Audi Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Removal lever -80 - 200-

t	Diesel injection pump locking pin -3359-

t	Hose clip pliers -VAS 6362-

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Bit XZN 10 -T10385-

Removing –  Drain coolant → Chapter. –  Remove radiator cowl → Chapter. –  Remove air cleaner housing → Rep. gr.23.

–  Remove battery → Electrical system; Rep. gr.27.

–  Remove bolts -arrows- and take out battery tray -1-.

–  Release hose clip -2-, lift retaining clip -1- and remove air hose.

–  Release hose clip -2-, lift retaining clip -1- and remove air hose.

–  Remove bolts -1- and -3-. –  Slacken hose clip -5- at intake manifold flap motor -V157- or throttle valve module -J338-, detach air pipe -2- but do not remove.   Note Disregard -item 4-.

–  Remove nuts -2- and bolts -3-, and detach exhaust gas recirculation pipe.   Note Disregard -item 1-.

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side).

–  Remove bolts -1, 2- and banjo bolt -3-. –  Detach support for turbocharger with oil return pipe.

–  Remove nuts -2-.   Note Disregard -item 1-.

–  Press release tabs and disconnect crankcase breather hose -1- from cylinder head cover. –  Move clear vacuum hoses -arrows- at air pipe. –  Loosen hose clip -2- and detach air pipe.

–  Unplug electrical connector -1- at position sender for charge pressure positioner -G581-. –  Detach vacuum hose -2- from vacuum unit of turbocharger. –  Disconnect vacuum hose -3-. –  Remove exhaust gas temperature sender 1 -G235- → Chapter.

–  Slacken bolt -2- and remove clamp.   Note Disregard -items 1, 3-. –  Move clear electrical wiring at turbocharger.

–  Unplug electrical connector -2- on exhaust gas pressure sensor. –  Remove bolt -3- and detach exhaust gas pressure sensor 1 -G450- from bracket -arrow-. –  Remove upper bolt -1- at bracket for particulate filter and tie particulate filter to rear.   Note The installation position can vary depending on version.

–  Unplug electrical connectors -1- at exhaust gas recirculation valve -N18- and -3- at intake manifold flap motor -V157- or throttle valve module -J338-. –  Remove bolt -arrow- for dipstick guide tube. –  Remove bolts -2- for exhaust gas recirculation pipe.   Note Disregard -item 4-.

–  Unclip wiring harness from retainer -arrow-.

Vehicles with dual clutch gearbox: –  Slacken hose clips -arrows- and detach coolant hoses from gear oil cooler.

All vehicles (continued): –  Move clear wiring harnesses -arrows- and electrical connector -1- at bracket.

–  Remove bolts -2, 5- and -arrows-. –  Using removal lever -80 - 200-, move clear electrical wiring and hoses at air pipe (left-side). –  Loosen hose clip -3- and detach air pipe (left-side).   Note Disregard -items 1, 4-.

–  Disconnect vacuum hose -1- from vacuum pump.   Note Disregard -arrows-.

–  Unplug electrical connector -2- at coolant temperature sender -G62-. –  Slacken hose clips -arrows- and detach coolant hoses from connection.   Note Disregard -item 1-.

Caution Risk of cracking in flexible joint. Do not bend flexible joint in exhaust gas recirculation pipe. –  Remove nut -1- and bolts -2-, detach exhaust gas recirculation pipe.

–  Disconnect oil supply line from connection on oil filter bracket. To do so, counterhold at hexagon flats with an open-end spanner and loosen union nut -3-.   Note Disregard -items 1, 2-.

–  Remove nut -2- at retaining clip for vacuum line. –  Remove bolt -1-. –  Unscrew oil supply line from connection on turbocharger. To do so, counterhold at hexagon flats with an open-end spanner and slacken union nut -3-.

–  Remove bolt -arrow- for toothed belt cover (rear). –  Take toothed belt off camshaft sprocket → Chapter.

–  Remove nut -1-.   Note Disregard -arrow-.

–  Unplug electrical connector -arrow- at Hall sender -G40-. –  Remove cylinder head cover → Chapter. –  Unplug electrical connectors on glow plugs → Rep. gr.28.

–  Remove bolts -1- and detach camshaft sprocket.

–  Counterhold using counterhold tool -T10051- and loosen bolt -1- for camshaft hub. –  Unscrew bolt approx. 2 turns.

–  Apply puller -T10052- to camshaft hub and and screw bolts -1- into hub. –  Counterhold on hexagon flats (30 mm) of puller and screw in bolt -2- to pull off camshaft hub. –  Detach hub from taper of camshaft.

–  Slacken cylinder head bolts in the sequence -1 ... 10-.   Note A second mechanic is required for removal of the cylinder head. –  Swivel cylinder head to left and out of rear toothed belt cover and detach tensioning roller at the same time. –  Take care not to damage oil return line for turbocharger. –  Take care to place cylinder head down without bending oil return line. If necessary, place a block of wood below exhaust manifold.   Caution Risk of damage to glow plugs when putting down cylinder head. After removal, the cylinder head must not be put down on the gasket side with the glow plugs still installed, because the glow plugs project slightly beyond the gasket surface.   Note Audi A3 models with a 2.0 ltr. 4-valve TDI engine (common rail) are always equipped with steel glow plugs. Installing l  Tightening torques → Chapter „Cylinder head - exploded view“   Caution Avoid damage to sealing surfaces. t  Carefully remove sealant residue from cylinder head and cylinder block. t  Ensure that no long scores or scratches are made on the surfaces. Avoid damage to cylinder block. No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. Risk of leaks at cylinder head gasket. t  Carefully remove any sealant residue 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  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  Handle the cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket. Avoid damage to open valves. When installing an exchange cylinder head, the plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted. Avoid damage to valves and piston crowns after working on valve gear. Turn the crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts as well as seals, gaskets and O-rings. t  Cylinder heads must not be reworked on TDI engines. t  When installing an exchange cylinder head, the contact surfaces between roller rocker fingers and cams must be oiled. t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and the coolant in the entire cooling system. –  Before fitting cylinder head, remove crankshaft stop -T10050- and turn crankshaft against normal direction of rotation until all pistons are positioned approximately equally below „TDC“. –  If not already fitted, install dowel sleeves in cylinder block for centring cylinder block and cylinder head.

–  Note cylinder head gasket identification: 1 -  Part number 2 -  Holes 3 -  Ignore   Note t  If the cylinder head gasket or cylinder head have been replaced, select the new cylinder head gasket according to the number of holes on the old gasket. t  If parts of the crankshaft drive have been renewed, the new cylinder head gasket must be selected by measuring the piston projection at „TDC“ → Chapter.

–  Fit cylinder head gasket onto dowel sleeves -arrows- in cylinder block. l  Installation position of cylinder head gasket: the word „oben“ (top) or the part number should face towards the cylinder head.   Note A second mechanic is required for fitting cylinder head. –  Swivel cylinder head so that stud for toothed belt tensioning roller is inserted into aperture in toothed belt cover (rear) and attach tensioning roller at the same time.   Note Make sure that electrical wiring to Hall sender -G40- is properly routed. –  Fit cylinder head. –  Screw in cylinder head bolts by hand until they make contact.

–  Tighten cylinder head bolts → Fig..   Note Cylinder head bolts do not have to be torqued down again later after repair work. –  Install rear toothed belt cover, camshaft hub and sprocket → Chapter.

–  Lock camshaft hub with diesel injection pump locking pin -3359-.   Note Disregard items marked -1- and -arrow-.

–  Lock high-pressure pump hub with diesel injection pump locking pin -3359-.   Note Disregard -item 1-.

–  Then turn crankshaft in direction of engine rotation until pin -arrow- on crankshaft stop -T10050- engages in sealing flange as crankshaft rotates. –  Install toothed belt (adjust valve timing) → Anchor. Remaining installation steps are carried out in reverse sequence; note the following: –  Install cylinder head cover → Chapter. –  Install oil supply line → Item. –  Install exhaust gas recirculation pipes → Chapter. –  Install air pipe (left-side) → Chapter. –  Install dipstick guide tube → Fig.. –  Install particulate filter → Chapter. –  Install exhaust gas temperature sender 1 -G235- → Chapter. –  Install heat shield for drive shaft (right-side) → Fig.. –  Install battery mounting and battery → Electrical system; Rep. gr.27. –  Install air cleaner housing → Rep. gr.23. –  Install support for turbocharger → Chapter. –  Install air hose with plug-in connector → Fig.. –  Install radiator cowl → Chapter. –  Change engine oil → Booklet808. –  Fill cooling system with fresh coolant → Anchor.