Audi Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Hose clip pliers -V.A.G 1921-

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Safety goggles

t	Protective gloves

Removing   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Disconnect earth wire at battery with ignition switched off. –  Drain off coolant → Chapter. –  Move lock carrier to service position → Chapter.

–  Disconnect air intake hose from turbocharger -arrow-.

–  Remove bolts -1- and -2- and detach support for turbocharger.   Note Place a cloth underneath to catch any escaping oil. –  Remove oil return pipe -3- at cylinder block.

–  Disconnect exhaust system at clamp -arrow- and push clamp back.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-.   Note Shown from rear for illustration purposes.

–  Unplug electrical connector -arrow- at coolant temperature sender -G62- and move wiring harness clear.   Note Shown from rear for illustration purposes.

–  Disconnect vacuum hose going to brake servo at bulkhead -arrow-.

–  Unplug electrical connector -arrow- at fuel temperature sender -G81- and move wiring clear.   Caution Rules for cleanliness when working on the injection system → Chapter.   WARNING t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles.

–  Disconnect fuel return pipe -1- and fuel supply pipe -2- from tandem pump.

–  Move clear electrical wiring at bracket for fuel filter. –  Unscrew nuts -arrows- and move fuel filter to side.

–  Unscrew bolts -1- and -2- and detach top coolant pipe from coolant hoses -arrows-.

–  Remove air intake hose at intake manifold flap motor -V157- by lifting retaining clip -arrow- slightly.

–  Unplug electrical connectors at exhaust gas recirculation valve -N18- / exhaust gas recirculation potentiometer -G212--item 1- and at intake manifold flap motor -V157--item 2-.

–  Remove bolts -arrows-. –  Pull guide tube for oil dipstick upwards out of the cylinder block and swing towards front to remove.

–  Unplug electrical connector -1- at oil pressure switch -F1-. –  Unscrew oil pressure switch -F1--item 2-. –  Detach oil supply pipe at oil filter bracket -3- and at connecting pipe for exhaust gas recirculation -4-.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Loosen hose clip -2- to remove air intake hose. –  Move clear wiring harness at air cleaner housing and remove air cleaner housing -arrow-.

–  Detach crankcase breather hose -2- from cylinder head cover. –  Remove bolts -3- and -4-. –  Disconnect air intake hose -1- from turbocharger.

–  Disconnect coolant hoses -1- and -2- at exhaust gas recirculation cooler. –  Detach vacuum hose -3- at exhaust gas recirculation cooler.

Vehicles with engine code letters BLB, BNA, BRE, BRF, BVF, BVG: –  Disconnect hose -arrow- from vacuum unit for charge pressure control. –  Move vacuum hoses at cylinder head clear.

Vehicles with engine code letters BRD, BVA: –  Detach vacuum hose -3-. –  Unplug electrical connector -2- at position sender for charge pressure positioner -G581-.   Note Disregard -item 1-.

All vehicles:   Note To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Unscrew nuts on turbocharger -arrows-. –  Disconnect front exhaust pipe / particulate filter from turbocharger.

–  Unscrew oil supply pipe at turbocharger and exhaust manifold -arrows-.

–  Remove toothed belt → Chapter. –  Pull out locking pins -3359- (2x). –  Remove securing bolts -arrows- for camshaft sprockets. –  Remove the camshaft sprockets from hubs.

–  Loosen securing bolt -1- for hub on inlet camshaft; use counterhold tool -T10051-.

–  Loosen securing bolt -1- for hub on exhaust camshaft; use counterhold tool -T10051-. –  Unscrew securing bolts of hubs approx. 2 turns.

–  Fit puller -T10052- on hub of inlet camshaft and screw in bolts -arrows- into hub. –  Remove hub by screwing in bolt -1- while counterholding at hexagon flats (30 mm) of puller.

–  Fit puller -T10052- on hub of exhaust camshaft and screw in bolts -arrows- into hub. –  Remove hub by screwing in bolt -1- while counterholding at hexagon flats (30 mm) of puller. –  Remove toothed belt tensioning roller.

–  Remove bolts -2 ... 4-. –  Unscrew bolt -5- and remove Hall sender -G40- from cylinder head. –  Unscrew stud -1- using two M8 locknuts.

–  Detach vacuum hose at cylinder head cover -arrow at bottom-. –  Remove cylinder head cover bolts in the sequence -11 ... 1-. –  Remove cylinder head cover.

–  If fitted, detach vacuum hose from intake manifold flap actuator -arrow-.

–  Remove bolts -1-, -3- and -5-. –  Unscrew bolts -2- and -4- alternately in several stages.   Note Do not pull bolts out of rocker arm shaft so that components remain attached to shaft. If necessary mark position on rocker arm. –  Detach rocker arm shaft. –  Remove bolts -6 ... 10-.

–  Remove cylinder head bolts in the sequence: -1 ... 10-. –  Remove the cylinder head with the assistance of a 2nd mechanic. –  Lay cylinder head aside on a clean surface with the combustion chamber side facing upwards.   Caution t  Vehicles with ceramic glow plugs: The ceramic glow plugs are very easily damaged and project slightly beyond the cylinder head gasket surface, so do NOT lay the cylinder head down on the gasket side while the glow plugs are still installed. t  Handling ceramic glow plugs → Chapter. Installing   Note 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  No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. 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, gaskets and O-rings. 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  When installing an exchange cylinder head with fitted camshafts, the contact surfaces between roller rocker fingers and cams must be oiled after installing the head. t  The plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. Do NOT use lubricant.

t  When installing air intake hoses with plug-in connectors, ensure that the securing clip -arrow- engages audibly on the retaining lug -A-. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the charge 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 refill the complete cooling system with fresh coolant.

–  Check whether both the camshafts and the crankshaft are positioned at TDC: l  The grooves -arrows- for the hubs must face upwards.

l  The crankshaft sprocket must be locked using crankshaft stop -T10050- for engines with circular crankshaft sprocket, or crankshaft stop -T10100- for engines with oval crankshaft sprocket.   Note The markings on the toothed belt sprocket and the crankshaft stop must align -arrow-.

–  Check whether there is a slit dowel sleeve inserted between cylinders 1 and 2 -arrow A-; insert if necessary. –  Check which type of dowel sleeve is inserted between cylinders 3 and 4 -arrow B-: Vehicles with slit dowel sleeve -arrow B-: l  A slit dowel sleeve remains installed. Vehicles with closed dowel sleeve -arrow B-: l  A closed dowel sleeve must be coated with new sealant as described in the following. –  Pull closed dowel sleeve -arrow B- out of cylinder block and remove any remaining sealant.

–  Blow out drilled holes for dowel sleeve in cylinder block -1- and in cylinder head -3- with compressed air. –  Clean and degrease each drilled hole down to a depth of 10 mm. –  Allow holes to dry for 3 minutes and then coat drilled holes in cylinder block and cylinder head all around with sealant -D 154 103 A1-. –  Insert closed dowel sleeve -4-. 2 -  Cylinder head gasket

All vehicles: –  Note identification markings on cylinder head gasket. 1 -  Part No. 2 -  Production code (can be disregarded) 3 -  Holes   Note t  If the cylinder head gasket or cylinder head is renewed, be sure to install a gasket with the same identification. 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. l  Note centring sleeves -arrows- in cylinder block. l  Check installation position of cylinder head gasket: the word “oben” (top) or the Part No. should face towards the cylinder head. –  Fit cylinder head.

–  Insert and hand-tighten cylinder head bolts. –  Tighten cylinder head bolts in 4 stages in the sequence shown:

1.  Tighten with torque wrench to 40 Nm. 2.  Tighten with torque wrench to 60 Nm. 3.  Turn 90° (1/4 turn) further using a rigid wrench. 4.  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.

–  Before installing rocker arm shaft, check that all ball studs -1- and O-rings -2- are fitted in unit injectors.

–  Secure the rocker arm shaft as follows:

1.  Tighten bolts -2- and -4- alternately in several stages until rocker arm shaft lies on bearing frame. 2.  Tighten bolts -1-, -3- and -5- to 20 Nm + 90° (1/4 turn). 3.  Tighten bolts -2- and -4- to 20 Nm + 90° (1/4 turn). 4.  Tighten bolts -6 ... 10- to 20 Nm.

–  Apply locking fluid to bolts -2 … 5- and tighten bolts; for locking fluid refer to → Electronic parts catalogue. –  Screw in stud -1-.

–  Attach hub to exhaust camshaft. –  Tighten securing bolt -1- to 100 Nm (use counterhold tool -T10051-).

–  Attach hub to inlet camshaft. –  Tighten securing bolt -1- to 100 Nm (use counterhold tool -T10051-).

–  Push camshaft sprockets onto hubs. l  The toothed segments -arrows- in the camshaft sprockets must both face upwards. –  Screw in bolts -1- finger-tight. –  Lock hubs with locking pin -3359- (2x). Remaining installation steps are carried out in reverse sequence; note the following: –  Install cylinder head cover → Chapter. –  Install toothed belt (adjust valve timing) → Anchor. –  Install vibration damper → Chapter. –  Install poly V-belt → Chapter. –  Install front exhaust pipe together with catalytic converter → Chapter. –  Install particulate filter: vehicles with manual gearbox → Chapter; vehicles with multitronic gearbox → Chapter. –  Align exhaust system so it is free of stress: vehicles without particulate filter → Chapter, vehicles with particulate filter → Chapter. –  Install coolant pipe (top) → Chapter. –  Install lock carrier with attachments → Rep. Gr.50.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten nuts -arrows-. –  Install bumper cover (front) → Rep. Gr.63. –  Connect battery. Procedures required → Rep. Gr.27. –  Change engine oil → Booklet803 or → Booklet805. –  Fill cooling system with fresh coolant → Anchor. Tightening torques

Component		Nm
Rocker arm shaft to cylinder head		20 + 90° 1)2)
Rear toothed belt cover to cylinder head		10 3)
Hall sender to cylinder head		10 3)
Stud to cylinder head		15
Hub to camshaft		100
Oil supply pipe to turbocharger		22
Bracket for oil supply pipe to exhaust manifold		22
Oil supply pipe to oil filter bracket		22
Oil pressure switch to oil filter bracket		20
Oil return pipe to cylinder block		30
Guide tube for	Engine lifting eye	10
oil dipstick to:	Oil filter bracket	10
Bracket for	Turbocharger	20
Turbocharger to:	Cylinder block	40
Stop for torque reaction support to lock carrier		28
Hose clips (9 mm wide)		3
Hose clips (13 mm wide)		5.5
l  1) Renew bolts. l  2) 90° = one quarter turn. l  3) Apply locking fluid when installing; refer to → Electronic parts catalogue for locking fluid.