Cylinder head, removing and installing: Removing

Remove engine. See ENGINE, REMOVING AND INSTALLING .
Disconnect electrical connector from air recirculation valve -2-.

Fig 1: Disconnecting Electrical Connector From Air Recirculation Valve
Courtesy of AUDI OF AMERICA, INC.
Disconnect electrical connector from camshaft timing control -1- (cylinder bank 4..6). See Fig 2.
Disconnect electrical connectors from injectors -2- (cylinder bank 4..6).
Disconnect electrical connectors from ignition coils -3- and move wiring harness clear (cylinder bank 4..6).
Disconnect crankcase breather -4- from cylinder head cover (cylinder bank 4..6).
Remove ignition coils.

Fig 2: Disconnecting Electrical Connectors At Cylinder Head (Cylinder Bank 4, 5, 6)
Courtesy of AUDI OF AMERICA, INC.
Disconnect electrical connectors from injectors -2- (cylinder bank 1..3).
Disconnect hose -5- going to turbocharger intake side.

Fig 3: Disconnecting Electrical Connectors From Fuel Injectors (Cylinder Bank 1, 2, 3)
Courtesy of AUDI OF AMERICA, INC.
Unclip solenoid valve for charge air pressure control -1-.
Disconnect connector from EVAP valve -2-.

Fig 4: Disconnecting Solenoid Valve For Charge Air Pressure Control And EVAP Valve
Courtesy of AUDI OF AMERICA, INC.
Disconnect connector from throttle unit -1-. See Fig 5.
Disconnect connector from charge air sensor -2-.
Disconnect crankcase breather -3-.
Disconnect connector from intake air temperature sensor -4-.

Fig 5: Disconnecting Connector From Throttle Unit
Courtesy of AUDI OF AMERICA, INC.
Remove pressure lines-1-. See Fig 6.

NOTE: Watch position of retaining strips -2-.

Fig 6: Removing Pressure Lines

G02724999

Courtesy of AUDI OF AMERICA, INC.

Remove tensioner -1- for ribbed belt.
Remove toothed belt guards -2- (left and right).
Remove toothed belt guard -3- (center).

Fig 7: Removing Tensioner
Courtesy of AUDI OF AMERICA, INC.
Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.

Fig 8: Aligning Match Marks -A- And -B- On Crankshaft
Courtesy of AUDI OF AMERICA, INC.

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

Check position of camshafts: larger holes in securing plates on camshaft sprockets must align opposite one another on inside. If not, turn crankshaft one revolution further.
Remove sealing plug from cylinder block, left.
TDC drilling in crankshaft must be visible (or able to be felt) in line with sealing plug hole.
Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.

Fig 9: Installing Screw Clamping Bolt 3242 For Crankshaft Into Sealing Plug
Courtesy of AUDI OF AMERICA, INC.
Remove vibration damper on crankshaft

Fig 10: Removing Vibration Damper On Crankshaft

G02725003

Courtesy of AUDI OF AMERICA, INC.

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-.

Fig 11: Removing Idler Wheel For Ribbed Belt And Toothed Belt Guard Behind Vibration Damper
Courtesy of AUDI OF AMERICA, INC.

NOTE:

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

Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm in direction of arrow until tensioning lever -2- compresses tensioning element -3- sufficiently to enable a 2 mm dia. spring pin to be installed in drilling and in plunger.
Insert spring pin and release toothed belt tensioning roller.
- Use spring pin from 2024 A.
Insert camshaft clamp 3391 in securing plates of two camshafts.
Loosen both camshaft bolts and remove approx. 5 turns.

Fig 12: Identifying Toothed (Timing) Belt Tensioning Roller
Courtesy of AUDI OF AMERICA, INC.
Take out camshaft clamp 3391.
Disconnect both camshaft sprockets with special tool T40001.

Fig 13: Disconnecting Camshaft Sprockets
Courtesy of AUDI OF AMERICA, INC.
Unbolt rear left toothed belt guard -arrows-.
Detach intake manifold using special tool 3249.

Fig 14: Removing Rear Left Toothed Belt Guard
Courtesy of AUDI OF AMERICA, INC.
Unbolt cylinder head lifting bracket with coolant line -arrows- from cylinder head.

Fig 15: Removing Cylinder Head Lifting Bracket
Courtesy of AUDI OF AMERICA, INC.
Unbolt water line -1- and disconnect it towards rear. See Fig 16.
Unbolt bracket -2- from cylinder head.
Remove heat sensor -2-.

Fig 16: Removing Water Line And Heat Sensor
Courtesy of AUDI OF AMERICA, INC.
Unbolt turbocharger -1- from exhaust manifold (3 bolts).

Fig 17: Removing Turbocharger
Courtesy of AUDI OF AMERICA, INC.
Unbolt coolant line at front of cylinder head -arrows-.
Unbolt cylinder head cover.
Loosen and remove cylinder head bolts in opposite sequence to tightening sequence using special tool 3452 (Polidrive).
Carefully lift off cylinder head.

Fig 18: Removing Coolant Line At Front Of Cylinder Head

G02725011

Courtesy of AUDI OF AMERICA, INC.

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

Fig 19: Identifying Special Tool

G02725012

Courtesy of AUDI OF AMERICA, INC.

Remove engine. See ENGINE, REMOVING AND INSTALLING .

Fig 1: Disconnecting Electrical Connector From Air Recirculation Valve
Courtesy of AUDI OF AMERICA, INC.
Disconnect electrical connector from air recirculation valve -2-.
Remove cover panel from right-hand cylinder head cover -arrows-.

Fig 2: Removing Cover Panel From Right-Hand Cylinder Head Cover
Courtesy of AUDI OF AMERICA, INC.
Disconnect hose -1-.
Disconnect hose -2-. See Fig 3.
Unbolt upper section of intake line -3-.

Fig 3: Disconnecting Hose

G02725018

Courtesy of AUDI OF AMERICA, INC.

NOTE: Plug lower section of intake line.

Disconnect connectors from injectors -2- (cylinder bank 4..6).

Fig 4: Disconnecting Connectors From Fuel Injectors (Cylinder Bank 4, 5, 6)
Courtesy of AUDI OF AMERICA, INC.
Disconnect connector for camshaft timing control -1- (cylinder bank 1..3).
Disconnect connectors from injectors -2-(cylinder bank 1..3).
Disconnect connectors from ignition coils -3- and move wiring harness clear (cylinder bank 1..3).
Disconnect crankcase breather -4- from cylinder head cover (cylinder bank 1..3).

Fig 5: Disconnecting Connectors On Cylinder Bank 1-3
Courtesy of AUDI OF AMERICA, INC.
Disconnect hose -5- going to turbocharger intake side.
Remove ignition coils.
Unclip solenoid valve for charge pressure control -1-.
Disconnect connector from EVAP valve -2-.

Fig 6: Removing Solenoid Valve And Disconnecting Connector From EVAP Valve
Courtesy of AUDI OF AMERICA, INC.
Disconnect connector from throttle unit -1-. See Fig 7.
Disconnect connector from charge air sensor -2-.
Disconnect crankcase breather -3-.
Disconnect connector from intake air temperature sensor -4-.
Disconnect connector -5- from Hall sensor.

Fig 7: Disconnecting Connector, Crankcase Breather And Temperature Sensor
Courtesy of AUDI OF AMERICA, INC.
Remove pressure lines -1-.

NOTE: Watch position of retaining strips -2-.

Fig 8: Removing Pressure Lines

G02725023

Courtesy of AUDI OF AMERICA, INC.

Remove tensioner -1- for ribbed belt.
Remove toothed belt guards -2- (left and right).
Remove toothed belt guard -3- (center).

Fig 9: Removing Ribbed Belt Tensioner And Toothed Belt Guards
Courtesy of AUDI OF AMERICA, INC.
Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.

Fig 10: Aligning Match Marks -A- and -B- On Crankshaft

G02725025

Courtesy of AUDI OF AMERICA, INC.

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

Check position of camshafts: larger holes in securing plates on camshaft sprockets must align opposite one another on inside. If not, turn crankshaft one revolution further.
Remove sealing plug from cylinder block, left.
TDC drilling in crankshaft must be visible (or able to be felt) in line with sealing plug hole.
Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.

Fig 11: Removing Sealing Plug 3242 From Cylinder Block
Courtesy of AUDI OF AMERICA, INC.
Remove vibration damper on crankshaft.

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

Fig 12: Removing Vibration Damper On Crankshaft

G02725027

Courtesy of AUDI OF AMERICA, INC.

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

Fig 13: Removing Idler Wheel For Ribbed Belt And Toothed Belt Guard Behind Vibration Damper
Courtesy of AUDI OF AMERICA, INC.

NOTE:

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 reinstalled.
The toothed belt tensioning element is oil-damped and can therefore only be compressed slowly by applying constant pressure.

Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm in direction of arrow until tensioning lever -2- compresses tensioning element -3- sufficiently to enable a 2 mm dia. spring pin to be installed in drilling and in plunger.
Insert spring pin and release toothed belt tensioning roller.
- Use spring pin from 2024 A.
Fig 14: Compressing Toothed Belt Tensioning Roller
Courtesy of AUDI OF AMERICA, INC.
Insert camshaft clamp 3391 in securing plates of two camshafts.
Loosen both camshaft bolts and remove approx. 5 turns.
Take out camshaft clamp 3391.
Disconnect both camshaft sprockets with special tool T40001.

Fig 15: Disconnecting Camshaft Sprockets
Courtesy of AUDI OF AMERICA, INC.
Unbolt rear right toothed belt guard -arrows-.
Detach intake manifold using special tool 3249.

Fig 16: Removing Rear Right Toothed Belt Guard
Courtesy of AUDI OF AMERICA, INC.
Unbolt water line -1- and disconnect toward rear.

Fig 17: Unbolting Water Line
Courtesy of AUDI OF AMERICA, INC.
Detach line -arrow- from cylinder head.

Fig 18: Disconnecting Line From Cylinder Head
Courtesy of AUDI OF AMERICA, INC.
Remove turbocharger -arrows-.

Fig 19: Removing Turbocharger
Courtesy of AUDI OF AMERICA, INC.
Unbolt cylinder head cover.
Loosen and remove 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.

Fig 20: Identifying Special Tool

G02725035

Courtesy of AUDI OF AMERICA, INC.