Hi Guys.

I'm looking for a bit of advice, after years of taking over my fathers garage with my own cars and projects it's time for me to repay him by fixing his car, an '03 A6. Basically after making a right 'ole racket last night and some investigation work today it appears the cam followers (arms that the cam shaft rotate onto) have snapped and there is excessive wear on the cams. I have found one of the valve cap's but not the second one so fear it might have dropped into the sump via the return oil ways.

I think the easiest way to attempt this mammoth task would be to drop the engine out from the front, and work on it on an engine stand instead of chewing about with it in situation, the question I have is what's the best way to attempt the removal? I know people will say the head can be removed in situation, but my worry is if I rebuild the head and fire it up there may have been an under lying problem that caused the followers to break and then were back to square one.

So whats the best way to attempt this task? Do I drop the engine and transmission as one or does the box come away from the engine with ease, I've read something before about 2.7 S6's having something to do with the TC causing problems upon removal but don't know if this is the case with the 2.5TDI.

A brief step by step would be great, but I appreciate not everyone has the time for this so just looking for general hints and tip's such as leave the exhaust manifolds on and just disconnect the exhaust at the down pipe flange.

Many thanks for your help, I'll hopefully produce a photo doccumented thread along the way.

 

Craig,
probably someone with a Bentley manual for C5s may give you some hints as far as engine removal how to.
However, the 2.5 TDI haven't been marketed on the US market. The pool of TDI owners may be too slim on this forum. On the gas (petrol) models the engine can be removed separate from the transmission, which remains in place supported by a jack. The Bentley manual has the step-by-step procedure, so you may want to look into buying one if some folks could confirm that the C5 TDI is covered by the manual.

 

Thanks for your help, I've been a long term browsing member but never had the need to post, never realised the TDI wasn't marketed in the US but I'm not a TDI person myself.

Hopefully someone can let up with some info, I'm thinking the multitronic box the car has fitted will be on non-diesel cars too?

 

That may be the case, indeed.
I would have looked it up, but I only have installed the C4 manual (1995-1997 models).