Audi Workshop Service and Repair Manuals

Removing and installing left cylinder head

Notes:

• ◆ All hose connections are secured with clips.
• ◆ Charge air system must be free of leaks.
• ◆ Renew all seals and gaskets

Removing

• ‒ Remove engine .

• ‒ → Unplug connector from air recirculation valve -2-.

• ‒ → Unplug connector for camshaft timing control -1- (cylinder bank 4..6).
• ‒ Unplug connectors from injectors -2- (cylinder bank 4..6).
• ‒ Unplug connectors from ignition coils -3- and move wiring harness clear (cylinder bank 4..6).
• ‒ Pull crankcase breather -4- off cylinder head cover (cylinder bank 4..6).
• ‒ Remove ignition coils.

• ‒ → Unplug connectors from injectors -2- (cylinder bank 1..3).
• ‒ Pull off hose -5- going to turbocharger intake side.

• ‒ → Unclip solenoid valve for charge pressure control -1-.
• ‒ Pull connector off ACF valve -2-.

• ‒ → Pull connector off throttle unit -1-.
• ‒ Pull connector off charge air sensor -2-.
• ‒ Pull off crankcase breather -3-.
• ‒ Pull connector off intake air temperature sender -4-.

• ‒ → Remove pressure pipes -1-.

Note:

Watch position of retaining strips -2-.

• ‒ → Remove tensioner -1- for ribbed belt.
• ‒ Remove toothed belt guards -2- (left and right).
• ‒ Remove toothed belt guard -3- (centre).

• ‒ → Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.

Note:

Turn over the engine at the central bolt on the crankshaft.

• ‒ Check position of camshafts: the larger holes in the securing plates on the camshaft sprockets must align opposite one another on the inside. If this is not the case, turn crankshaft one revolution further.

• ‒ Remove sealing plug from cylinder block, left.
• ‒ The TDC drilling in the crankshaft must be visible (or able to be felt) in line with the sealing plug hole.
• ‒ → Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.

• ‒ → Remove vibration damper on crankshaft.

Note:

The central bolt does not have to be loosened to remove the vibration damper.

• ‒ → Remove idler wheel for ribbed belt
  -arrows-.
• ‒ Remove toothed belt guard behind vibration damper -arrows-.

Notes:

• ◆ Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when refitted.
• ◆ The toothed belt tensioning element is oil-damped and can therefore only be compressed slowly by applying constant pressure.

• ‒ → Using an 8 mm hexagon key, turn toothed belt tensioning roller -1- clockwise in direction of arrow until tensioning lever -2- compresses tensioning element -3- far enough to insert special tool T40011 in the drilling and in the plunger.
• ‒ Insert special tool T40011 and release toothed belt tensioning roller.

• ‒ Insert camshaft clamp 3391 in the securing plates of the two camshafts.
• ‒ Loosen both camshaft bolts and unscrew approx. 5 turns.
• ‒ Take out camshaft clamp 3391.
• ‒ → Pull off both camshaft sprockets with special tool T40001.

• ‒ → Unbolt rear left toothed belt guard
  -arrows-.
• ‒ Detach intake manifold using special tool 3249.

• ‒ → Unbolt cylinder head lifting bracket with coolant pipe -arrows- from cylinder head.

• ‒ → Unbolt water pipe -1- and pull it towards the rear.
• ‒ Unbolt bracket -2- from cylinder head.

• ‒ Unscrew heat sensor -2-.
• ‒ → Unbolt turbocharger -1- from exhaust manifold (3 bolts).

• ‒ → Unbolt coolant pipe at front of cylinder head
  -arrows-.
• ‒ Unbolt cylinder head cover.
• ‒ Loosen and unscrew cylinder head bolts in opposite sequence to tightening sequence using special tool 3452 (Polidrive).
• ‒ Carefully lift off cylinder head.

Note:

→ Use special tool 3452 together with a normal commercial 10 mm socket when removing and installing.

Installing

Notes:

• ◆ Do not allow any oil or coolant to remain in the blind holes for the cylinder head bolts in the cylinder block.
• ◆ Fit new cylinder head bolts.
• ◆ Connecting vacuum hoses =>Page 10-23.

When installing a new cylinder head:

• ‒ Screw in centring pin for intake manifold.

The cylinder head supplied as a replacement part can be used on both sides (left or right). But a sealing cap (core plug) must be fitted in the front end of the cylinder head in each case.

• ‒ Coat outside circumference of sealing cap (core plug) with sealant.

=> Parts Catalogue

• ‒ → Using drift VW 295, knock in sealing cap (core plug) until the outside rim is flush with the end of the chamfer in the cylinder head.

• ‒ Before fitting cylinder head in position, turn crankshaft and camshafts to TDC of No. 3 cylinder.
• ‒ Fit cylinder head gasket on dowel sleeves. The marking "oben" (top) or the part number must face towards the cylinder head.
• ‒ Fit cylinder head, insert cylinder head bolts and tighten finger-tight.

• ‒ → Tighten cylinder head bolts in two stages in the sequence shown, as follows:

• ◆ Stage 1 = 60 Nm.
• ◆ Stage 2 = turn a further 1/2 turn (180°) with a rigid wrench (turning 2 x 90°is also permissible).

It is not necessary to torque down cylinder head bolts again after repairs have been completed.

• ‒ → Seal end points of joints between bearing caps and cylinder head.
• ‒ Before installing cylinder head cover and gasket, carefully apply a small quantity of sealant at the four end points of the sealing surfaces on the cylinder head -arrows-, using a small screwdriver.

• ◆ Sealant

=> Parts Catalogue

Tightening torques

Removing and installing right cylinder head

Notes:

• ◆ All hose connections are secured with clips.
• ◆ Charge air system must be free of leaks.
• ◆ Renew all seals and gaskets

Removing

• ‒ Remove engine => Page 10-1.

• ‒ → Unplug connector from air recirculation valve -2-.

• ‒ → Remove cover panel from right-hand cylinder head cover -arrows-.

• ‒ → Disconnect hose -1-.
• ‒ Disconnect hose -2-.
• ‒ Unbolt upper section of intake pipe -3-.

Note:

Insert plug in lower section of intake pipe.

• ‒ → Unplug connectors from injectors -2- (cylinder bank 4..6).

• ‒ → Unplug connector for camshaft timing control -1- (cylinder bank 1..3).
• ‒ Unplug connectors from injectors -2- (cylinder bank 1..3).
• ‒ Unplug connectors from ignition coils -3- and move wiring harness clear (cylinder bank 1..3).
• ‒ Pull crankcase breather -4- off cylinder head cover (cylinder bank 1..3).
• ‒ Pull off hose -5- going to turbocharger intake side.
• ‒ Remove ignition coils.

• ‒ → Unclip solenoid valve for charge pressure control -1-.
• ‒ Pull connector off ACF valve -2-.

• ‒ → Pull connector off throttle unit -1-.
• ‒ Pull connector off charge air sensor -2-.
• ‒ Pull off crankcase breather -3-.
• ‒ Pull connector off intake air temperature sensor -4-.
• ‒ Pull connector -5- off Hall sender.

• ‒ → Remove pressure pipes -1-.

Note:

Watch position of retaining strips -2-.

• ‒ → Remove tensioner -1- for ribbed belt.
• ‒ Remove toothed belt guards -2- (left and right).
• ‒ Remove toothed belt guard -3- (centre).

• ‒ → Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.

Note:

Turn over the engine at the central bolt on the crankshaft.

• ‒ Check position of camshafts: the larger holes in the securing plates on the camshaft sprockets must align opposite one another on the inside. If this is not the case, turn crankshaft one revolution further.

• ‒ Remove sealing plug from cylinder block, left.
• ‒ The TDC drilling in the crankshaft must be visible (or able to be felt) in line with the sealing plug hole.
• ‒ → Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.

• ‒ → Remove vibration damper on crankshaft.

Note:

The central bolt does not have to be loosened to remove the vibration damper.

• ‒ → Remove idler wheel for ribbed belt
  -arrows-.
• ‒ Remove toothed belt guard behind vibration damper -arrows-.

Notes:

• ◆ Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when refitted.
• ◆ The toothed belt tensioning element is oil-damped and can therefore only be compressed slowly by applying constant pressure.

• ‒ → Using an 8 mm hexagon key, turn toothed belt tensioning roller -1- clockwise in direction of arrow until tensioning lever -2- compresses tensioning element -3- far enough to insert special tool T40011 in the drilling and in the plunger.
• ‒ Insert special tool T40011 and release toothed belt tensioning roller.

• ‒ Insert camshaft clamp 3391 in the securing plates of the two camshafts.
• ‒ Loosen both camshaft bolts and unscrew approx. 5 turns.
• ‒ Take out camshaft clamp 3391.
• ‒ → Pull off both camshaft sprockets with special tool T40001.

• ‒ → Unbolt rear right toothed belt guard
  -arrows-.
• ‒ Detach intake manifold using special tool 3249.

• ‒ → Unbolt water pipe -1- and pull it towards the rear.
• ‒ Unbolt bracket -2- from cylinder head.

• ‒ → Unbolt line -arrow- from cylinder head.

• ‒ → Remove turbocharger -arrows-.

• ‒ Unbolt cylinder head cover.
• ‒ Loosen and unscrew cylinder head bolts in opposite sequence to tightening sequence using special tool 3452 (Polidrive).
• ‒ Carefully lift off cylinder head.

Note:

→ Use special tool 3452 together with a normal commercial 10 mm socket when removing and installing.

Installing

Notes:

• ◆ Do not allow any oil or coolant to remain in the blind holes for the cylinder head bolts in the cylinder block.
• ◆ Fit new cylinder head bolts.
• ◆ Connecting vacuum hoses =>Page 10-23.

When installing a new cylinder head:

• ‒ Screw in centring pin for intake manifold.

The cylinder head supplied as a replacement part can be used on both sides (left or right). But a sealing cap (core plug) must be fitted in the front end of the cylinder head in each case.

• ‒ Coat outside circumference of sealing cap (core plug) with sealant.

=> Parts Catalogue

• ‒ → Using drift VW 295, knock in sealing cap (core plug) until the outside rim is flush with the end of the chamfer in the cylinder head.

• ‒ Before fitting cylinder head in position, turn crankshaft and camshafts to TDC of No. 3 cylinder.
• ‒ Fit cylinder head gasket on dowel sleeves. The marking "oben" (top) or the part number must face towards the cylinder head.
• ‒ Fit cylinder head, insert cylinder head bolts and tighten finger-tight.

• ‒ → Tighten cylinder head bolts in two stages in the sequence shown, as follows:

• ◆ Stage 1 = 60 Nm.
• ◆ Stage 2 = turn a further 1/2 turn (180°) with a rigid wrench (turning 2 x 90°is also permissible).

It is not necessary to torque down cylinder head bolts again after repairs have been completed.

• ‒ → Seal end points of joints between bearing caps and cylinder head.
• ‒ Before installing cylinder head cover and gasket, carefully apply a small quantity of sealant at the four end points of the sealing surfaces on the cylinder head -arrows-, using a small screwdriver.

• ◆ Sealant

=> Parts Catalogue

Tightening torques