Audi Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Dial gauge -VAS 6079-

t	Puller -T10094-

t	Adapter for dial gauge -T10170-

t	Camshaft clamp -T10171-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t  Spark plug socket and extension -3122 B-

t  Water pump spanner -V.A.G 1590- Removing   WARNING The fuel system operates under high pressure. The pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening the system → Chapter. A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection. –  Remove engine → Chapter.

–  Unplug electrical connector -1- at throttle valve module -J338-. –  Unscrew bolts -arrows- and remove throttle valve module -J338-.

–  Remove bolts -arrows- for connecting pipe for exhaust gas recirculation at exhaust gas recirculation valve -N18- and remove gasket.

–  Unplug electrical connector -2- at activated charcoal filter system solenoid valve 1 -N80-. –  Detach vacuum hose -1- at intake manifold. –  Detach solenoid valve 1 for activated charcoal filter -N80- from its retainers -arrows- and remove with vacuum hoses attached.

–  Disconnect hose -2- for crankcase breather system at intake manifold by pressing release tabs. –  Unplug electrical connectors at intake manifold pressure sender -G71--item 1- and intake manifold flap air flow control valve -N316--item 3-.

–  Disconnect vacuum hose -arrow- at actuator for intake manifold change-over. –  Unscrew bolts -1- and -2- and detach intake manifold.

–  Detach electrical connector -2-. –  Detach connecting pipe for exhaust gas recirculation -1- (front) at exhaust gas recirculation valve -N18-. –  Disconnect coolant hoses -3- at exhaust gas recirculation valve -N18-. –  Remove bolts -arrows- and detach exhaust gas recirculation valve -N18-.

–  Unplug electrical connector -arrow- at oil pressure switch.

–  Unplug electrical connector -arrow- at coolant temperature sender -G62-.

–  Unplug electrical connectors -1 … 5- at injectors and at fuel pressure sender -G247-. –  Unscrew bolts -arrows- and remove wiring guide. –  Detach electrical connectors at following components: 6 -  Intake manifold flap potentiometer -G336- 7 -  Knock sensor 1 -G61- 8 -  Engine speed sender -G28-

–  Detach electrical connectors at following components: 1 -  Hall sender -G40- 2 -  If fitted: fuel pressure sender, low pressure -G410- 3 -  High-pressure pump (fuel pressure regulating valve -N276-) 4 -  Inlet camshaft control valve 1 -N205-

–  Unscrew earth cable from camshaft housing. –  Remove ignition coils by applying puller -T10094- at each ignition coil -arrow- and pulling out ignition coils one by one.   Note The assembly tool -T10118- is only required if the electrical connector needs to be unplugged. –  Detach wiring guide together wiring harness from camshaft housing. –  Move engine wiring harness clear and detach. –  Remove spark plugs with spark plug socket -3122 B-.

–  Remove high pressure pipe by unscrewing securing bolt -5- and union nuts -1- and -2-. –  Unscrew banjo bolts -3- and -4- and detach fuel pipes at high-pressure pump.   Note The fuel pipes remain attached to the engine. –  Pull out oil dipstick.

–  Remove bolts -arrows- for thermostat housing.

–  Remove retaining clip for coolant pipe -arrow-.   Note Shown in illustration with thermostat removed. –  Detach thermostat housing from coolant pipe.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil. –  Unscrew sump/gearbox bolts -arrows-. –  Unscrew bolts for sump -1- in diagonal sequence and remove. –  Take off sump; if necessary loosen it by striking lightly with a rubber hammer.

–  Unbolt crankshaft pulley; use tool -T10172- with -T10172/2- to counterhold.

–  File out the 3 round corners on the water pump wrench -V.A.G 1590- to dimension -a-. l  Dimension -a- = 1 mm.

–  Unbolt coolant pump pulley; use water pump wrench -V.A.G 1590- to counterhold.

–  Unbolt pressure control valve for crankcase breather system -arrows-.

–  Unscrew bolts -arrows- and remove engine lifting eye.

–  Unscrew hexagon socket head bolts -1 ... 6- for timing chain cover and hexagon bolts -arrows-. –  Detach timing chain cover. –  Use drift to drive out oil seal.

–  Fit central bolt -1- with mounting bush -2- to rotate crankshaft.   Note Before tightening central bolt, lock crankshaft by inserting a suitable block of wood at crank web.

–  Unscrew bolts -arrows-. –  Detach sealing caps -1- and -2-.

–  Screw adapter for dial gauge -T10170- into spark plug hole as far as the stop. –  Insert dial gauge -VAS 6079- with extension -T10170/1- as far as the stop and secure using locking nut -arrow-. –  Turn crankshaft in normal direction of rotation to TDC position. Note the position of the small dial gauge needle. –  Then turn crankshaft back 45° in the opposite direction of normal rotation.

–  Press the tensioning rail -2- in the direction of the arrow and lock piston of chain tensioner -1- using locking pin -T40011-.

–  Mark the rotation direction of the timing chain -3- with a coloured pen.   Caution t  The camshaft clamp -T10171- must not be used as a counterhold. t  The centre bolt -2- for the camshaft adjuster has left-hand threads. –  Unscrew bolts -2- and -4- using counterhold tool -T10172-. –  Remove camshaft sprocket -5- and camshaft adjuster -1- together with timing chain -3-.

–  Pull off the tensioning rail -1- and the guide rail -2- from mounting pins.

–  Unscrew camshaft housing bolts in the sequence -15 ... 1-.   Note The bolt -item 9- (below high-pressure pump) remains in the camshaft housing. –  Carefully remove camshaft housing. –  Mark the allocation of the roller rocker fingers and supporting elements for reinstallation. –  Remove roller rocker fingers together with the supporting elements and place down on a clean surface.

–  Loosen cylinder head bolts in the sequence -1 ... 10-. –  Take off cylinder head and place it on a soft surface (such as foam plastic). Installing   Note t  Renew the cylinder head bolts. t  Renew self-locking nuts and bolts when performing assembly work. t  Renew bolts which are tightened to a specified angle as well as oil seals and gaskets. t  If repairing, carefully remove any remaining gasket material from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. t  Carefully remove any remaining emery and abrasive material. t  No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. t  When installing an exchange cylinder head, the contact surfaces between supporting elements, roller rocker fingers and cams must be oiled before installing the camshaft housing. t  All bearings and running surfaces must be oiled before installing. t  The plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted. t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  Handle gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks. t  Position cylinder head gasket on dowel sleeves. The word -oben- (top) or the Part No. must face towards cylinder head. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. t  All cable ties which are released or cut open when removing must be refitted in the same position when installing. t  When fitting a new cylinder head or cylinder head gasket, drain off all the old coolant and refill with new coolant. –  Turn the crankshaft to TDC and then back again approx. 45° in the opposite direction of normal rotation. –  Fit new cylinder head gasket. l  The inscription (part No.) must be legible. –  Fit cylinder head; make sure that dowel sleeves are seated safely in cylinder block. –  Insert new cylinder head bolts and tighten finger-tight.

–  Tighten cylinder head bolts in 3 stages in the sequence indicated: 1.  Tighten with torque wrench to 30 Nm. 2.  Turn 90° (1/4 turn) further using a rigid wrench. 3.  Turn 90° (1/4 turn) further using a rigid wrench.   Note Cylinder head bolts do not have to be torqued down again later after repair work.

–  Turn the inlet and exhaust camshafts in the removed camshaft housing by hand until the camshaft clamp -T10171- can be inserted all the way into the camshaft openings. l  The locking pins -arrows 1- must engage in the holes -arrows 2-. The marking “TOP”-arrow 3- should be legible from above.   Caution The camshafts must not be moved axially when turning.

–  To secure the camshaft clamp -T10171-, screw in an M6 bolt -arrow- finger-tight, but do not tighten.

–  Ensure all roller rocker fingers contact the valve ends -1- correctly and are clipped into their respective support elements -2-.

–  Apply a thin and even layer of sealant to the clean sealing surface of the camshaft housing -hatched area-.   Note The sealant must not be applied too thick; otherwise excess sealant can get into the oil channels and obstruct the strainer in the oil intake pipe.

–  Renew oil strainer -arrow- and insert in cylinder head.

–  Before fitting camshaft housing, screw in 2 studs M6x80 -arrows- into the cylinder head. –  Carefully fit the camshaft housing vertically onto the studs and dowel pins on cylinder head from above.   Note Be sure that no oil residue can drip onto the sealing surfaces. –  Screw in new bolts for camshaft housing finger-tight.

–  Tighten camshaft housing bolts in 2 stages in the sequence shown:

1.  Tighten with torque wrench to 10 Nm. 2.  Turn 90° (1/4 turn) further using a rigid wrench.

Note t  Be sure that camshaft housing is not canted. t  After installing the camshaft housing, wait about 30 minutes for the sealant to dry.

–  Fit timing chain onto crankshaft and camshaft adjuster -1- noting direction of rotation. –  Fit camshaft sprocket -5- together with timing chain.   Caution The centre bolt -2- for the camshaft adjuster has left-hand threads. –  Renew bolts -2- and -4- and screw in until camshaft sprocket and camshaft adjuster can just be turned on the camshaft and do not tilt.

–  Tension the timing chain by removing the locking pin -T40011- from the tensioner -1-.

–  Screw adapter for dial gauge -T10170- into spark plug hole as far as the stop. –  Insert dial gauge -VAS 6079- with extension -T10170/1- as far as the stop and secure using locking nut -arrow-. –  Turn crankshaft in normal direction of rotation to TDC position. l  Permissible deviation from TDC: ± 0.01 mm.   Note If the crankshaft is more than 0.01 mm beyond TDC, you must turn the crankshaft approx. 45° in opposite direction of rotation. Then turn crankshaft in normal direction of rotation to TDC.   Caution The centre bolt -2- for the camshaft adjuster has left-hand threads.

–  Hold camshaft adjuster -1- and camshaft sprocket -5- in this position using counterhold tool -T10172- and tighten bolts -2- and -4-.   Note When tightening the camshaft bolts, the crankshaft must not turn and the timing chain -3- must remain tensioned on both sides. –  Remove the camshaft clamp -T10171-. –  Turn crankshaft two turns in normal direction of rotation to TDC position. l  Permissible deviation from TDC: ± 0.01 mm.

–  Insert the camshaft clamp -T10171- into the openings in the camshafts as far as the stop. If the camshaft clamp -T10171- cannot be inserted: –  Repeat adjustment.

If the camshaft clamp -T10171- can be inserted: –  Remove camshaft clamp -T10171-, lock camshaft adjuster -1- and camshaft sprocket -5- using counterhold tool -T10172- and turn bolts -2- and -4- with a rigid wrench 1/4 turn further (90°). –  Turn crankshaft two turns in normal direction of rotation to TDC position for a second time. l  Permissible deviation from TDC: ± 0.01 mm.

–  Insert the camshaft clamp -T10171- into the openings in the camshafts as far as the stop. If the camshaft clamp -T10171- cannot be inserted: –  Repeat adjustment. Installation is carried out in the reverse order; note the following: –  Install timing chain cover → Chapter. –  Renew crankshaft oil seal → Chapter. –  Install crankshaft pulley → Chapter. –  Install sump → Anchor. –  Renew seals for camshaft sealing caps and lubricate with oil before installing. –  Install exhaust gas recirculation valve -N18- → Chapter. –  Install intake manifold → Rep. Gr.24. –  Install engine → Chapter. Tightening torques

Component		Nm
Camshaft adjuster to camshaft		40 + 90° 1)2)3)
Camshaft sprocket to camshaft		50 + 90° 2)3)
Spark plugs in cylinder head		30
Sealing caps to camshaft housing		10
Engine lifting eye to timing chain cover		20
Pressure control valve for crankcase breather system to timing chain cover		10
Coolant pump pulley to coolant pump		20
Thermostat housing to cylinder head		10
High-pressure pipes	High-pressure pump	15
to:	Fuel rail	15
High-pressure pump bracket		7
EGR connecting pipe to exhaust gas recirculation valve -N18-		8
Throttle valve module -J338- to intake manifold		7
l  1) The central bolt for the camshaft adjuster has a left-hand thread. l  2) Renew bolts. l  3) 90° = one quarter turn.