Audi Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ 3036 Counter-hold

• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ AMV 188 001 02 Sealant

Removing

Notes:

• ◆ The sealing surfaces on cylinder head cover and cylinder head must not be reworked.

• ◆ In this cylinder head the camshaft bearings are integrated into the cylinder head and cylinder head cover. Before removing cylinder head cover, the toothed belt tension must be relieved.
• ◆ If the cylinder head cover has been loosened, replace camshaft oil seal.

Work sequence

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

• ‒ With the ignition switched off disconnect the battery earth strap.
• ‒ Remove toothed belt , removing, installing and tensioning toothed belt.
• ‒ Remove camshaft sprocket. When loosening camshaft sprocket bolt counter-hold with 3036.
• ‒ Unscrew the three upper securing bolts for rear toothed belt guard.

• ‒ Unscrew ignition transformer screws out of cylinder head cover.

• ‒ → Pull 3-pin connector off Hall sender -arrow-.
• ‒ Open cylinder head cover sealing cap and unclip screening cover and remove.

• ‒ → Remove cylinder head cover bolts in the sequence prescribed and loosen items9and10alternately using diagonal sequence.
• ‒ Carefully remove cylinder head cover.
• ‒ Lift camshaft carefully, remove and place on a clean surface.
• ‒ Remove roller rocker fingers together with support elements and place on a clean surface.

• ‒ Ensure the roller rocker fingers and the support elements are not interchanged.

Installing

Prerequisites

• ● Prevent dirt and sealant remnants from entering cylinder head.
• ● Sealing surfaces must be free of oil and grease.
• ● When installing cylinder head cover or camshaft, the cams for Cyl. 1 must face upwards.
• ● The pistons must not be positioned at TDC.

• ‒ Remove sealant remnants on cylinder head and camshaft housing with a commercially available sealant remover.
• ‒ Oil the camshaft contact surfaces.
• ‒ Insert support element in cylinder head and fit roller rocker finger onto respective valve stem end and support element.

• ‒ → Ensure all roller rocker fingers contact the valve ends -1- correctly and they are clipped into their respective support elements -2-.
• ‒ Carefully place camshaft in camshaft bearings of cylinder head.

• ‒ → Apply a thin even coat of sealant onto the clean cylinder head cover sealing surface.

Note:

The sealant must not be applied too thick, otherwise excess sealant can enter the oil channels or camshaft bearing and cause damage to the engine.

• ‒ → Install the cylinder head cover carefully from above ensuring that the dowel pins fit in holes -arrows- in the cylinder head.

Notes:

• ◆ Positioning and securing the cylinder head cover must be completed without interruption, as the sealing surfaces start to cure immediately they have contact.
• ◆ The cylinder head cover bolts must be replaced.

• ‒ → First tighten bolts items 1 and 2 alternately using diagonal sequence and tighten to 6 Nm.

• ‒ Then tighten the other bolts to 6 Nm in sequence prescribed.
• ‒ Then tighten all bolts a 1/4 turn (90 °) further.

Note:

Sealant must be left dry for approx. 30 minutes after installing cylinder head cover.

• ‒ Install new oil seal in camshaft,
  => Page 15-44.

The rest of the assembly is basically a reverse of the dismantling sequence.

Installing toothed belt and adjusting timing.

• ‒ Perform the work sequence "Procedure after voltage supply open circuit".

=> Repair group 24; Engine control unit; Procedure after interrupting voltage supply.