
– Install catalytic converter: left-side ⇒ page 251 ; right-side
⇒ page 252 .
– Install intake manifold (bottom sections) ⇒ Rep. gr. 24 .
– Install poly V-belt ⇒ page 54 .
– Change engine oil ⇒ Maintenance ; Booklet 406 .

Audi Q7 2007 ➤
– Fill cooling system with fresh coolant ⇒ page 179 .
2.5 Checking compression

♦ Spark plug socket and extension - 3122 B-
♦ Compression tester - V.A.G 1763-
Procedure
• Engine oil temperature at least 30 ℃ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Battery voltage at least 12.5 V permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Remove all ignition coils ⇒ Rep. gr. 28 .
– Unplug electrical connector -1- for injectors at rear of cylinder

head (left and right).
Note
– Remove spark plugs with spark plug socket and extension -

3122 B- .
– Check compression pressure with compression tester -
V.A.G 1763- .

Audi Q7 2007 ➤
Note
Using the compression tester ⇒ Operating instructions .
– Have a 2nd mechanic press down the accelerator pedal com‐

pletely and at the same time operate the starter until the
pressure on the tester display no longer increases.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 11.0 … 14.0
Wear limit 10.0
Difference between cylinders 3.0 (maximum)
– Install spark plugs ⇒ Maintenance ; Booklet 406 .
– Erase any entries in event memory resulting from testing
⇒ Vehicle diagnostic tester, Guided Functions , then In-
terrogate event memory .

Audi Q7 2007 ➤
3 Valve gear
⇒ “3.1 Exploded view - valve gear”, page 132
⇒ “3.2 Checking axial clearance of camshafts”, page 135
⇒ “3.3 Measuring radial clearance of camshafts”, page 136
⇒ “3.4 Removing and installing camshafts”, page 136
⇒ “3.5 Checking hydraulic compensation elements”, page
143
⇒ “3.6 Renewing valve stem oil seals with cylinder head in‐
stalled”, page 145
⇒ “3.7 Renewing valve stem oil seals with cylinder head re‐
moved”, page 148
⇒ “3.8 Valve dimensions”, page 152
⇒ “3.9 Checking valve guides”, page 152
⇒ “3.10 Checking valves”, page 153
Caution
Risk of damage to valves and piston crownsProtected

after working on
valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30

minutes after installing camshafts before starting engine.
erated.
Note
Cylinder heads which have cracks between the valve seats or

between a valve seat insert and the spark plug thread can be re-
installed without reducing service life, provided the cracks are
only slight and do not exceed a maximum of 0.3 mm in width, and
no more than the first 4 turns of the spark plug threads are
cracked.
3.1 Exploded view - valve gear
Note

Audi Q7 2007 ➤
1 - Sealing plug
❑ Apply sealant when in‐
stalling; refer to ⇒ Elec‐
tronic parts catalogue
2 - Cylinder head
❑ Checking valve guides
⇒ “3.9 Checking valve
guides”, page 152
3 - Valve stem oil seal
❑ Renewing with cylinder
head installed ⇒
“3.6 Renewing valve
stem oil seals with cylin‐
der head installed”,
page 145
❑ Renewing with cylinder
head removed ⇒
“3.7 Renewing valve
stem oil seals with cylin‐
der head removed”,
page 148
4 - Valve spring
❑ Installation position ⇒
Fig. ““Installation posi‐
tion of valve spring”“ ,
page 134
5 - Hydraulic compensation el‐
ement
❑ Clipped into roller rocker
finger -item 8-
❑ Checking ⇒ “3.5 Check‐
ing hydraulic compen‐
sation elements”, page
143
❑ Mark installation posi‐
❑ Lubricate contact surface before installing
6 - Valve spring plate
7 - Valve cotters
8 - Roller rocker finger
❑ Mark installation position for re-installation
❑ Check roller bearings for ease of movement
❑ Lubricate contact surface before installing
❑ Assembly: attach to hydraulic compensation element -item 5- using securing clip -item 9-
9 - Securing clip
❑ Not supplied separately
❑ Check for firm attachment
10 - Inlet camshaft
❑ Removing and installing ⇒ “3.4 Removing and
Protected by installing
copyright. Copyingcamshafts”, pagepurposes,
for private or commercial 136 in part or in whole, is not
❑ Measuring axial clearance ⇒ “3.2 Checking axial clearance of camshafts”, page 135
❑ Measuring radial clearance ⇒ “3.3 Measuring radial clearance of camshafts”, page 136
❑ Runout: max. 0.04 mm
11 - Bolt
❑ Renew
3. Valve gear 133

Audi Q7 2007 ➤
❑ Tightening torque and sequence ⇒ Fig. ““Retaining frame for camshafts - tightening torque and se‐
12 - Retaining frame
❑ With integrated camshaft bearings
❑ Removing and installing ⇒ “3.4 Removing and installing camshafts”, page 136
13 - Compression ring
14 - Rectangular section seals
❑ One or two fitted depending on version; for allocation, refer to ⇒ Electronic parts catalogue
15 - Exhaust camshaft
❑ Removing and installing ⇒ “3.4 Removing and installing camshafts”, page 136
❑ Measuring axial clearance ⇒ “3.2 Checking axial clearance of camshafts”, page 135
❑ Measuring radial clearance ⇒ “3.3 Measuring radial clearance of camshafts”, page 136
❑ Runout: max. 0.04 mm
16 - Oil strainer
❑ Not fitted on all versions; for allocation, refer to ⇒ Electronic parts catalogue
17 - Inlet valve
❑ Must not be machined; only grinding-in is permissible
❑ Checking ⇒ “3.10 Checking valves”, page 153
❑ Valve dimensions ⇒ “3.8 Valve dimensions”, page 152
❑ Checking valve guides ⇒ “3.9 Checking valve guides”, page 152
18 - Exhaust valve
❑ Must not be machined; only grinding-in is permissible
❑ Checking ⇒ “3.10 Checking valves”, page 153
❑ Valve dimensions ⇒ “3.8 Valve dimensions”, page 152
❑ Checking valve guides ⇒ “3.9 Checking valve guides”, page 152
Installation position of valve spring

• Closely spaced spring coils -arrow- face towards cylinder
head.

Audi Q7 2007 ➤
Retaining frame for camshafts - tightening torque and sequence
Note
♦ The illustration shows the retaining frame for the camshafts of

the left-hand cylinder head. The procedure is symmetrically
opposite on the right-hand cylinder head.

1. -1 … 21- Screw in by hand until they make con‐
tact.
• The retaining frame should make
contact with the cylinder head over
the full surface
2. -1 … 21- 8 Nm
3. -1 … 21- Turn 90° further
3.2 Checking axial clearance of camshafts

3. Valve gear 135

Audi Q7 2007 ➤
Procedure
– Remove camshafts ⇒ page 136 .
– Mark allocation of roller rocker fingers for re-installation.
– Carefully remove roller rocker fingers and place them on a
clean surface.
– Re-insert camshafts, install retaining frame ⇒ Fig. ““Retaining
frame for camshafts - tightening torque and sequence”“ , page
135 and tighten with old bolts to 8 Nm.
– Secure universal dial gauge bracket - VW 387- with dial gauge
- VAS 6079- to cylinder head as shown in illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
• Axial clearance: 0.100 ... 0.191 mm
3.3 Measuring radial clearance of

camshafts
♦ Plastigage
Procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove camshafts ⇒ page 136 . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Mark allocation of roller rocker fingers for re-installation.

– Carefully remove roller rocker fingers and place them on a
clean surface.
– Clean bearings and bearing journals.
bearing on the bearing journal or bearing shell to be measured.
• The Plastigage must be positioned in the centre of the bearing.
– Re-insert camshafts, fit retaining frame, secure with old bolts
and tighten to final torque without rotating camshafts ⇒ Fig.
““Retaining frame for camshafts - tightening torque and se‐
– Remove retaining frame and camshafts again.
Radial clearance:
• 24 mm bearing diameter: 0.024 ... 0.066 mm
• 36 mm bearing diameter: 0.032 ... 0.078 mm
– When carrying out final assembly, use new bolts.
3.4 Removing and installing camshafts


Audi Q7 2007 ➤
♦ Impact extractor attachment -T10133/3- from tool set for FSI

engines - T10133 C-
♦ Electric drill with plastic brush

♦ Safety goggles
Note
The following description is for removing and installing on cylinder

head (left-side).
Removing
– Remove timing chains from camshafts ⇒ page 104 .
– To remove camshafts in cylinder head (left-side), first remove
vacuum pump ⇒ Rep. gr. 47 .
3. Valve gear 137

Audi Q7 2007 ➤
– To remove camshafts in cylinder head (right-side), first re‐

move high-pressure pump and housing for high-pressure
pump drive ⇒ Rep. gr. 24 .
– Remove bolt -arrow- and detach camshaft control valve -

N205- / -N208- .
– Unplug electrical connector -1- at Hall sender -G40- / -G163- .
Note
Disregard -arrow-.
Note
Disregard -item 1-.

Audi Q7 2007 ➤
– Move clear vacuum hose -1- on cylinder bank 2 (left-side).

– Remove bolts -arrows- and detach cover -2-.
– Slacken retaining frame bolts in the sequence -21 ... 1-.
Note
Perform the same procedure (laterally reversed) on retaining

frame (right-side).
– Remove bolts, carefully release retaining frame from bonded

joint and set it down with camshafts on a soft surface on work‐
bench.
– Remove camshaft clamp - T40133- -arrows-.

– Mark camshafts, remove and place on a clean surface.
Installing
• Tightening torques ⇒ “3.1 Exploded view - valve gear”, page
132
Note
Renew seals/gaskets and sealing plugs.

T40069- .
• Hydraulic compensation elements and roller rocker fingers in‐
stalled.
3. Valve gear 139

Audi Q7 2007 ➤
Caution
Protect lubrication system and bearings against contamina‐

tion.
WARNING

– Remove remaining sealant from cylinder head and retaining

frame using rotating plastic brush or similar.
– Check strainer -arrow- for dirt and clean as necessary.
Note
Strainer -arrow- is not fitted on all versions; for allocation refer to

⇒ Electronic parts catalogue .
– Oil running surfaces of both camshafts.
– Fit camshafts in retaining frame.

• Camshafts must be in correct position in axial bearings
-arrows- in retaining frame.
• The ends of the rectangular section seals -1, 2, 3- must point
up or down. The ends of the rectangular section seals must
never point to the side.
Note
One or two rectangular section seals are installed on the exhaust

camshaft -2 and/or 3- (depending on version). For allocation, re‐
fer to ⇒ Electronic parts catalogue .
– Turn retaining frame over with camshafts fitted, holding

camshafts firmly in position.

Audi Q7 2007 ➤
– Turn camshafts until threaded holes -arrows- point upwards.

– Check that camshafts are still in correct position in axial bear‐
ings in retaining frame.

tighten bolts -arrows- to 25toNm.

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

mm).
– Turn retaining frame upside down again.
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
♦ The beads of sealant must not be thicker than specified.
– Apply beads of sealant -4 ... 8- onto clean sealing surfaces of

retaining frame as shown in illustration.
• Width of beads of sealant: 2.0 mm.
– Apply beads of sealant -1 ... 3- onto clean sealing surfaces of
retaining frame as shown in illustration.
• Width of beads of sealant: 2.5 mm.
Note
3. Valve gear 141

Audi Q7 2007 ➤
The retaining frame must be installed within 5 minutes after ap‐

plying the sealant.
– Fit retaining frame onto cylinder head.

– Insert locating pins -T40116- in retaining frame and cylinder
head.
– Tighten bolts securing retaining frame for camshafts ⇒ Fig.

““Retaining frame for camshafts - tightening torque and se‐
Note
After installing the retaining frame, wait about 30 minutes for the
sealant to dry.
– Clean bore for sealing plug in cylinder head; it must be free of

oil and grease.
– Coat outer circumference of sealing plug -arrow- with sealant;
for sealant refer to ⇒ Electronic parts catalogue .
– Drive in sealing plug until flush.

Audi Q7 2007 ➤
– Use impact extractor attachment -T40116- to pull out locating

pins -T10133/3- .
note the following:
– Install camshaft control valves -N205- / -N208- ⇒ page 116 .
– Install housing for high-pressure pump drive and high-pres‐
sure pump ⇒ Rep. gr. 24 .
– Install vacuum pump ⇒ Rep. gr. 47 .
Caution
Risk of damage to valves and piston crowns after working on

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
erated.
3.5 Checking hydraulic compensation ele‐

ments
Note
♦ The hydraulic compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge
ProcedureProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Start engine and run until radiator fan has started up once.
– Increase engine speed to approx. 2500 rpm for 2 minutes

(perform road test if necessary).
– If the compensation elements are still noisy, locate the defec‐
tive compensation element as follows:
WARNING
3. Valve gear 143

Audi Q7 2007 ➤

– Remove cylinder head cover: left-side ⇒ page 119 ; right-side

⇒ page 120 .
– Insert guide pin of adapter
with respect-T40058- as follows:
to the correctness of information in this document. Copyright by AUDI AG.

gine.
– Use adapter - T40058- and angled ring spanner to turn

crankshaft in direction of engine rotation -arrow-.

Audi Q7 2007 ➤
– Press roller rocker finger down -arrow- to determine clearance

between cam and roller rocker finger.
– If it is possible to insert a feeler gauge of 0.20 mm between
cam and roller rocker finger, renew hydraulic compensation
element ⇒ “3.4 Removing and installing camshafts”, page
136 .
Additional steps required
– Install cylinder head cover: left-side ⇒ page 119 ; right-side ⇒
page 120 .
3.6 Renewing valve stem oil seals with cylinder head installed

equipment required
♦ Spark plug socket and extension - 3122 B-

♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
♦ Removal and installation device for valve cotters - VAS 5161-
with guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS
5161/19C-
3. Valve gear 145

Audi Q7 2007 ➤
♦ Adapters - T40012-
Removing
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Remove spark plugs with spark plug socket and extension -
3122 B- .
– Set piston of appropriate cylinder to “bottom dead centre”.
– Apply drift -VAS 5161/3A- to valve spring plate and use plas‐
tic-headed hammer to release sticking valve cotters.
– Fit guide plate -VAS 5161/19C- from removal and installation

device for valve cotters - VAS 5161- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw adapter - T40012- with seal hand-tight into the corre‐
sponding spark plug thread.
– Connect adapter to compressed air line using a commercially
available connection piece, and apply constant air pressure.
• Minimum pressure: 6 bar
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screwProtected
back and forth Copying
by copyright. slightly; the valve
for private cotters
or commercial purposes, in part or in whole, is not
are thus forced apartpermitted
and taken up by the assembly cartridge.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Release pressure fork.

– Take out assembly cartridge.
– Detach guide plate and turn to one side.
• The compressed air hose remains connected.
– Detach valve spring with valve spring plate.

Audi Q7 2007 ➤
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
If the valve stem seal puller - 3364- cannot be used on some of

the valve stem oil seals due to the confined space, proceed as
follows:
– Knock out pin -arrow- of puller using a drift and remove impact
extractor attachment.
– Apply bottom section of puller -3364- to valve stem oil seal.

– Secure puller with a punch or roll-pin drift -1-, as shown in il‐
lustration.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.
Caution
Make sure valve stem oil seals are not damaged when in‐
stalling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
3. Valve gear 147

Audi Q7 2007 ➤
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate.

• The closely spaced spring coils -arrow- face the cylinder head.
– Secure guide plate -VAS 5161/19C- back onto cylinder head.

– Insert assembly cartridge in guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install spark plugs ⇒ Maintenance ; Booklet 406 .
3.7 Renewing valve stem oil seals with cylinder head removed

Audi Q7 2007 ➤

equipment required
♦ Valve stem seal puller - 3364-

♦Protected
Valvebystem seal fitting tool - 3365-
copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Removal and installation device for valve cotters - VAS 5161-

with guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS
5161/19C-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
Procedure
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
3. Valve gear 149

Audi Q7 2007 ➤
– Insert cylinder head tensioning device - VAS 6419- into engine

and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
shown in illustration.
– Connect cylinder head tensioning device to compressed air.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seal is to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
– Apply drift -VAS 5161/3A- to valve spring plate and use plas‐
tic-headed hammer to release sticking valve cotters.
– Fit guide plate -VAS 5161/19C- from removal and installation

device for valve cotters - VAS 5161- on cylinder head.
– Secure guide plate with knurled screws -VAS 5161/12- .
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161/8A- in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
– Detach valve spring with valve spring plate.

Audi Q7 2007 ➤
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
Caution
Make sure valve stem oil seals are not damaged when in‐
stalling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate.

• The closely spaced spring coils -arrow- face the cylinder head.
3. Valve gear 151

Audi Q7 2007 ➤
– Bolt guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS
5161/19C- onto cylinder head once again.
– Insert assembly cartridge in guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
3.8 Valve dimensions
Note
Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 33.85 ± 0.10 28.0 ± 0.10
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c Protected bymm 104.00for±private
copyright. Copying 0.20or commercial101.9 ± in0.20
purposes, part or in whole, is not
α ∠° 45 45
WARNING
Care must be taken when disposing of old sodium-cooled ex‐

haust valves - risk of injury.
♦ The valves must be sawn in two with a metal saw between
the centre of the stem and valve head. When doing so, the
valves must not come into contact with water.
♦ Then throw a maximum of ten valves into a bucket of water
and step away immediately.
♦ A sudden chemical reaction will occur upon contact with
water in which the sodium filling burns.
♦ After performing these steps the valves can be disposed
of in the normal way.
3.9 Checking valve guides


Audi Q7 2007 ➤
Procedure
Note
♦ If the valve has to be renewed as part of a repair, use a new

valve for the measurement.
♦ Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.
– Secure dial gauge - VAS 6079- to cylinder head with universal

dial gauge bracket - VW 387- as shown in illustration.
– Insert valve into guide.
• End of valve stem must be flush with valve guide.
– Measure the amount of sideways play.

– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be renewed.
3.10 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.
– Renew valve if scoring is clearly visible.
3. Valve gear 153

Audi Q7 2007 ➤
17 – Lubrication
1 Sump (bottom section), sump (top
section), oil pump, engine oil cooler
⇒ “1.1 Exploded view - sump (bottom section), sump (top sec‐
tion), oil pump, engine oil cooler”, page 154
⇒ “1.2 Removing and installing engine oil cooler”, page 157
⇒ “1.3 Removing and installing oil level and oil temperature
sender G266 ”, page 158
⇒ “1.4 Removing and installing sump (bottom section)”, page
159
⇒ “1.5 Removing and installing oil pump”, page 161
⇒ “1.6 Removing and installing sump (top section)”, page 161
Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the “MAX” mark on the
dipstick.
Note
♦ If large quantities of metal shavings or abrasion are found

when performing engine repairs, this may be an indication of
damage to the crankshaft or conrod bearings. To prevent fur‐
ther damage, the following steps are required after completion
of repair work: clean the oil galleries carefully and renew the
oil spray jets, engine oil cooler and oil filter.
♦ For engine oil capacity, oil specifications and by viscosity grades,
permitted unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
refer to ⇒ Maintenance tables or ⇒
with respect Technical
to the correctness ofdata for en‐
information in this document. Copyright by AUDI AG.
gines; Rep. gr. 00 ; Overview of engines .
♦ Oil spray jet for piston cooling ⇒ Fig. ““Oil spray jet for piston
cooling”“ , page 75 .
1.1 Exploded view - sump (bottom section), sump (top section), oil pump, en‐
gine oil cooler
154 Rep. gr.17 - Lubrication

Audi Q7 2007 ➤
1 - Nut
❑ 9 Nm
2 - Oil level and oil temperature
sender - G266-
stalling oil level and oil
temperature sender
G266 ”, page 158
3 - Seal
❑ Renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Sump (bottom section)

stalling sump (bottom
section)”, page 159
5 - Bolt
❑ Steel bolts:
♦ 9 Nm
❑ Aluminium bolts:
♦ Renew
♦ 3 Nm +90°
6 - Baffle plate (bottom)
7 - Bolt
❑ Renew
sequence ⇒ Fig. ““Sump
(top section) - tightening
torque and sequence”“ ,
page 157
8 - Sump (top section)
❑ Removing and installing ⇒ “1.6 Removing and installing sump (top section)”, page 161
9 - Dowel sleeve
❑ 2x
10 - O-ring
❑ Insert in retaining frame
❑ Renew
11 - Bolt
❑ Clean threaded holes for bolts
❑ Apply locking fluid when installing; refer to ⇒ Electronic parts catalogue
❑ Steel bolts:
♦ 9 Nm
❑ Aluminium bolts:
♦ Renew
♦ 3 Nm +90°
12 - Baffle plate (top)
13 - Seal
❑ Insert in retaining frame
❑ Renew
1. Sump (bottom section), sump (top section), oil pump, engine oil cooler 155
Audi Q7 2007 ➤
14 - Gasket
❑ Renew
15 - Bolt
❑ Renew
❑ 3 Nm +90°
16 - Engine oil cooler
❑ With oil cooler bypass valve
❑ See note ⇒ page 154
❑ Removing and installing ⇒ “1.2 Removing and installing engine oil cooler”, page 157
17 - Bolt
❑ 9 Nm
18 - Oil pump drive shaft
19 - Compression spring
20 - Sleeve
❑ 2x
21 - Bearing bracket
22 - Bolt
❑ 9 Nm
23 - Chain sprocket for oil pump
❑ Can only be fitted in one position on drive shaft
24 - Bolt
❑ Renew
❑ 30 Nm +90°
❑ To loosen and tighten, use pin wrench - 3212- to counterhold chain sprocket
25 - O-ring
❑ Renew
26 - Seal
❑ Renew
27 - O-ring
❑ Renew
28 - Oil pump
❑ Do not dismantle
❑ Removing and installing ⇒ “1.5 Removing and installing oil pump”, page 161
29 - Bolt
❑ 20 Nm
30 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ Fig. ““Sump
permitted(bottom section)
unless authorised - tightening
by AUDI AG. AUDI AG torque and sequence”“
does not guarantee ,
or accept any liability
page 157 with respect to the correctness of information in this document. Copyright by AUDI AG.
31 - Seal
❑ Renew
32 - Oil drain plug
❑ 30 Nm

Audi Q7 2007 ➤
Sump (bottom section) - tightening torque and sequence
Note
– Tighten bolts in 2 stages as follows:

For steel bolts
Stage Tightening torque/angle specification
1. 8 Nm in diagonal sequence
2. Turn 90° further in diagonal sequence
For aluminium bolts
Stage Tightening torque/angle specification
1. 3 Nm in diagonal sequence
2. Turn 90° further in diagonal sequence
Sump (top section) - tightening torque and sequence
Note
For steel bolts

Stage Bolts Tightening torque
1. M7 -1 … 6- Screw in by hand until contact is made
2. M7 -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 16 Nm.
Stage Bolts Tightening torque

1. M8 -1 … 6- Screw in by hand until contact is made
2. M8 -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 20 Nm.
For aluminium bolts
1. -1 … 6- Screw in by hand untilbycontact
Protected is made
2. -1 … 6- 8 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1.2 Removing and installing engine oil cool‐

er
Audi Q7 2007 ➤
Removing
Vehicles not equipped with continued coolant circulation pump -
V51- :
– Drain coolant ⇒ page 179 .
Vehicles with continued coolant circulation pump - V51- :
– Remove continued coolant circulation pump -V51- ⇒ page
212 .
– Detach coolant hose -1- and, if necessary, -2- from engine oil
cooler; release hose clip to do so.
– Position used oil collection and extraction unit - V.A.G 1782-
below engine.
– Unscrew bolts -arrows- and detach engine oil cooler.
Installing
• Tightening torques ⇒ “1.1 Exploded view - sump (bottom sec‐
tion), sump (top section), oil pump, engine oil cooler”, page
154
Note
♦ Renew gasket.
– Install continued coolant circulation pump - V51- ⇒ page

212 .
– Check oil level ⇒ Maintenance ; Booklet 406 .
1.3 Removing and installing oil level and oil

temperature sender - G266-

Audi Q7 2007 ➤
Removing
– Remove nuts -1- and detach oil level and oil temperature
sender - G266- -item 3-.
Installing
154
Note
Renew seal -4-.
406 .
1.4 Removing and installing sump (bottom

section)
♦ Safety goggles
Removing
V51- :
Note
Lay a cloth under the engine oil cooler to catch escaping engine
oil.
– Remove bolts -arrows- and tie up engine oil cooler to one side
with coolant hoses -1- and -2- attached.

– Remove continued coolant circulation pump - V51- ⇒ page
212 .
– Remove engine oil cooler
permitted ⇒ page
unless authorised 157AG.
by AUDI . AUDI AG does not guarantee or accept any liability
– Remove bolt -arrow- for ATF lines.
Audi Q7 2007 ➤

– Unplug electrical connector -2- at oil level and oil temperature
sender - G266- and move electrical wiring clear.
– Remove bolts for sump (bottom section) -1-.
– Release sump (bottom section) from bonded joint, taking care
not to bend sump.
Installing
• Tightening torques ⇒ Fig. ““Sump (bottom section) - tightening
torque and sequence”“ , page 157
Note

♦ Renew seals.
♦ The sump (bottom section) must be renewed if its coating is
damaged or if it is bent.
Caution

tion.
WARNING

– Remove sealant residue from sump (bottom section) and

sump (top section) using rotating plastic brush or similar.
Note
Take care not to damage the coating on the sump (bottom sec‐
tion).
Note

mm).

Audi Q7 2007 ➤
Caution

– Apply bead of sealant -arrow- onto clean sealing surface of

sump (bottom section) as illustrated.
• Width of sealant bead: approx. 1.5 mm.
Note
The sump (bottom section) must be installed within 5 minutes af‐

ter applying the sealant.
– Fit sump (bottom section) and tighten bolts ⇒ Fig. ““Sump

(bottom section) - tightening torque and sequence”“ , page
157 .
note the following:
– Install engine oil cooler ⇒ page 157 .
212 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Install ATF lines ⇒ Rep. gr. 37 .

406 .
1.5 Removing and installing oil pump

Removing
– Remove sump (bottom section) ⇒ page 159 .
– Pull oil pump forwards off drive shaft.
Installing
154
Note
Renew gasket and O-ring.
– Fit oil pump onto drive shaft and tighten bolts.

– Install sump (bottom section) ⇒ page 159 .
406 .
1.6 Removing and installing sump (top sec‐

tion)
Audi Q7 2007 ➤

♦ Safety goggles
Removing
• Engine secured to engine and gearbox support ⇒ page 31 .
– Remove oil pump ⇒ page 161 .
– Remove bolts -arrows- and detach baffle plate (bottom).
– Remove bolt -arrow- for coolant pipes (left-side).
– Slacken bolts -1 ... 6- for sump (top section) in diagonal se‐

quence and remove.
– Carefully release sump (top section) from bonded joint and pry
sump off dowel pins on cylinder block.
Installing
154
Note

♦ Renew gasket and O-ring. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Caution

tion.

Audi Q7 2007 ➤
– Remove old sealant from grooves on sump (top section) and

from sealing surfaces.
WARNING

– Remove sealant residue from sump (top section) and cylinder

block using rotating plastic brush or similar.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 1.5

mm).
Caution

– Apply bead of sealant -arrow- onto clean sealing surface of

sump (top section) as shown in illustration.
• The grooves on the sealing surfaces must be completely filled
with sealant.
• The bead of sealant must project 1.5 … 2.0 mm above the
sealing surface.
Note
The sump (top section) must be installed within 5 minutes after

Audi Q7 2007 ➤
– Fit seal -1- and O-ring -2- in retaining frame.
– Check that dowel sleeves are fitted, fit sump (top section) and
tighten bolts ⇒ Fig. ““Sump (top section) - tightening torque
and sequence”“ , page 157 .
note the following:
– Secure coolant pipes (left-side) ⇒ page 192 .
– Install oil pump ⇒ page 161 .

Audi Q7 2007 ➤
2 Oil filter housing, oil pressure switch

⇒ “2.1 Exploded view - oil filter housing”, page 165
⇒ “2.2 Removing and installing oil filter housing”, page 167
⇒ “2.3 Checking oil pressure switch F22 / oil pressure switch for
reduced oil pressure F378 ”, page 169
⇒ “2.4 Removing and installing oil pressure switch F22 ”, page
169
⇒ “2.5 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 170
⇒ “2.6 Removing and installing valve for oil pressure control N428
”, page 171
⇒ “2.7 Checking oil pressure”, page 172
2.1 Exploded view - oil filter housing
1 - Bolt
❑ 13 Nm
2 - Oil pressure switch - F22-
❑ Opening/closing pres‐
sure 2.5 ... 3.2 bar
❑ Grey insulation
❑ Checking in Guided
Fault Finding ⇒ Ve‐
hicle diagnostic tester
stalling oil pressure
switch F22 ”, page
169
❑ 20 Nm
3 - Seal
❑ Renew
4 - Flange nut
❑ 13 Nm
5 - Bolt
❑ 9 Nm
6 - Sleeve
7 - Rubber grommet
8 - Oil filter housing
❑ With filter bypass valve
❑ With oil retention valve
❑ The oil retention valve
cannot be renewedProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
9 - O-ring with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Renew
❑ Installing ⇒ Fig. ““Installing O ring on oil filter housing”“ , page 166
10 - Sealing cap
❑ 25 Nm
2. Oil filter housing, oil pressure switch 165

Audi Q7 2007 ➤
11 - Seal
❑ Renew
❑ Removing and installing ⇒ Fig. ““Renewing seal on sealing cap”“ , page 166
12 - Oil filter element
❑ Removing and installing ⇒ Maintenance ; Booklet 406
13 - Threaded pin
❑ 16 Nm
14 - Seal
❑ Renew
Renewing seal on sealing cap

– Take hold of tab -arrow A- and pull seal -2- out of sealing cap
-1-.
– Install new seal so that semi-circular profile fits in groove
-arrow B- in sealing cap.
• The tab -arrow A- must face upwards.
Installing O ring on oil filter housing

– Install O-ring -2- in groove -arrow- on oil filter housing -1-.
Valve for oil pressure control - N428-

2- O-ring - renew
3- Bolt, 9 Nm
4- Valve for oil pressure control - N428-

Audi Q7 2007 ➤
Oil pressure switch for reduced oil pressure - F378-

1- Oil pressure switch for reduced oil pressure - F378-
♦ Opening/closing pressure 0.75 ... 1.05 bar
♦ Grey insulation
♦ Checking in Guided Fault Finding ⇒ Vehicle diagnostic
tester
♦ Removing and installing ⇒ page 170
♦ 20 Nm
2.2 Removing and installing oil filter housing

Removing
– Remove oil filter element ⇒ Maintenance ; Booklet 406 .
– Extract engine oil from oil filter housing using used oil collec‐
tion and extraction unit - V.A.G 1782- .

Audi Q7 2007 ➤
– Move electrical wiring clear.

– Remove bolts -3- and move bracket with electrical connectors
to one side.
Note
– Remove bolts -3- and push secondary air hose to rear.
Note
– Unplug electrical connector -arrow- on oil pressure switch
with - the correctness of information in this document. Copyright by AUDI AG.
respect to
F22- .
Note
Place a cloth beneath the oil filter housing to catch escaping oil.

– Remove nut -1- and unscrew centre hex stud.
– Remove oil filter housing with centre hex stud.
Installing

Audi Q7 2007 ➤
• Tightening torques ⇒ “2.1 Exploded view - oil filter housing”,

page 165
Note
Renew seals, gasket and O-ring.
– Install secondary air hose ⇒ page 263 .

– Install oil filter element, fill up with engine oil and check oil level
⇒ Maintenance ; Booklet 406 .
2.3 Checking oil pressure switch - F22- / oil

pressure switch for reduced oil pressure
- F378-
Checking oil pressure switch - F22- / oil pressure switch for re‐
duced oil pressure - F378-
Protected in Guided
by copyright. Copying forFault
private or Finding ⇒ Vehicle
commercial purposes, in part or in whole, is not
diagnostic tester.
2.4 Removing and installing oil pressure

switch - F22-
Articulated wrench, 24 mm - T40175-
Removing
Note
Place a cloth beneath the oil filter housing to catch escaping oil.
– Unplug electrical connector -arrow-.

– Unscrew oil pressure switch - F22- .
Installing
• Tightening torque ⇒ “2.1 Exploded view - oil filter housing”,
page 165
Note
♦ Renew seal.
♦ Fit the new oil pressure switch - F22- into the connection im‐
mediately to avoid loss of oil.
– Check oil level ⇒ Maintenance ; Booklet 406 .

Audi Q7 2007 ➤
2.5 Removing and installing oil pressure

switch for reduced oil pressure - F378-
♦ Assembly tool - T10118-
♦ Articulated wrench, 24 mm - T40175-
Removing

Audi Q7 2007 ➤
– Take out noise insulation.

– Use assembly tool - T10118- to unplug electrical connector
-2-.
– Use articulated wrench (24 mm) - T40175- to unscrew oil
pressure switch for reduced oil pressure - F378- -item 1-.
Note
For illustration purposes, the installation position is shown with

the supercharger removed.
Installing
• Tightening torque ⇒ Fig. ““ Oil pressure switch for reduced oil
pressure -F378- ”“ , page 167
Note
Renew seal.
2.6 Removing and installing valve for oil

pressure control - N428-
Removing with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove front left wheel housing liner ⇒ Rep. gr. 66 .

– Remove engine mounting (left-side) ⇒ page 39 .
– Unscrew bolts -arrows- and remove engine support (left-side).

Audi Q7 2007 ➤

– Remove bolt -3- and detach valve for oil pressure control -
N428- -item 4-.
Installing
• Tightening torque ⇒ Fig. ““ Valve for oil pressure control -
N428- ”“ , page 166
Note
Fit new O-ring -2-.
– Install engine support (left-side) ⇒ page 39 .

– Install engine mounting (left-side) ⇒ page 39 .
– Install front left wheel housing liner ⇒ Rep. gr. 66 .
2.7 Checking oil pressure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment required permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch - F22- ⇒ page 169 .
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw oil pressure switch - F22- into oil pressure tester.
– Start engine.
• Minimum oil pressure at idling speed: 1.2 bar.
• Minimum oil pressure at 2000 rpm: 1.5 bar.
Assembling
– Install oil pressure switch - F22- ⇒ page 169 .

Audi Q7 2007 ➤
3 Oil separator, crankcase breather

system
⇒ “3.1 Exploded view - oil separator, crankcase breather system”,
page 173
⇒ “3.2 Removing and installing crankcase breather hoses”, page
174
⇒ “3.3 Removing and installing cover with oil separator”, page
175
⇒ “3.4 Engine oil”, page 176
⇒ “3.5 Checking oil level”, page 176
3.1 Exploded view - oil separator, crankcase breather system
1 - Screw plug
❑ 20 Nm
2 - Gasket
❑ Renew
3 - Cover with oil separator
❑ With connection for
crankcase breather
stalling cover with oil
separator”, page 175
4 - Bolt
❑ 9 Nm
5 - O-ring
❑ Renew
6 - Connection
❑ Installation position
permitted⇒ unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Fig. ““Installing connec‐
tion for crankcase
breather”“ , page 174
7 - O-ring
❑ Renew
8 - Bolt
❑ 2.5 Nm
9 - Bolt
❑ 2.5 Nm
10 - Crankcase breather hoses
❑ To cylinder head covers
⇒ “3.2 Removing and installing crankcase breather hoses”, page 174
11 - O-rings
❑ Renew
12 - Crankcase breather hose
❑ To air pipe
3. Oil separator, crankcase breather system 173

Audi Q7 2007 ➤
13 - Hose clip
14 - Screw plug
❑ 20 Nm
Installing connection for crankcase breather

– Insert connection -1- for crankcase breather with new O-rings
in cover for oil separator.
• Installation position:Protected
lug -2-bymust engage in guide -arrow-.
3.2 Removing and installing crankcase

breather hoses
⇒ “3.2.1 Removing and installing crankcase breather hoses -
rest-of-world vehicles”, page 174
⇒ “3.2.2 Renewing crankcase breather hoses - USA vehicles”,
page 174
3.2.1 Removing and installing crankcase

breather hoses - rest-of-world vehicles
Removing
Note
– Remove supercharger ⇒ page 230 .

– Detach crankcase breather hoses -arrows- from cylinder head
covers.
– Move crankcase breather hoses clear.
– Remove bolt -1- and detach connection with crankcase
breather hoses.
Installing
• Tightening torque ⇒ “3.1 Exploded view - oil separator,
crankcase breather system”, page 173
Note
Fit new O-rings.
– Install supercharger ⇒ page 230 .
3.2.2 Renewing crankcase breather hoses -

USA vehicles

Audi Q7 2007 ➤
Caution

♦ Crankcase breather hoses cannot be removed without
being irreparably damaged. Once removed, they must be
renewed.
Removing
Note

– Detach crankcase breather hoses -arrows- from cylinder head
covers.
– Move crankcase breather hoses clear.
– Remove bolt -1- and detach connection with crankcase
breather hoses.
Installing
• Tightening torque ⇒ “3.1 Exploded view - oil separator,
Note
Fit new O-rings.
3.3 Removing and installing cover with oil

separator
Removing
– Remove crankcase breather hoses ⇒ page 174 .
– Remove intake manifold bottom section (left-side) ⇒ Rep. gr.
24 .
3. Oil separator, crankcase breather system 175

Audi Q7 2007 ➤

– Detach bracket for high-pressure pipes and cover -1- with oil
separator.
Installing
• Tightening torques ⇒ “3.1 Exploded view - oil separator,
Note
Renew gasket.
– Install intake manifold bottom section (left-side) ⇒ Rep. gr.

24 .
– Install crankcase breather hoses ⇒ page 174 .
3.4 Engine oil

Refer to ⇒ Maintenance tables or ⇒ Technical data for engines;
Rep. gr. 00 ; Overview of engines for engine oil capacity, oil
specifications and viscosity grades.
3.5 Checking oil level

Check oil level ⇒ Maintenance ; Booklet 406 .

Audi Q7 2007 ➤
19 – Cooling
1 Cooling system
⇒ “1.1 Connection diagram - coolant hoses”, page 177
⇒ “1.2 Draining and filling cooling system”, page 179
⇒ “1.3 Checking cooling system for leaks”, page 186
WARNING

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.
Note
♦ The arrow markings on coolant pipes and on ends of hoses
must align.
1.1 Connection diagram - coolant hoses

♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Orange = Coolant circuit for charge air cooler.
♦ Brown = Heating circuit.
♦ Arrows show direction of coolant flow.
1. Cooling system 177

Audi Q7 2007 ➤
1 - Bleeder screw
2 - Water radiator (right-side)
for charge air cooling circuit
❑ If renewed, refill system
with fresh coolant
3 - Charge air cooling pump -
V188-
4 - Alternator
5 - Charge air cooler (right-
side)
❑ In supercharger hous‐
ing
with fresh coolant
6 - Bleeder screw
7Protected
- Coolant expansion tank
8 - with
Filler cap
❑ For coolant expansion

tank
❑ Checking pressure re‐
lief valve ⇒ page 188
9 - Non-return valve
❑ Located in coolant hose
10 - Cylinder head, bank 1
(right-side)
with fresh coolant
11 - From heat exchanger for
heater
12 - To heat exchanger for
heater
13 - Cylinder head, bank 2 (left-side)
❑ If renewed, refill system with fresh coolant
14 - Bleeder screw
15 - Charge air cooler (left-side)
❑ In supercharger housing
16 - Coolant pump
17 - Engine oil cooler
18 - Continued coolant circulation pump - V51-
❑ Country-specific version
20 - Bleeder screw
21 - Water radiator (left-side) for charge air cooling circuit
22 - Radiator
178 Rep. gr.19 - Cooling

Audi Q7 2007 ➤
23 - Thermostat
24 - Coolant temperature sender - G62-
1.2 Draining and filling cooling system

equipment required
♦ Adapter for cooling system tester - V.A.G 1274/8- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Pipe for cooling system tester - V.A.G 1274/10-

♦ Cooling system charge unit - VAS 6096-
♦ Refractometer - T10007 A-
♦ ⇒ Vehicle diagnostic tester
Draining

Audi Q7 2007 ➤

gr. 43 .
WARNING


Note
Collect drained coolant in a container for disposal.
gine.
– Lift retaining clip, disconnect coolant hose (bottom right)
-arrow- from radiator and drain off coolant.

Audi Q7 2007 ➤
– Release hose clips -1 and 2-, disconnect coolant hoses from

coolant pipes and drain off coolant.
– Release hose clips -arrows-, disconnect coolant hoses from

coolant pipes on longitudinal member (left-side) and drain off
coolant.
– Release hose clip -1-, disconnect coolant hose from coolant

pipe on lock carrier and drain off coolant.
Note
Disregard -item 2-.
– Release hose clip -arrow-, disconnect coolant hose from en‐

gine oil cooler and drain off coolant.
Filling
Tightening torques
• ⇒ “2.1 Exploded view - coolant pump/thermostat”, page
189
• ⇒ “3.1 Exploded view - coolant pipes”, page 192 .
• Ignition off.
Caution
Always use distilled water for mixing coolant additives as this

ensures optimum corrosion protection.

Audi Q7 2007 ➤
Note
♦ The effectiveness of the coolant is greatly influenced by the

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts cat‐
alogue (ETKA) . Other coolant additives could seriously impair
in particular the anti-corrosion properties. The resulting dam‐
age could lead to loss of coolant and consequently to serious
engine damage.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- MUST be used to determine the
current level of frost protection.
♦ The mixture must guarantee frost protection down to at least
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ Read off the level of frost protection on the scale for the rele‐
vant coolant additive.
♦ The temperature indicated on the refractometer - T10007A-
corresponds to the temperature at which the first ice crystals
can formbyincopyright.
Protected the coolant.
♦ Do with
notrespect
reuseto the
coolant.
correctness of information in this document. Copyright by AUDI AG.
♦ Only use water/coolant additive as a lubricant for coolant

hoses.
Recommended mixture ratio for coolant

• Coolant (40 %) and water (60 %) for frost protection to –25 °
C
• Coolant (50 %) and water (50 %) for frost protection to –36 ℃
• Coolant ⇒ Electronic parts catalogue

Audi Q7 2007 ➤
Procedure
– Connect coolant hose to engine oil cooler with hose clip
-arrow-.
– Connect coolant hose to coolant pipe on lock carrier with hose

clip -1-.
– Fit coolant hoses with hose clips -arrows- onto coolant pipes
on longitudinal member (left-side).
– Connect coolant hoses with hose clips -1 and 2- to coolant

pipes.

Audi Q7 2007 ➤
– Connect coolant hose (bottom right) -arrow- with plug-in con‐

nector to radiator ⇒ Fig. ““Connecting coolant hose with plug-
in connector”“ , page 217 .
– Fill reservoir of cooling system charge unit - VAS 6096- with

at least 15 litres of premixed coolant (according to recom‐
mended ratio) ⇒ page 182 .
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-.
Note
The vented air draws along a small amount of coolant, which

should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air.
• Pressure: 7 ... 10 bar.
– Connect ⇒ Vehicle diagnostic tester to vehicle.
– Select following menu options on ⇒ Vehicle diagnostic tester:
♦ Guided Functions mode
♦ 01 - Simos fuel injection and ignition system
♦ Functions - engine
♦ 01 - Coolant circuit vent routine
– Follow instructions shown on vehicle diagnostic tester .
– Open valve -B- by setting lever in direction of flow.

• The suction jet pump generates a vacuum in the cooling sys‐
tem. The needle on the gauge should move into the green
zone.
– Also briefly
permitted open
unless valveby-A-
authorised AUDI(turn lever
AG. AUDI in direction
AG does oforflow)
not guarantee so liability
accept any
that hose on reservoir of -VAS 6096- can fill with coolant.
– Close valve -A- again.

– Leave valve -B- open for another 2 minutes.
• The suction jet pump will continue generating a vacuum in the
cooling system. The needle on the gauge should remain in the
green zone.
– Close valve -B-.

Audi Q7 2007 ➤
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the pro‐
cess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of the cooling system charge unit -
VAS 6096- ; the cooling system is then filled.
– Detach cooling system charge unit - VAS 6096- from adapter
-V.A.G 1274/8- on coolant expansion tank.
– Attach pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .

– Fill up with coolant until pipe for cooling system tester is filled.
If required, add further coolant when performing bleeding pro‐
cedure.

Audi Q7 2007 ➤
Note
Place a cloth underneath to catch escaping coolant.
– Open bleeder screws -1- and -2- on charge air coolers one
after the other until coolant comes out.
– Close bleeder screws.
– Open bleeder screw -arrow- on water radiator (left and right)

for charge air cooling circuit one after the other until coolant
comes out.
– Close bleeder screws.
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Firmly close filler cap on coolant expansion tank.
– Start engine.
– Set temperature to “HI” for all zones and select lowest blower
speed (= 0).
– Switch off air conditioner compressor (press ECON/ON/OFF
button).
– with
Run engine
respect for 3 minutes
to the correctness at 2000
of information rpm. Copyright by AUDI AG.
in this document.
– Allow engine to run at idling speed until both large coolant

hoses at radiator become warm.
– Run engine for 1 minutes at 2000 rpm.
– Switch off ignition and allow engine to cool down.
– Install noise insulation ⇒ Rep. gr. 66 .
– Check coolant level.

• The coolant level must be at the MAX marking -arrow- when
the engine is cold.
• The coolant level can be above the MAX marking when the
engine is warm.
Rep. gr. 43 .
1.3 Checking cooling system for leaks

Audi Q7 2007 ➤

equipment required
♦ Adapter for cooling system tester - V.A.G 1274/8-

♦ Adapter for cooling system tester - V.A.G 1274/9-
♦ Cooling system tester - V.A.G 1274 B-
Procedure
• Engine must be warm.
WARNING


Audi Q7 2007 ➤
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.5 bar.
• The pressure should not drop more than 0.2 bar within 10
minutes.
– If the pressure drops more than 0.2 bar, locate leak and elim‐
inate fault.
Note
The drop in pressure of 0.2 bar within 10 minutes is caused by

the decrease in coolant temperature. The colder then engine is,
the less the pressure will fall. If necessary, check again when the
engine is cold.
Checking pressure relief valve in filler cap

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- onto filler cap.
– Build up pressure with hand pump on cooling system tester.
• The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
– Renew filler cap if pressure relief valve does not open as de‐
scribed.

Audi Q7 2007 ➤
2 Coolant pump, thermostat

⇒ “2.1 Exploded view - coolant pump/thermostat”, page 189
⇒ “2.2 Removing and installing coolant pump”, page 190
⇒ “2.3 Removing and installing thermostat”, page 190
2.1 Exploded view - coolant pump/thermostat
1 - Bolt
❑ 9 Nm
2 - Bolt
❑ 20 Nm
3 - Poly V-belt pulley for
coolant pump
4 - Coolant pump
❑ With seal
stalling coolant pump”,
page 190
5 - Bolt
❑ 9 Nm
6 - Bolt
Item 2 (page 49)
7 - Washer
8 - Idler roller for poly V-belt
9 - Connection
❑ For coolant hose
10 - Gasket
❑ Renew
11 - Seal
12 - Thermostat
stalling thermostat”,
page 190
When removing and installing the

thermostat, make sure that the nee‐
dle is fitted correctly (conical end
fitted in wax expansion element of
thermostat). If necessary, push ther‐
mostat needle as far as possible into
wax expansion element.
13 - Bolt
❑ 9 Nm
2. Coolant pump, thermostat 189

Audi Q7 2007 ➤
2.2 Removing and installing coolant pump

Removing
– Detach poly V-belt from air conditioner compressor, but do not
remove completely ⇒ “1.5 Removing and installing poly V-
belt”, page 54 .
Note
– Remove bolts -arrows- and detach coolant pump.

Installing
• Tightening torques ⇒ “2.1 Exploded view - coolant pump/ther‐

mostat”, page 189
– Install poly V-belt for air conditioner compressor ⇒ page 49 .
2.3 Removing and installing thermostat

Removing
– Remove coolant pipe (front) ⇒ page 197 .

Audi Q7 2007 ➤
Note
Place a cloth underneath to catch any escaping coolant.

– Detach coolant thermostat with hose connection.
Installing
• Tightening torques ⇒ “2.1 Exploded view - coolant pump/ther‐
mostat”, page 189
Note
When removing and installing the thermostat, make sure that the
needle is fitted correctly (conical end fitted in wax expansion el‐
ement of thermostat). If necessary, push thermostat needle as far
as possible into wax expansion element.
Note
Renew seal. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install coolant pipe (front) ⇒ page 197 .

2. Coolant pump, thermostat 191

Audi Q7 2007 ➤
3 Coolant pipes and continued coolant

circulation pump - V51-
⇒ “3.1 Exploded view - coolant pipes”, page 192
⇒ “3.2 Fitting coolant hoses”, page 195
⇒ “3.3 Removing and installing coolant temperature sender G62
”, page 196
⇒ “3.4 Removing and installing coolant pipe (front)”, page 197
⇒ “3.5 Removing and installing coolant pipes (front left)”, page
198
⇒ “3.6 Removing and installing coolant pipes (left-side)”, page
200
⇒ “3.7 Removing and installing coolant pipes (rear left) on gear‐
box”, page 202
⇒ “3.8 Removing and installing coolant pipe (top)”, page 203
⇒ “3.9 Removing
permitted unlessand installing
authorised by AUDI coolant
AG. AUDI AG pipedoes(right-side)
not guarantee or on gear‐
accept any liability
box”, page 205
⇒ “3.10 Removing and installing coolant pipes on supercharger”,

page 208
⇒ “3.11 Removing and installing charge air cooling pump V188 ”,
page 210
⇒ “3.12 Exploded view - continued coolant circulation pump V51
”, page 211
⇒ “3.13 Removing and installing continued coolant circulation
pump V51 ”, page 212
3.1 Exploded view - coolant pipes

Coolant pipes on engine

Audi Q7 2007 ➤
1 - Bolt
❑ 9 Nm
2 - Coolant pipes (front left)
stalling coolant pipes
(front left)”, page 198
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
5 - Bracket
6 - Bolt
❑ 22 Nm
7 - Bolt
❑ 2.5 Nm
8 - Bolt
❑ 9 Nm
9 - Coolant pipe (front)
stalling coolant pipe
(front)”, page 197
10 - Seal
❑ Renew
11 - O-rings
❑ Renew
12 - Coolant temperature
sender - G62-
❑ Removing and installing permitted
⇒ “3.3unless
Removing
authorisedand installing
by AUDI AG. AUDI AG coolant
does not temperature
guarantee or acceptsender G62 ”, page
any liability
196 with respect to the correctness of information in this document. Copyright by AUDI AG.
13 - Bolt
❑ 5 Nm
14 - Coolant pipe (bottom) on supercharger
❑ Remove and install together with -item 20- ⇒ “3.10 Removing and installing coolant pipes on super‐
charger”, page 208
15 - Bolt
❑ 5 Nm
16 - Dowel sleeve
17 - Seal
❑ Renew
18 - Bolt
❑ 5 Nm
19 - Seal
❑ Renew
20 - Coolant pipe (top) on supercharger
❑ Remove and install together with -item 14- ⇒ “3.10 Removing and installing coolant pipes on super‐
charger”, page 208
3. Coolant pipes and continued coolant circulation pump V51 193

Audi Q7 2007 ➤
21 - Dowel sleeve
22 - Bolt
❑ 5 Nm
23 - Seal
❑ Renew
24 - Seal
❑ Renew
25 - O-ring
❑ Renew
26 - Coolant pipe (top)
❑ Removing and installing ⇒ “3.8 Removing and installing coolant pipe (top)”, page 203
27 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 9 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
28 - Seal
❑ Renew
29 - Bolt
❑ 9 Nm
30 - Bolt
❑ Renew
❑ 3 Nm +90°
31 - Bolt
❑ Renew
❑ 3 Nm +90°
32 - Coolant pipes (left-side)
❑ Removing and installing ⇒ “3.6 Removing and installing coolant pipes (left-side)”, page 200
33 - O-ring
❑ Renew
34 - Retaining clip
Coolant pipes on gearbox

Audi Q7 2007 ➤
1 - Bolt
❑ 9 Nm
2 - Bolt
❑ 9 Nm
3 - Coolant pipe (right-side) on
gearbox
stalling coolant pipe
(right-side) on gearbox”,
page 205
4 - Bolt
❑ 9 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 9 Nm
6 - Coolant pipes (rear left) on
gearbox
stalling coolant pipes
(rear left) on gearbox”,
page 202
7 - Bolt
❑ 9 Nm
Charge air cooling pump - V188- - tightening torque

– Tighten bolt -4- to 9 Nm.
3.2 Fitting coolant hoses

Audi Q7 2007 ➤
– Fit coolant hose on connection as follows:

• Push coolant hose -6- onto connection -1- as far as stop -3-.
• If stop is not fitted, push coolant hose 28 mm onto connection.
• Arrow marking -4- on coolant hose must align with arrow mark‐
ing -2- on connection. Some parts have line markings instead
of arrows.
• Use only undamaged hose clips -5- (same as original equip‐
ment).
• Position hose clips between coloured markings -7-.
• Position lugs of hose clips for maximum clearance from sur‐
rounding parts.
3.3 Removing and installing coolant tem‐

perature sender - G62-
Removing
• Engine cold.
– Open filler cap on coolant expansion tank briefly to release
residual pressure in cooling system and then tighten cap
again.
Note
– Pull off retaining clip -2- and detach coolant temperature

sender - G62- .
Note
Disregard -arrow-.
Installing
Note
♦ Fit new O-ring.

Audi Q7 2007 ➤
♦ To avoid loss of coolant, insert new coolant temperature

sender - G62- immediately in coolant pipe (front).
– Check coolant level ⇒ page 186 .
3.4 Removing and installing coolant pipe

(front)
Removing
– Remove coolant pipes (front left) ⇒ page 198 .

Audi Q7 2007 ➤
– Unplug electrical connector -3- at coolant temperature sender

- G62- .
– Lift retaining clips and disconnect coolant hoses -1 and 4-.
– Release hose clip -2- and detach coolant hose (top).
– Loosen hose clip -5-.
– Remove bolts -arrows- and detach coolant pipe (front).
Installing
• Tightening torques ⇒ “3.1 Exploded view - coolant pipes”,
page 192
Note
♦ Renew seals and O-rings.

– Clean or smoothen sealing surfaces for seals and O-rings.
– Lubricate seals and O-rings with coolant and slide onto coolant
pipe.
– Connect coolant hose with plug-in connector ⇒ Fig. ““Con‐
necting coolant hose with plug-in connector”“ , page 217 .
– Install poly V-belt pulley for coolant pump ⇒ page 189 .
– Install poly V-belt ⇒ page 54 .
– Install coolant pipes (front left) ⇒ page 198 .
3.5 Removing and installing coolant pipes

(front left)
♦ Hose clamps, up to 25 mm - 3094-

Audi Q7 2007 ➤
Removing

Audi Q7 2007 ➤
WARNING

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.

gine.
Note
For illustration purposes, the installation position is shown in the
following illustrations with the engine removed.

– Clamp off coolant hose using hose clamp -3094- , release

hose clip -1- and disconnect hose from coolant pipe (front left).
– Clamp off coolant hose -3- using hose clamp -3094- , release
hose clip and disconnect hose.
– Release hose clips -1- and detach coolant hoses from coolant
pipes at supercharger.
– Remove bolt -2- and detach coolant pipes (front left).
Installing
page 192
Note
Secure all hose connections with the correct type of hose clips


(left-side)

Audi Q7 2007 ➤
Removing
V51- :
– Remove continued coolant circulation pump -V51- ⇒ page
212 .
– Remove air conditioner compressor ⇒ Rep. gr. 87 .
– Remove bolts -arrows- and detach bracket for air conditioner

compressor.

Audi Q7 2007 ➤

– Release hose clips -1 and 2- and disconnect coolant hoses
from coolant pipes.
Note
For illustration purposes, the installation position is shown with

the power steering pump removed.
Installing
page 192
Note
♦ Fit new O-ring.

– Clean and smoothen sealing surface for O-ring.

– Lubricate O-ring with coolant and slide onto coolant pipe.
– Install bracket for air conditioner compressor ⇒ page 51 .
– Install air conditioner compressor ⇒ Rep. gr. 87 .
212 .

(rear left) on gearbox

Audi Q7 2007 ➤
Removing
– Remove catalytic converter (left-side) ⇒ page 251 .
– Move clear B+ wire -2- and gearbox breather hose -4-.
– Release hose clips and disconnect coolant hoses -1 and 3-.
– Detach coolant pipes (rear left).
Installing
page 192
Note
♦ Renew O-rings.
– Install catalytic converter (left-side) ⇒ page 251 .


(top)
Removing
Note

– Remove intake manifold (bottom section, right-side) ⇒ Rep.
gr. 24 .
– Remove nuts -arrows- and detach guard plate -1- for high-
pressure pipe.

Audi Q7 2007 ➤
– Press release tabs and detach secondary air hose -arrow- to

front from bracket.
– Unscrew connection -1-.
WARNING

– Unscrew union nuts -2- and -3- (counterhold connection).

– Unscrew bolts -arrows- on retaining clips and detach high-
pressure pipe.
Note
The threaded connection in the fuel permitted
rail must be renewed if it has
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
been loosened or detached at union nuts -2- and -3- ⇒ Rep. gr.
24 .
• Place a cloth under coolant pipe to catch escaping coolant.

– Lift retaining clip and disconnect coolant hose -2- from coolant
pipe.
– Remove bolt -1- and pull coolant pipe rearwards out of cylinder
block -arrow-.
Installing
• Tightening torque ⇒ “3.1 Exploded view - coolant pipes”, page
192
Note
Fit new O-rings.
– Clean and smoothen sealing surface for O-ring.

– Lubricate O-ring with coolant and slide onto coolant pipe.
– Connect coolant hose with plug-in connector ⇒ Fig. ““Con‐
necting coolant hose with plug-in connector”“ , page 217 .

Audi Q7 2007 ➤
– Install high-pressure pipe and intake manifold (bottom section,

right-side) ⇒ Rep. gr. 24 .

(right-side) on gearbox
Removing
Note

– Remove front wheel (right-side) ⇒ Wheels and tyres; Rep. gr.
44 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

Audi Q7 2007 ➤

– Remove bolt -1- for coolant pipe on gearbox (right-side).

– Loosen hose clip -2-.
– Remove engine mounting (right-side) ⇒ page 39 .

– Remove nuts -2- and loosen nut -5-.
– Detach secondary air pump motor - V101- with bracket.
Note
Disregard -item 4-.
– Remove bolt -2- for earth wire at longitudinal member (right-

side).
Disregard -item 1-. with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi Q7 2007 ➤

-1-.

– Remove nuts -1 and 3- and move B+ wire clear at starter.
Note
– Remove bolts -1- for coolant pipe (right-side) on gearbox.

– Remove bolt -2- for ATF line.
– Move clear electrical wiring harness and detach coolant pipe
(right-side) from gearbox.
Note
Disregard -item 3-.
Installing
page 192
Note
installing.
– Install ATF lines ⇒ Rep. gr. 37 .

– Install starter ⇒ Electrical system; Rep. gr. 27 .
– Install engine support (right-side) ⇒ page 39 .
– Install engine mounting (right-side) ⇒ page 39 .

Audi Q7 2007 ➤
– Install secondary air pump motor - V101- ⇒ page 269 .

– Install alternator ⇒ Electrical system; Rep. gr. 27 .
– Fit front wheel (right-side) ⇒ Wheels and tyres; Rep. gr. 44 .

on supercharger

Audi Q7 2007 ➤
Removing
WARNING

gine.
– Clamp off coolant hoses using hose clamps -3094- , release
hose clips -1- and detach coolant hoses from coolant pipes on
supercharger.
Note

Audi Q7 2007 ➤
– Remove bolts -1 and 2- and detach coolant pipes from super‐

charger.
Installing
page 192
Note
♦ Renew seals and/or gaskets.


3.11 Removing and installingProtected

charge air cool‐
ing pump - V188- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability


Audi Q7 2007 ➤
Removing

– Move coolant hose clear -arrow-.
– Unscrew bolt -4- and remove bracket.
– Clamp off coolant hoses at charge air cooling pump - V188-
using hose clamps -3094- , release hose clips -2 and 3- and
disconnect coolant hoses.
Installing
• Tightening torque ⇒ Fig. ““ Charge air cooling pump
Protected -V188-
by copyright. - for private or commercial purposes, in part or in whole, is not
Copying
tightening torque”“ , page 195 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note

3.12 Exploded view - continued coolant circulation pump - V51-

Audi Q7 2007 ➤
1 - Coolant hose
2 - Bracket
3 - Bolts
❑ 9 Nm
4 - Coolant hose
5 - Bolt
❑ 4 Nm
6 - Continued coolant circula‐
tion pump - V51-
❑ Country-specific version
⇒ page 212
3.13 Removing and installing continued

coolant circulation pump - V51-
Note
The continued coolant circulation pump - V51- is fitted on versions

for some countries.

Audi Q7 2007 ➤
Removing
WARNING


Audi Q7 2007 ➤

– Remove bolt -1-.
gine.
– Release hose clips -arrows- and disconnect coolant hoses
from continued coolant circulation pump - V51- .
Installing
• Tightening torque ⇒ “3.12 Exploded view - continued coolant
circulation pump V51 ”, page 211
Note


Audi Q7 2007 ➤
4 Radiator, radiator cowl and radiator

fans
⇒ “4.1 Exploded view - radiator”, page 215
⇒ “4.2 Removing and installing radiator”, page 217
⇒ “4.3 Exploded view- water radiator for charge air cooling cir‐
cuit”, page 219
⇒ “4.4 Removing and installing water radiator for charge air cool‐
ing circuit”, page 220
⇒ “4.5 Exploded view - radiator cowl and radiator fans”, page
222
⇒ “4.6 Removing and installing radiator cowl”, page 223
⇒ “4.7 Removing and installing radiator fans V7 / V177 ”, page
224
WARNING

4.1 Exploded view - radiator
4. Radiator, radiator cowl and radiator fans 215

Audi Q7 2007 ➤
1 - Hydraulic fluid cooler

❑ For power steering
2 - ATF cooler
❑ For automatic gearbox
3 - Retaining clip
❑ Check for firm attach‐
ment
4 - Air duct
5 - Air duct
6 - Radiator
stalling radiator”, page
217
with fresh coolant
7 - Grommet
8 - Bolt
❑ 5.5 Nm
9 - Sealing strip
10 - O-ring
❑ Renew
11 - Coolant hose
❑ Version fitted in vehicle
may differ from illustra‐
tion
❑ Connecting to radiator ⇒
Fig. ““Connecting
coolant hose with plug-
in connector”“ , page
217
12 - Coolant hose
13 - Coolant hose
❑ Connecting to radiator ⇒ Fig. ““Connecting coolant hose with plug-in connector”“ , page 217
14 - O-ring
❑ Renew
15 - Bolt
❑ 8 Nm
16 - Locking device
❑ For radiator
17 - Rubber buffer
18 - Washer
19 - Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 8 Nm
20 - Retaining clip
21 - Retaining clip

Audi Q7 2007 ➤
22 - Condenser
❑ For air conditioning system
Connecting coolant hose with plug-in connector

– Remove old O-ring -2- from coolant hose -3-.
– Lightly lubricate new O-ring with coolant and fit O-ring in
coolant hose.
– Press coolant hose onto connection -1- until it engages audi‐
bly.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
4.2 Removing and installing radiator

Removing
– Discharge refrigerant system ⇒ Air conditioner with refrigerant
R134a .
– Remove radiator cowl ⇒ page 223 .
– Lift retaining clip and disconnect coolant hose -1- (top) from
radiator.
Note
Disregard -item 2-.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Unscrew bolts -1 and 2- and disconnect refrigerant lines from

condenser.

Audi Q7 2007 ➤
– Remove locking elements for radiator on left and right (press

clip from below -arrow-).
– Unscrew bolt -2- for hydraulic fluid cooler on rear of radiator.

– Disengage cooler for power steering -1- at air conditioner con‐
denser.
– Unscrew bolt -1- for ATF temperature regulator on rear of ra‐

diator.
– Release retaining clips -2 and 3-.
– Detach ATF cooler -4- from radiator.

Audi Q7 2007 ➤
– Remove bolts -2- on lock carrier on both sides.

– Swivel top of radiator towards rear and lift out of engine com‐
partment.
Note
Disregard -item 1-.
– Unscrew bolts -3- for condenser on rear of radiator.

– Release retaining clips -2 and 4-.
– Detach condenser -1- from radiator.
Installing
• Tightening torques ⇒ “4.1 Exploded view - radiator”, page
215
Note
If there are slight impressions on the fins, refer to ⇒ page 7 .
– Secure ATF lines.

– Secure hydraulic lines for power steering ⇒ Rep. gr. 48 .
– Install refrigerant lines ⇒ Rep. gr. 87 .
– Install radiator cowl ⇒ page 223 .
– Charge refrigerant system ⇒ Air conditioner with refrigerant
R134a .
– Connect coolant hose with plug-in connector ⇒ page 217 .
Note
The coolant in the entire system must be changed if the radiator

is renewed.

4.3 Exploded view- water radiator for charge air cooling circuit
Note
The illustration shows the water radiator for the charge air cooling circuit on the left side of the vehicle.

Audi Q7 2007 ➤
1 - Air duct
2 - Water radiator for charge air
cooling circuit
stalling water radiator
for charge air cooling
circuit”, page 220
3 - Coolant hose
4 - Bolt
❑ 9 Nm
5 - Coolant hose
4.4 Removing and installing water radiator

for charge air cooling circuit

Audi Q7 2007 ➤
Removing
Note
The following description shows the removal and installation of

the water radiator for charge air cooling circuit (left-side). The
procedure for the other side is basically the same.
WARNING


– Remove bumper cover (front) ⇒ Rep. gr. 63 .

Audi Q7 2007 ➤
– Clamp off coolant hoses -arrows- with hose clamps -3094- .

– Release hose clips and detach coolant hoses.
– Unclip air duct -1- from water radiator for charge air cooling
circuit.
– Remove nut -1- and bolts -2, 3- and detach water radiator for
charge air cooling circuit.
Installing
• Tightening torque ⇒ “4.3 Exploded view- water radiator for
charge air cooling circuit”, page 219
Note
♦ If there are slight impressions on the fins, refer to ⇒ page 7 .

– Install bumper cover (front) ⇒ Rep. gr. 63 .

4.5 Exploded view - radiator cowl and radiator fans

Audi Q7 2007 ➤
1 - Bolt
❑ 10 Nm
2 - Bolt
❑ 10 Nm
3 - Bolt
❑ 5 Nm
4 - Radiator cowl
stalling radiator cowl”,
page 223
5 - Radiator fan - V7- with ra‐
diator fan control unit - J293-
stalling radiator fans
V7 / V177 ”, page
224
6 - Radiator fan 2 - V177- with
radiator fan control unit 2 -
J671-
stalling radiator fans
V7 / V177 ”, page
224
4.6 Removing and installing radiator cowl

Removing
– Detach cover above radiator -arrows-.

Audi Q7 2007 ➤
WARNING

♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.
– If fitted, unscrew bolts -1, 4, 5 and 6- at radiator cowl.

– Unplug electrical connectors -2 and 3- and move electrical
wiring clear.
– Press locking tabs on left and right sides of radiator cowl
-arrow- and at the same time lift radiator cowl out of engine
compartment.
Installing
Install in reverse order.
• Tightening torques ⇒ “4.5 Exploded view - radiator cowl and
radiator fans”, page 222
4.7 Removing and installing radiator fans -

V7- / -V177-
Removing
– Remove radiator cowl ⇒ page 223 .
– Move electrical wiring clear.
– Remove bolts -1, 2, 3, 4 and 8- and detach radiator fan 2 -
V177- with radiator fan control unit 2 - J671- .
– Remove bolts -5, 6 and 7- and detach radiator fan - V7- with
radiator fan control unit - J293- .
Installing
• Tightening torques ⇒ “4.5 Exploded view - radiator cowl and
radiator fans”, page 222
– Install radiator cowl ⇒ page 223 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi Q7 2007 ➤
21 – Turbocharging/supercharging
1 Supercharger
⇒ “1.1 Connection diagram - vacuum lines”, page 225
⇒ “1.2 Exploded view - supercharger”, page 226
⇒ “1.3 Removing and installing charge pressure sender G31 /
G447 ”, page 228
⇒ “1.4 Removing and installing supercharger”, page 230
⇒ “1.5 Exploded view - charge air coolers”, page 235
⇒ “1.6 Securing supercharger to engine and gearbox support for
assembly work”, page 236
⇒ “1.7 Securing supercharger to engine and gearbox support for
leak test”, page 237
⇒ “1.8 Removing and installing charge air cooler”, page 238
⇒ “1.9 Exploded view - drive unit”, page 242
⇒ “1.10 Removing and installing drive unit and damper spring”,
page 243
⇒ “1.11 Checking supercharger for leaks”, page 245
Note
♦ Observe rules for cleanliness ⇒ “4.1 Rules for cleanliness

when working on fuel supply system, injection system and tur‐
bocharger/supercharger”, page 6 .
♦ Check that all air pipes and hoses and vacuum lines are cor‐
rectly fitted and that there are no leaks before carrying out tests
or repairs.
1.1 Connection diagram - vacuum lines
Caution
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.
Note
♦ Red = Vacuum supply line

♦ Blue = Control pipe to vacuum unit for actuating intake mani‐
fold flaps
♦ Orange = Control pipe to combination valve for secondary air
system (left-side)
♦ Brown = Control pipe to combination valve for secondary air
system (right-side)
♦ Green = Control pipe to switchable coolant pump
1. Supercharger 225
Audi Q7 2007 ➤
1 - Secondary air inlet valve -

N112-
2 - Intake manifold flap valve -
N316-
3 - Secondary air inlet valve 2
- N320-
Note
Not fitted on some USA vehicles
4 - To brake servo
5 - Connecting piece with cap
6 - Combination valve for sec‐
ondary air system (left-side)
8 - Vacuum pump
9 - Coolant valve for cylinder
head - N489-
10 - Vacuum unit
❑ For intake manifold flap
on cylinder bank 2 (left-
side)
11 - Coolant pump
13 - Vacuum unit
❑ For intake manifold flap
on cylinder bank 1
(right-side)
ondary air system (right-side)
1.2 Exploded permitted

view unless
- supercharger
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
226 Rep. gr.21 - Turbocharging/supercharging

Audi Q7 2007 ➤
1 - Engine lifting eye

2 - Bolt
❑ 27 Nm
3 - Supercharger
❑ With charge air coolers
supercharger ⇒
“1.4 Removing and in‐
stalling supercharger”,
page 230
❑ Exploded view - charge
air coolers ⇒ “1.5 Ex‐
ploded view - charge air
coolers”, page 235
❑ Secure to engine and
gearbox support - VAS
6095- when performing
assembly work ⇒
“1.6 Securing super‐
charger to engine and
gearbox support for as‐
sembly work”, page
236
❑ Secure to engine and
gearbox support - VAS
6095- when checking Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
for leaks ⇒ “1.7 Secur‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ing supercharger to en‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
gine and gearbox sup‐
port for leak test”, page
237
4 - Insulating plate
5 - Bolt
❑ 5 Nm
6 - Rubber grommet
❑ 2x
7 - Intermediate flange
8 - Bolt
9 - Throttle valve module - J338-
10 - O-rings
❑ Renew
11 - Connection
12 - Bolt
❑ Tightening torque and sequence ⇒ Rep. gr. 24
13 - Bracket
❑ For change-over valves
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ Tightening torque and sequence ⇒ Rep. gr. 24
1. Supercharger 227
Audi Q7 2007 ➤
16 - Intermediate flange
17 - Regulating flap control unit - J808-
18 - Bleeder screw
❑ For charge air cooler (left-side)
❑ 1.5 … 3.0 Nm
19 - Bolt
20 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
21 - O-rings
❑ Renew
22 - Nut
❑ 20 Nm
23 - O-ring
❑ Renew
24 - Threaded pin
❑ 17 Nm
25 - Bolt
❑ Self-locking
❑ Renew
❑ Before assembly, always remove residues from threaded holes using a thread tap
❑ 10 Nm
26 - Charge pressure sender
❑ Cylinder bank 1 (right-side): charge pressure sender - G31-
❑ Cylinder bank 2 (left-side): charge pressure sender 2 - G447-
❑ Removing and installing ⇒ “1.3 Removing and installing charge pressure sender G31 / G447 ”, page
228
27 - Seals
❑ Renew
28 - O-ring
❑ 2x on USA versions
❑ Renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
29 - Connection
❑ Installation position ⇒ Fig. ““Installing connection for crankcase breather”“ , page 174
30 - O-ring
❑ 2x on USA versions
❑ Renew
1.3 Removing and installing charge pres‐

sure sender -G31- / -G447-

Audi Q7 2007 ➤
Removing
– Remove bolts -arrows- and detach cover -2-.
Cylinder bank 1 (right-side):

– Lift off cover -arrow-.
Caution

♦ Observe rules for cleanliness when working on the fuel
supply system ⇒ page 6 .
WARNING


– withLoosen
respect to union nut -2- and push fuel supply line bytoAUDI
oneAG. side.
the correctness of information in this document. Copyright

1. Supercharger 229
Audi Q7 2007 ➤
Note
Disregard -item 1-.

– Unscrew bolts -arrows- and detach charge pressure sender -
G31- or -G447- .
Installing
• Tightening torques ⇒ “1.2 Exploded view - supercharger”,
page 226
Note
♦ Renew self-locking bolts and O-ring.

♦ Before assembly, always remove residues from threaded
holes for charge pressure senders in supercharger housing
using a thread
Protected tap.Copying for private or commercial purposes, in part or in whole, is not
by copyright.
♦ Do not remove
with respect plugs
to the or protective
correctness caps
of information in until you
this document. are by
Copyright ready to
AUDI AG.
– Install fuel supply line ⇒ Rep. gr. 24 .
1.4 Removing and installing supercharger


Audi Q7 2007 ➤
Removing
gine.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Clampwith
offrespect
coolantto thehoses using
correctness hose inclamps
of information -3094-
this document. , release
hose clips -1- and detach coolant hoses from coolant pipes on
supercharger.
Note
1. Supercharger 231
Audi Q7 2007 ➤

– Unplug electrical connector -1- at activated charcoal filter

solenoid valve 1 - N80- and detach vacuum hose -2- (press
release tabs).
– Detach activated charcoal filter solenoid valve 1 - N80- from
bracket and move it clear to the side with hose still attached.
– Unplug
permittedelectrical connector
unless authorised by AUDI AG. -arrow- at throttle
AUDI AG does valve
not guarantee module
or accept -
any liability
J338-
with .respect to the correctness of information in this document. Copyright by AUDI AG.

Audi Q7 2007 ➤
– Unplug electrical connector -arrow- at regulating flap control

unit - J808- .
– Unplug electrical connectors -1, 2, 3-.
Note
Mark position of vacuum hoses for re-installation.
– Disconnect vacuum hoses -4 ... 7-.
– Unplug
with respect electrical
to the correctness connector
of information -1- at intake
in this document. airbytemperature
Copyright AUDI AG.
sender - G42- / intake manifold pressure sender - G71- .
Note
Disregard -arrows-.

– Remove bolts -arrows- and detach cover (left-side) -2-.
1. Supercharger 233
Audi Q7 2007 ➤
– Lift off cover -arrow- (right-side).
– Move clear vacuum hose -2- leading to brake servo at bracket

-1-.
– Unplug electrical connectors -1- and -2-.

– Remove nuts -arrows- and lift off supercharger with charge air
coolers.
– Seal openings on supercharger and all relevant ducts and
hoses of the charge air system using plugs from engine bung
set - VAS 6122- or clean cloths.
Installing
Installation is carried
with respect out in ofthe
to the correctness reverse
information order;
in this note
document. the following:
• Tightening torques ⇒ “1.2 Exploded view - supercharger”,

page 226
Note
♦ Renew seals and O-rings.

installing.

Audi Q7 2007 ➤
– Ensure that crankcase breather connection is positioned cor‐

rectly when fitting supercharger ⇒ page 174 .
– Install poly V-belt for supercharger ⇒ page 49 .
1.5 Exploded
Protectedview - charge
by copyright. air coolers
1 - Gasket
❑ Renew
2 - O-ring
❑ Renew
❑ Coat with engine oil
when installing charge
air cooler
3 - O-ring
❑ Renew
air cooler
4 - Supercharger housing
5 - Gasket
❑ Renew
6 - Charge air cooler (right-
side)
stalling charge air cool‐
er”, page 238
7 - Bolt
❑ Self-locking
❑ Renew
❑ 10 Nm
8 - Seal
❑ Must not be detached
from charge air cooler
air cooler
9 - Bolt
❑ Self-locking
❑ Renew
❑ 10 Nm
10 - Charge air cooler (left-side)
1. Supercharger 235
Audi Q7 2007 ➤
❑ Removing and installing ⇒ “1.8 Removing and installing charge air cooler”, page 238
11 - Seal
❑ Must not be detached from charge air cooler
❑ Coat with engine oil when installing charge air cooler
1.6 Securing supercharger to engine and

gearbox support for assembly work
Note
When performing assembly work, the openings in the bottom of

the supercharger housing make it possible for you to see and ac‐
cess the charge air coolers. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

♦ Gearbox support - T40206- with -T40206/1- and -T40206/2-

Audi Q7 2007 ➤
Procedure
• Supercharger removed ⇒ page 230 .
– Insert gearbox support -T40206- with -T40206/1- into engine
– Secure supercharger to gearbox support, as shown in illus‐
tration (use holes “1”, “4”, “9”, “11” and “13” for bolted connec‐
tions -1-).
– Attach sealing element -T40206/2- directly to supercharger
housing at front right with bolt -2-.
Installation position of sealing elements -T40206/2- :

• Seals -arrow 1- of sealing elements should point downwards.
• Openings -arrow 2- in supercharger housing make it possible
for you to see and access charge air coolers.
1.7 Securing supercharger to engine and

gearbox support for leak test
When checking for leaks, the seals on the sealing elements -
T40206/2- should seal off the openings in the supercharger hous‐
ing.

1. Supercharger 237
Audi Q7 2007 ➤
♦ Gearbox support - T40206- with -T40206/1- and -T40206/2-
Procedure
• Supercharger removed ⇒ page 230 .
– Insert gearbox support -T40206- with -T40206/1- into engine
– Secure supercharger to gearbox support, as shown in illus‐
tration (use holes “1”, “4”, “9”, “11” and “13” for bolted connec‐
tions -1-).
– Attach sealing element -T40206/2- directly to supercharger
housing at front right with bolt -2-.
Installation position of sealing elements -T40206/2- :

• Seals of sealing elements should seal off openings in super‐
charger housing.
1.8 Removing and installing charge air cool‐

er

Audi Q7 2007 ➤
♦ Fitting sleeve - 2033-
♦ Assembly device for valves - 2036-
♦ Tyre lever for aluminium rims - V.A.G 1942-

Removing
• Supercharger secured to engine and gearbox support - VAS
6095- for assembly work ⇒ page 236 .
Charge air cooler (left-side):
– Unclip bracket -1- for vacuum hose.
Note
Disregard -item 2-.
– Remove charge pressure sender 2 - G447- ⇒ page 228 .
Charge air cooler (right-side):

– Remove throttle valve module - J338- ⇒ Rep. gr. 24 .
– Remove charge pressure sender - G31- ⇒ page 228 .
1. Supercharger 239
Audi Q7 2007 ➤

– Remove bolts -1 and 2- and detach coolant pipes from super‐
charger.
– Remove bolts -1, 2- for charge air cooler (left-side) and

bolts -3, 4- for charge air cooler (right-side).
– Attach valve assembly device - 2036- with -2036/1- to super‐

charger, as shown in illustration.
– Apply fitting sleeve - 2033- at front of charge air cooler.
– Using tyre lever - V.A.G 1942- , apply moderate pressure and
slowly press charge air cooler out of supercharger housing.
Installing
• Tightening torques ⇒ “1.5 Exploded view - charge air coolers”,
page 235
Note
♦ Renew seals, gaskets, O-rings and self-locking bolts.

♦ Before assembly, always remove residues from threaded
holes in supercharger housing using a thread tap.
– Check gasket -5- on charge air cooler -4-.

• The gasket must not be cracked or damaged.
– Slide gasket -1- onto charge air cooler.
– Insert O-ring -2- into opening in supercharger housing -3-.

Audi Q7 2007 ➤
– Coat sealing surface -arrow A- and gasket -arrow B- of charge

air cooler -1- with engine oil.
– Also coat sealing surface inside supercharger housing with
engine oil.
– When fitting charge air cooler, make sure that seals align with
recesses in supercharger housing -arrows-.
Note
To make it easier to insert and press in the charge air cooler,

position the supercharger housing vertically in engine and gear‐
box support - VAS 6095- .
Caution
Risk of damage to charge air cooler.

♦ Only insert charge air cooler by hand.
– Insert charge air cooler in supercharger housing -arrow A- by

hand as far as stop, letting charge air cooler slide into hole
-arrow B- in front of supercharger housing.
– If necessary, guide charge air cooler by hand via openings

-arrows- in supercharger housing when inserting cooler.
– As soon as possible (due to length of bolts), screw in 2 bolts
loosely by hand to guide charge air cooler additionally.
1. Supercharger 241
Audi Q7 2007 ➤
Caution
Risk of damage to charge air cooler.

♦ The charge air cooler must not be pulled in by screwing in
the securing bolts.
♦ Insert charge air cooler by hand (without using tools) until
sealing flange with gasket makes contact with super‐
charger housing (maximum: 1 mm distance). Only then
tighten bolts, as described in the following.
– Tighten bolts -1, 2- for charge air cooler (left-side) and bolts
-3, 4- for charge air cooler (right-side) in diagonal sequence
and in small steps.
note the following:
– Install coolant pipes on supercharger ⇒ page 208 .
– Remove charge pressure sender -G31- ⇒ page 228 .
– Install throttle valve module - J338- ⇒ Rep. gr. 24 .
– Check supercharger for leaks ⇒ page 245 .
1.9 Exploded view - drive unit

Audi Q7 2007 ➤
1 - Bolt
❑ Self-locking
❑ Renew
❑ Before assembly, al‐
ways remove residues
from threaded holes us‐
ing a thread tap
❑ 27 Nm
2 - Drive unit
installing drive unit and
damper spring”, page
243
3 - Damper spring
installing drive unit and
damper spring”, page
243
4 - Supercharger housing
1.10 Removing and installing drive unit and

damper spring

♦ Oil for supercharger drive ⇒ Electronic parts catalogue
♦ Spreader tool (commercially available)
1. Supercharger 243
Audi Q7 2007 ➤
Removing
6095- ⇒ page 236 .
– Detach coolant pipes from supercharger ⇒ page 208 .
– Position supercharger vertically in engine and gearbox sup‐
port.
• Drive unit faces upwards.
Caution
♦ To make sure bearing cover -1- does not come loose and
remains properly sealed, always use spreader tool
-arrows- to press off drive unit -2- as shown in illustration
(do not use a hammer).
– Carefully press off drive unit from bearing cover and detach.
– Detach damper spring.
– With the aid of used oil collection and extraction unit - V.A.G
1782- , extract all oil for supercharger drive from bearing cover
(including oil chambers -arrows- between ribs).
Installing
• Tightening torques ⇒ “1.9 Exploded view - drive unit”, page
242
Note
♦ Renew the drive unit bolts.

♦ Fit self-locking bolts
permitted unlessor insert bybolts
authorised AUDI with locking
AG. AUDI AG doesfluid ⇒ Elec‐
tronic parts catalogue .

– Before assembly, always remove residues from threaded
holes for drive unit in bearing cover using a thread tap.
– Fill bearing cover with oil for supercharger drive.

Audi Q7 2007 ➤
Note
The container is filled with the required amount of oil. It is not

possible to check the oil level at a later stage.
– Insert damper spring in damper element.

• The end of the damper spring -1- must engage in the hole
-arrow- in the damper element at the rear.
– Apply a thin layer of sealant to sealing surface of drive unit.
– Fit drive unit to supercharger housing (pay attention to dowel
sleeves).
Caution
Avoid damage to drive shaft. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ The drive unit must not be pulled in by screwing in the
bolts.
– Simultaneously turn drive pulley until opposite end of damper

spring engages in hole in drive unit.
note the following:
– Make sure that pulley and rotors turn freely and are not ob‐
structed.
– Check supercharger for leaks ⇒ page 245 .
– Install coolant pipes on supercharger ⇒ page 208 .
1.11 Checking supercharger for leaks

♦ Charge air system tester - V.A.G 1687- with adapters - V.A.G
1687/10- , -V.A.G 1687/13-1- , -V.A.G 1687/13-2- and -V.A.G
1687/13-3-
Procedure
6095- for leak test ⇒ page 236 .
• Regulating flap control unit - J808- installed ⇒ Rep. gr. 24 .
1. Supercharger 245
Audi Q7 2007 ➤
– Secure -V.A.G 1687/13-1- to bottom of supercharger housing.

– Secure hose connections with hose clips.
Note
For illustration purposes the supercharger is shown without the

gearbox support.
– Secure -V.A.G 1687/13-3- to top of supercharger housing.

– Secure -V.A.G 1687/13-2- to supercharger housing with

adapter - V.A.G 1687/10- . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
• Make sure knob is pulled out before turning pressure control
valve.

Audi Q7 2007 ➤
– Connect charge air system tester - V.A.G 1687- as shown in

illustration, and connect to compressed air line using a com‐
mercially available connection piece -1-.
– If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high.

♦ The pressure must not exceed 0.5 bar.
– Adjust pressure
Protected byto 0.5 bar
copyright. via for
Copying pressure control purposes,
private or commercial valve -2-.
in part or in whole, is not
– Open valvewith
-4- andtowait
respect until test
the correctness systeministhispressurised.
of information If by AUDI AG.
document. Copyright
necessary, adjust pressure to 0.5 bar again.
– Close valve -3-.
• Pressure must not drop by more than 0.1 bar for 30 seconds.
– Check charge air system for audible leaks or leaks that can be
felt with the hand; apply commercially available leak detecting
spray or use ultrasonic tester - V.A.G 1842- .
Note
♦ For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒

Operating instructions .
♦ Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
1. Supercharger 247
Audi Q7 2007 ➤
26 – Exhaust system
1 Silencers
⇒ “1.1 Exploded view - silencers, catalytic converter”, page
248
⇒ “1.2 Removing and installing catalytic converter (left-side)”,
page 251
⇒ “1.3 Removing and installing catalytic converter (right-side)”,
page 252
⇒ “1.4 Removing and installing front silencer”, page 253
⇒ “1.5 Separating centre and rear silencers”, page 254
⇒ “1.6 Renewing tailpipe”, page 256
⇒ “1.7 Stress-free alignment of exhaust system”, page 256
⇒ “1.8 Checking exhaust system for leaks”, page 257
1.1 Exploded view - silencers, catalytic converter

Catalytic converter and front silencer
1 - Front silencer
❑ Protect against knocks
and impact
stalling catalytic con‐
verter (left-side)”, page
251
❑ Align exhaust system so
it is free of stress ⇒
“1.7 Stress-free align‐
ment of exhaust sys‐
tem”, page 256
2 - Gasket
❑ Renew
3 - Nut
❑ Renew
❑ 23 Nm
4 - Catalytic converter
❑ Protect against knocks
and impact
stalling catalytic con‐
verter (right-side)”, page
252
“1.7 Stress-free align‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ment of exhaust sys‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tem”, page 256 with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Nut
❑ Renew
248 Rep. gr.26 - Exhaust system

Audi Q7 2007 ➤
❑ 23 Nm
6 - Gasket
❑ Renew
7 - Clamp (front)
❑ Installation position ⇒ Fig. ““Installation position of front clamps”“ , page 250
❑ Before tightening, align exhaust system so it is free of stress ⇒ “1.7 Stress-free alignment of exhaust
system”, page 256
❑ Tighten bolted connections evenly
8 - Nut
❑ 23 Nm
9 - Mounting
❑ Renew if damaged
10 - Bolt
❑ 23 Nm
11 - Bolt
❑ 23 Nm
1 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes
❑ Cutting point: centre si‐
lencer / rear silencer ⇒
“1.5 Separating centre
and rear silencers”,
page 254
“1.7 Stress-free align‐
ment of exhaust sys‐
tem”, page 256
2 - Bolt
❑ 60 Nm
3 - Mounting
4 - Bolt
❑ 23 Nm
5 - Clamp
❑ For tailpipe
6 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 23 Nm
7 - Mounting
8 - Tailpipe
newing tailpipe”, page
256
1. Silencers 249
Audi Q7 2007 ➤
9 - Rear silencer
❑ Combined in one unit with centre silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point: centre silencer / rear silencer ⇒ “1.5 Separating centre and rear silencers”, page 254
❑ Align exhaust system so it is free of stress ⇒ “1.7 Stress-free alignment of exhaust system”, page
256
10 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
❑ Installation position ⇒ Fig. ““Installation position of rear clamps”“ , page 250
❑ Before tightening, align exhaust system so it is free of stress ⇒ “1.7 Stress-free alignment of exhaust
system”, page 256
❑ Tighten bolted connections evenly
11 - Nut
❑ 23 Nm
12 - Bolt
❑ 23 Nm
13 - Mounting
Installation position of front clamps

– Install the clamps with bolts at the bottom.
• Ends of bolts point towards outside of vehicle.
Installation position of rear clamps

– Install clamp (left-side) with bolts pointing towards centre of
vehicle.
• Ends of bolts point downwards.
– Install clamp (right-side) with bolts at the top.
• Ends of bolts point to right.

Audi Q7 2007 ➤
Components of exhaust pipe mountings (left-side)

1- Bolt, 9 Nm
2- Bracket
3- Bolt, 23 Nm
Components of exhaust pipe mountings (right-side)

1- Bolt, 23 Nm
2- Bracket
3- Bolt, 23 Nm
1.2 Removing and installing catalytic con‐

verter (left-side)
Removing
Note
– Loosen hose clips -arrows- and move air pipe clear to one side
(vacuum hose -1- remains connected).
– Remove front silencer (left-side) ⇒ page 253 .
– Take electrical connector -3- for Lambda probe 2 after catalytic

converter - G131- out of bracket on suspension turret (right-
side), unplug and move Lambda probe wiring clear.
Note
1. Silencers 251
Audi Q7 2007 ➤
– Remove bolts -1- and -arrows- and detach bracket -2- for cat‐
alytic converter.
Note
Bolt -1- is accessible from above.
– Remove nuts -arrows- and detach catalytic converter.

Installing
Tightening torques
• ⇒ “1.1 Exploded view - silencers, catalytic converter”, page
248 .
• ⇒ Fig. ““Components of exhaust pipe mountings (left-side)”“ ,
page 251 .
Note
♦ Renew gaskets and self-locking nuts.

mover onto the worm thread of the used hose clipsCopyright

beforeby AUDI AG.
with respect to the correctness of information in this document.
installing.
– Install front silencer (left-side) ⇒ page 253 .
1.3 Removing and installing catalytic con‐

verter (right-side)
Removing
Note
– Loosen hose clips -arrows- and move air pipe clear to one side
(vacuum hose -1- remains connected).
– Remove front silencer (right-side) ⇒ page 253 .

Audi Q7 2007 ➤
– Take electrical connector -1- for Lambda probe after catalytic

converter - G130- out of bracket on suspension turret (right-
side), unplug and move Lambda probe wiring clear.
Note
– Remove bolt -1- and nuts -arrows- and detach catalytic con‐
verter.
Installing
Installation is carried out in the reverse order;Protected
note the following:
Tightening torques with respect to the correctness of information in this document. Copyright by AUDI AG.
• ⇒ “1.1 Exploded view - silencers, catalytic converter”, page

248 .
• ⇒ Fig. ““Components of exhaust pipe mountings (right-side)”“ ,
page 251 .
Note
♦ Renew gaskets and self-locking nuts.

installing.
– Install front silencer (right-side) ⇒ page 253 .
1.4 Removing and installing front silencer
1. Silencers 253
Audi Q7 2007 ➤
Removing
– Remove rear noise insulation panel -2- ⇒ Rep. gr. 66 .
– Remove bolt -2- and nuts -3-.

– Loosen nuts -1-, push back clamp and remove front silencer
on relevant side.
Installing
• Tightening torques ⇒ “1.1 Exploded view - silencers, catalytic
converter”, page 248
Note
Renew gaskets and self-locking nuts.

256 .
1.5 Separating centre and rear silencers

♦ The connecting pipe can be cut through at the cutting point
provided in order to renew the centre and rear silencers sep‐
arately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.

Audi Q7 2007 ➤
♦ Chain pipe cutter - VAS 6254-
Procedure
gr. 43 .
– Cut through exhaust pipes at right angle at the position marked
-arrows- using chain pipe cutter - VAS 6254- .
– Position centre of clamps -arrows- over cutting location.
1. Silencers 255
Audi Q7 2007 ➤
– Install clamp (left-side) with bolts pointing towards centre of

vehicle.
• Ends of bolts point downwards.
– Install clamp (right-side) with bolts at the top.
• Ends of bolts point to right.
256 .
Rep. gr. 43 .
1.6 Renewing tailpipe

Procedure
• Tightening torque ⇒ “1.1 Exploded view - silencers, catalytic
converter”, page 248
– Unbolt tailpipe -arrow-.
– Push tailpipe onto rear silencer and align.

– Check clearance between tailpipes and bumper on both sides:
• Dimension -x- (left-side) = dimension -x- (right-side)
1.7 Stress-free alignment of exhaust sys‐

tem
• The exhaust
permitted systembymust
unless authorised beAUDI
AUDI AG. aligned when
AG does it is cool.
– Loosen bolted connections on front clamps.
– Loosen bolted connections on rear clamps (if fitted).

Audi Q7 2007 ➤
– Push exhaust system towards front -arrow- until rubber mount‐

ings are pre-loaded to specified dimensions:
• Rubber mounting (front right): dimension -a- = 2 mm.
• Rubber mounting (front left): dimension -a- = 4 mm.
• Rubber mounting (rear left and right): dimension -a- = 10 mm.

– Hold exhaust system in this position and tighten clamps even‐
ly.
Note
♦ Aligning the exhaust system with clamps between centre and

rear silencer requires the assistance of a second mechanic.
♦ If any of the specified dimensions is not attained, remove rel‐
evant brackets from body and adjust as required.
– Align tailpipes ⇒ page 256 .
1.8 Checking exhaust system for leaks

– Start the engine and run at idling speed.
– Plug tailpipes during leak test (e.g. with cloth or plugs).
– Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/catalytic converter, etc.) to locate
any leaks.
– Rectify any leaks that are found.
1. Silencers 257
Audi Q7 2007 ➤
2 Exhaust manifolds
⇒ “2.1 Exploded view - exhaust manifold”, page 258
⇒ “2.2 Removing and installing exhaust manifold (left-side)”, page
259
⇒ “2.3 Removing and installing exhaust manifold (right-side)”,
page 261
2.1 Exploded view - exhaust manifold
1 - Nut
❑ Renew
❑ Coat thread with high-
temperature paste; for
high-temperature paste
refer to ⇒ Electronic
parts catalogue
sequence ⇒ Fig. ““Ex‐
haust manifold (left-
side) - tightening torque
and sequence”“ , page
259 , ⇒ Fig. ““Exhaust
manifold (right-side) -
tightening torque and
259
2 - Bracket
❑ For heat shield
3 - Exhaust manifold
❑ Removing and in‐
stalling: left-side ⇒ page
259 , right-side ⇒
page 261
4 - Gasket
❑ Renew
5 - Bolt
❑ 9 Nm
6 - Heat shield
7 - Washer
8 - Bolt
❑ 9 Nm
9 - Lambda probe
❑ Before catalytic converter
10 - Nut
❑ RenewProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Coat thread with tohigh-temperature
with respect paste;
the correctness of information in thisfor high-temperature
document. Copyright by AUDI paste
AG. refer to ⇒ Electronic parts cata‐
logue
❑ 23 Nm
11 - Gasket
❑ Renew

Audi Q7 2007 ➤
Exhaust manifold (left-side) - tightening torque and sequence
Note
♦ Renew the nuts.

♦ Coat threads of nuts with high-temperature paste; for high
temperature paste refer to ⇒ Electronic parts catalogue .
– Tighten nuts in 3 stages in the sequence shown:

Stage Nuts Tightening torque
1. -1 … 9- Screw in by hand until contact is made
2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm
Exhaust manifold (right-side) - tightening torque and sequence
Note
♦ Renew nuts for exhaust manifold.

– Tighten nuts in 3 stages in the sequence shown:

Stage Nuts Tightening torque
1. -1 … 9- Screw in by hand until contact is made
2. -1 … 9- 15 Nm
3. -1 … 9- 25 Nm
2.2 Removing and installing exhaust mani‐

fold (left-side)
Removing
Note
– Remove catalytic converter (left-side) ⇒ page 251 .

– In addition, remove front noise insulation -1- ⇒ Rep. gr. 66 .
2. Exhaust manifolds 259

Audi Q7 2007 ➤
– Unscrew Lambda probe 2 - G108- -item 1- ⇒ Rep. gr. 24 .
– Remove bolts -1 … 4- and detach heat shield.
– Remove nuts -1- and -8- and detach bracket for heat shield.
– Remove nuts -2 … 7- and -9- and detach exhaust manifold.
Installing
Tightening torques
• ⇒ Fig. ““Exhaust manifold (left-side) - tightening torque and
• ⇒ “2.1 Exploded view - exhaust manifold”, page 258 .
Note
♦ Renew gasket and nuts.

– Fit exhaust manifold with gasket for catalytic converter and

tighten nuts ⇒ page 259 .
– Install Lambda probe 2 - G108- ⇒ Rep. gr. 24 .
– Install catalytic converter (left-side) ⇒ page 251 .

Audi Q7 2007 ➤
2.3 Removing and installing exhaust mani‐

fold (right-side)
Removing
Note
– Remove catalytic converter (right-side) ⇒ page 252 .

– In addition, remove front noise insulation -1- ⇒ Rep. gr. 66 .

2. Exhaust manifolds 261

Audi Q7 2007 ➤
– Remove Lambda probe - G39- -item 2- ⇒ Rep. gr. 24 .
– Remove bolts -1 … 4- and detach heat shield.

– Remove nuts -7- and -9- and detach bracket for heat shield.
– Remove nuts -1 … 6- and -8- and detach exhaust manifold.
Installing
Tightening torques
• ⇒ Fig. ““Exhaust manifold (right-side) - tightening torque and
• ⇒ “2.1 Exploded view - exhaust manifold”, page 258 .
Note
♦ Renew gasket and nuts.

– Fit exhaust manifold with gasket for catalytic converter and

tighten nuts ⇒ page 259 .
– Install Lambda probe - G39- ⇒ Rep. gr. 24
– Install catalytic converter (right-side) ⇒ page 252 .

Audi Q7 2007 ➤
3 Secondary air system

⇒ “3.1 Exploded view - secondary air system”, page 263
⇒ “3.2 Checking combination valves for secondary air system for
correct operation and leakage”, page 265
⇒ “3.3 Removing and installing combination valve for secondary
air system (left-side)”, page 267
⇒ “3.4 Removing and installing combination valve for secondary
air system (right-side)”, page 268
⇒ “3.5 Removing and installing secondary
Protected by copyright. air
Copying for pump
private ormotor V101
commercial purposes, in part or in whole, is not
”, page 269 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “3.6 Removing and installing sender 1 for secondary air pres‐
sure G609 ”, page 270
3.1 Exploded view - secondary air system
1 - Secondary air pump motor

- V101-
❑ Fitting location: At front
right in engine compart‐
ment below longitudinal
member
stalling secondary air
pump motor V101 ”,
page 269
❑ Checking in Guided
Fault Finding ⇒ Ve‐
hicle diagnostic tester
2 - Bracket
❑ For secondary air pump
motor - V101-
3 - Nut
❑ 9 Nm
4 - Nut
❑ 9 Nm
5 - Nut
❑ 9 Nm
6 - Hose
❑ From air cleaner hous‐
ing
7 - O-ring
❑ Renew
8 - Hose
❑ To combination valves
for secondary air inlet
9 - O-ring
❑ Renew
10 - O-ring
❑ Renew
3. Secondary air system 263

Audi Q7 2007 ➤
11 - O-ring
❑ Renew
12 - Bonded rubber bush
❑ 3x
1 - Hose
❑ From secondary air
pump motor - V101-
2 - Gasket
❑ Renew
3 - Bolts
❑ 9 Nm
4 - Vacuum hose
ondary air system (right-side)
❑ Check operation and
check for leaks ⇒
“3.2 Checking combina‐
tion valves for sec‐
ondary air system for
correct operation and
leakage”, page 265
stalling combination
valve for secondary air
system (right-side)”,
page 268
6 - Bolt
❑ 9 Nm
7 - O-ring permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renew
8 - Sender 1 for secondary air
pressure - G609-
❑ Fitted on some USA ve‐
hicles
stalling sender 1 for secondary air pressure G609 ”, page 270
9 - Bolt
❑ 9 Nm
10 - Combination valve for secondary air system (left-side)
❑ Check operation and check for leaks ⇒ “3.2 Checking combination valves for secondary air system for
correct operation and leakage”, page 265
❑ Removing and installing ⇒ “3.3 Removing and installing combination valve for secondary air system (left-
side)”, page 267
11 - Vacuum hose
12 - Bolts
❑ 9 Nm
13 - Gasket

Audi Q7 2007 ➤
❑ Renew
Heat shield for combination valve (left-side) for secondary air

system - tightening torque
– Tighten bolts -arrows- for heat shield -1- to 9 Nm.
Heat shield for combination valve (right-side) for secondary air

system - tightening torque
– Tighten bolts -arrows- for heat shield -1- to 9 Nm.
3.2 Checking combination valves for sec‐

ondary air system for correct operation
and leakage

♦ Hand vacuum pump - VAS 6213-

Audi Q7 2007 ➤
Procedure
WARNING

• Vacuum hoses and hose connections do not leak.

• Vacuum hoses are not clogged.
– Lift off engine cover panels -1- and -2-.
Version with two secondary air inlet valves

– Detach vacuum hose -1- or -2- leading to relevant combination
valve.
Version with one secondary air inlet valve

– Follow routing of vacuum hose -1- from secondary air inlet
valve downwards to T-piece -2-.
– Detach vacuum hose -arrow- leading to combination valve to
be checked from T-piece -2-.

Audi Q7 2007 ➤

– Connect hand vacuum pump - VAS 6213- to vacuum hose
leading to relevant combination valve.
– Press release tabs and detach secondary air hose -arrow- to
front from bracket.
– Blow lightly into secondary air hose with your mouth (do not
use compressed air).
• The combination valves for secondary air should be closed; it
should not be possible to blow through the hose.
– Operate hand vacuum pump.
• The combination valve should open; it should now be possible
to blow through the hose.
Note
It is necessary to overcome slight initial resistance before it is

possible to blow through the hose.
– Renew combination valve for secondary air system if valve

does not react as described: left-side ⇒ page 267 , right-side
⇒ page 268 .
3.3 Removing and installing combination

valve for secondary air system (left-
side)
Removing
Note

– Remove front wheel (left-side) ⇒ Wheels and
with respect tyres;
to the Rep.
correctness gr.
of information in this document. Copyright by AUDI AG.
44 .
– Detach electrical connectors -1 and 2- from bracket at rear of
cylinder head (left-side) and move clear to side.
Note
Disregard -item 3-.
– Remove bolts -arrows- and detach heat shield -1-.

Audi Q7 2007 ➤
– Remove bolts -3- for secondary air system hose.

– Detach vacuum hose -2- from combination valve for sec‐
ondary air system.
– Unscrew bolts -1- and detach combination valve for secondary
air system.
Installing
Tightening torques
• ⇒ “3.1 Exploded view - secondary air system”, page 263 .
• ⇒ Fig. ““Heat shield for combination valve (left-side) for sec‐
ondary air system - tightening torque”“ , page 265 .
Note
Renew gasket.
– FitProtected
front wheel (left-side)
by copyright. Copying for ⇒ Wheels
private and purposes,
or commercial tyres; Rep.
in part orgr. 44 .is not
in whole,
3.4 Removing and installing combination

valve for secondary air system (right-
side)
Removing
– Remove front wheel (right-side) ⇒ Wheels and tyres; Rep. gr.
44 .
– Remove throttle valve module - J338- ⇒ Rep. gr. 24 .
– Detach electrical connectors -2 and 3- from bracket and move

clear to side.
Note
Disregard -item 1-.

Audi Q7 2007 ➤
– Disconnect vacuum line -2- for brake servo, release vacuum

line and move to right side of vehicle.
Note
Disregard -item 1-.
– Remove bolts -arrows- and detach heat shield -1-.
– Detach vacuum hose -2- from combination valve for sec‐

ondary air system.
– Remove bolts -3- and detach combination valve (right-side) for
secondary air system and bolts -1- for secondary air hose.
Installing
Tightening torques
• ⇒ “3.1 Exploded view - secondary air system”, page 263 .
• ⇒ Fig. ““Heat shield for combination valve (right-side) for sec‐
ondary air system - tightening torque”“ , page 265 .
Note
♦ Renew gasket.
– Install throttle valve module - J338- ⇒ Rep. gr. 24 .

– Fit front wheel (right-side) ⇒ Wheels and tyres; Rep. gr. 44 .
3.5 Removing and installing secondary air

pump motor - V101-

Audi Q7 2007 ➤
Removing
Note
– Move clear and unplug electrical connector -3-. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove nuts -4- and detach secondary air pump motor -
V101- .
Note
Installing
• Tightening torques ⇒ “3.1 Exploded view - secondary air sys‐
tem”, page 263
3.6 Removing and installing sender 1 for

secondary air pressure - G609-
Removing

Audi Q7 2007 ➤


– Release catches -arrows- and detach sender 1 for secondary
air pressure - G609- -item 2-.
Installing
Note
♦ Fit new O-ring.

♦ To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.

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Service

Service Department. Technical Information

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Copyright © 2017 Audi AG, Ingolstadt D3E8028E5C0

4.2 Checking fuel system for withleaks

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.1 Exploded view - oil separator, crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . 173

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

1.2 Removing and installing catalytic converter (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

♦ The engine number (“engine code” and “serial number”) can

♦ The 4-character engine code can be found on the type plate

2 Rep. gr.00 - Technical data

3.1 Safety precautions when working on the fuel supply system

3.2 Safety precautions when working on the cooling system

3.3 Safety precautions when working on vehicles with start/stop system

On vehicles with the start/stop system activated, the engine may

3.5 Safety precautions when working on the

Risk of damage to flexible joint.

3.6 Safety precautions when working on the ignition system

Risk of damage to components

4 Rep. gr.00 - Technical data

4 General repair instructions

4.1 Rules for cleanliness when working on

♦ Carefully clean connection points and the surrounding area

4.2 Checking fuel system for leaks

4.3 Foreign particles in engine

6 Rep. gr.00 - Technical data

4.4 Contact corrosion!

4.5 Routing and attachment of pipes, hoses

4.6 Installing radiators and condensers

4.7 Checking vacuum system

4. General repair instructions 7

8 Rep. gr.00 - Technical data

10 – Removing and installing engine

Special tools and workshop

♦ Removal lever - 80 - 200-

♦ Hose clip pliers - VAS 6362-

♦ Locking pin - T10060 A-

♦ Ball joint puller - T10187-

♦ The engine is removed from underneath together with the

– Activate jacking mode on vehicles with air suspension ⇒ Rep.

10 Rep. gr.10 - Removing and installing engine

To prevent irreparable damage to the electronic components

– Disconnect earth cable -4- ⇒ Electrical system; Rep. gr. 27 .

The cooling system is under pressure when the engine is hot.

– Open filler cap on coolant expansion tank.

– Remove noise insulation panels -1- and -2- ⇒ Rep. gr. 66 .

– Remove rear propshaft ⇒ Transfer box 0BU, front final drive

Collect drained coolant in a clean container for re-use or disposal.

– Release hose clips -1 and 2-, disconnect coolant hoses from

12 Rep. gr.10 - Removing and installing engine

– Release hose clips -arrows-, disconnect coolant hoses from

– Release hose clip -1-, disconnect coolant hose from coolant

– Release hose clip -arrow-, disconnect coolant hose from en‐

– Lift off engine cover panels -1- and -2-.