Audi A4 1995 On 2.5 TDI 6-Cylinder Diesel Engine Workshop Manual – AFB AKN

Description

File Details

• Manual Type: Workshop Manual (Mechanics)
• Brand: Audi
• Model: A4 1995 onwards
• Engine: 6-cylinder diesel direct injection engine (TDI)
• Engine Codes: AFB, AKN
• Language: English
• Page Count: 272
• File Format: PDF
• Edition: 09.2008
• Document Number: SM-19-1

Chapters Covered

• 00 – Technical data
• 10 – Removing and installing engine
  • Removing engine
  • Securing engine to engine and gearbox support
  • Installing engine
  • Lock carrier service position
• 13 – Crankshaft group
  • Poly V-belt drive for power steering pump, alternator and viscous fan
  • Poly V-belt drive for air conditioner compressor
  • Toothed belt drive for camshafts
  • Toothed belt drive for injection pump
  • Removing and installing toothed belt
  • Sealing flanges and dual-mass flywheel/drive plate
  • Crankshaft
  • Pistons and conrods
• 15 – Cylinder head, valve gear
  • Cylinder head
  • Valve gear
  • Removing and installing intake manifold
  • Removing and installing cylinder head cover
  • Removing and installing cylinder head
  • Checking compression
  • Measuring axial and radial clearance of camshafts
  • Renewing oil seals for camshafts
  • Checking hydraulic valve compensation elements
  • Renewing valve stem oil seals
  • Valve dimensions and checking valve guides
• 17 – Lubrication
  • Sump (bottom section), oil pump, sump (top section)
  • Oil filter bracket, oil cooler
  • Engine oil
  • Checking oil pressure and oil pressure switch
• 19 – Cooling
  • Cooling system
  • Draining and filling cooling system
  • Coolant pump and thermostat
  • Coolant pipes
  • Viscous fan
  • Radiator
  • Checking cooling system for leaks
• 21 – Turbocharging/supercharging
  • Charge air system with turbocharger
  • Hose connection diagram for charge pressure control
  • Checking turbocharger and charge pressure control
  • Checking charge pressure control solenoid valve N75
  • Checking linkage and vacuum unit for charge pressure control
  • Checking intake manifold pressure sender G71
  • Turbocharger – removing and installing
  • Charge air cooling
• 26 – Exhaust system
  • Exhaust system on vehicles with front-wheel drive
  • Exhaust system on vehicles with four-wheel drive
  • Exhaust manifold
  • Exhaust gas recirculation system
  • Checking exhaust gas recirculation valve N18
  • Checking mechanical exhaust gas recirculation valve

This Audi A4 1995 On 2.5 TDI 6-Cylinder Diesel Engine Workshop Manual is a 272-page technical repair guide covering the AFB and AKN engine codes fitted to the Audi A4 from 1995 onwards. It gives the professional technician and serious DIY mechanic the complete factory procedures for removing and installing the engine, servicing the crankshaft group, cylinder head and valve gear, lubrication and cooling systems, turbocharging and charge air system, and the full exhaust system including exhaust gas recirculation. Every section is supported by detailed exploded views, assembly illustrations, torque specifications, tightening sequences, and special tool references, making it the essential reference for anyone performing major engine work on these 2.5-litre V6 TDI diesel units.

What This Workshop Manual Enables You To Do

With this Audi A4 1995 On 2.5 TDI 6-Cylinder Diesel Engine Workshop Manual, you can confidently tackle the jobs that keep these 2.5 TDI engines running correctly. The manual walks you through engine removal from the front without the gearbox, including the service position for the lock carrier, disconnecting fuel, coolant, vacuum and electrical connections, and securing the engine to the engine and gearbox support. You get the correct procedures for removing and installing the poly V-belt drives for the power steering pump, alternator, viscous fan and air conditioner compressor, including belt routing and tensioning values.

The crankshaft group section covers the toothed belt drive for camshafts and injection pump, with detailed instructions for removing the toothed belt, adjusting valve timing, and setting the injection pump timing. You also get the procedures for renewing the crankshaft oil seals, removing and installing the sealing flanges, the dual-mass flywheel and drive plate, the crankshaft bearing caps with their tightening sequence, and the pistons and conrods with their piston ring and cylinder bore specifications.

The cylinder head and valve gear section is particularly thorough, covering intake manifold removal for both left and right sides, cylinder head cover removal and installation, cylinder head removal and installation for both cylinder banks, checking compression, measuring camshaft axial and radial clearance, renewing camshaft oil seals, removing and installing camshafts, checking and renewing hydraulic valve compensation elements, and renewing valve stem oil seals with the cylinder head installed or removed. Valve dimensions and valve guide wear limits are also included.

Lubrication coverage includes the sump (top and bottom sections), oil pump removal and installation, oil filter bracket and oil cooler, checking oil pressure and the oil pressure switch. Cooling system coverage gives you draining and filling procedures, coolant pump and thermostat removal and installation, coolant pipe removal and installation for the front, left and right sides, viscous fan and radiator removal, and leak testing. Turbocharging and supercharging is covered with the charge air system, charge pressure control, testing the turbocharger, checking the charge pressure control solenoid valve N75, checking the linkage and vacuum unit, and checking the intake manifold pressure sender G71. The exhaust system section covers front-wheel drive and four-wheel drive exhaust systems, exhaust manifold removal for both sides, and the full exhaust gas recirculation system including valve testing.

Why This Manual Matters

The Audi A4 2.5 TDI V6 engine (AFB and AKN) is a sophisticated diesel unit with tight tolerances and specific procedures for valve timing, injection pump timing, turbocharger control and torque settings. Using the wrong sequence or values can lead to poor running, expensive damage, or premature failure. This Audi A4 1995 On 2.5 TDI 6-Cylinder Diesel Engine Workshop Manual gives you the exact factory procedures, torque values, tightening sequences and special tool requirements so every job is done correctly the first time. It is the same technical information used by professional workshops, presented in a clear step-by-step format with supporting illustrations.

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This Audi A4 1995 On 2.5 TDI 6-Cylinder Diesel Engine Workshop Manual is delivered as an instant PDF download after payment. There is no shipping, no waiting, and no physical book to lose. You can view it on any device — laptop, tablet or smartphone — and print the pages you need for the workshop. Whether you are a professional mechanic or a dedicated owner maintaining your own Audi A4 2.5 TDI, this manual gives you the technical depth and precision you need.