Cylinder Head

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Drip Tray VAS 6208
Retainer 3036
Puller T40001
Ignition Coil Puller T40039
Hose Clip Pliers V.A.G 1921
Engine Support Bridge 10 - 222 A
Shackle 10 - 222 A /12
Locking Pin T10060A
Tooth Belt Tensioner T10020
Polydrive Bit and Drive Socket T10070
Engine Bung Set VAS 6122

Removing

Engine installed.

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Perform oil change if engine oil is contaminated.

If using sealant, note current specifications.

-- Note radio code (for vehicles equipped with coded anti-theft radio / radio navigation system), obtain if necessary.

-- Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Fig 1: Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector, Clips & Front Air Intake Connector On Lock Carrier

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-- Open clips -1 and 2- and remove air guide hose from MAF sensor.

-- Remove front air intake connector on lock carrier -4-.

-- Remove engine cover.

-- Remove air guide hose -arrow- with the V.A.G 1921.

Fig 2: Remove Air Guide Hose

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WARNING:

Cover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

-- Open cap of coolant expansion tank.

-- Remove center noise insulation fasteners -1 to 4-.

Fig 3: Center Noise Insulation Fasteners And Center Noise Insulation Panel

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-- Remove the right noise insulation -arrows-.

Fig 4: Identifying Right Noise Insulation -Arrows-, Removal

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-- Remove noise insulation frame -arrow-.

Fig 5: Identifying Noise Insulation Frame, Removal

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-- Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

-- Remove electrical connector -arrow- for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.

Fig 6: Disconnecting Heated Oxygen Sensor (HO2S) G39 Harness Connector

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-- Disconnect the coolant line to coolant expansion tank -arrow-.

Fig 7: Disconnecting Coolant Line To Coolant Expansion Tank

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-- Disconnect coolant hose -1-.

Fig 8: Identifying Coolant Hoses

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-- Disconnect coolant hose -2-.

-- Remove Ground (GND) wire nut -1-.

Fig 9: Identifying Ground (GND) Wire & Connector

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-- Separate electrical connector -2-.

-- Disconnect coolant hoses -arrows-.

-- Remove the intake manifold. Refer to Removal and Installation .

-- Remove the right drive axle heat shield -arrows-.

Fig 10: Identifying Protective Cap For Drive Axle On Engine

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-- Remove nuts -1- and -2- on oxygen sensor electrical connector bracket under vehicle floor and remove cover.

Fig 11: Electrical Connector For Oxygen Sensor (O2S) After Three Way Catalytic Converter (TWC) -G130- And Heater For Oxygen Sensor (O2S) 1 After Catalytic Converter -Z29- (Under Cover)

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-- Remove bolt -3- and free up electrical wiring to oxygen sensor.

-- Remove connector coupling from bracket -arrow-.

Fig 12: Electrical Connector -arrow-

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-- Disconnect electrical connector to oxygen sensor (O2S) after three way catalytic converter (TWC) -G130-.

-- Remove the remaining nuts -arrows- for the front exhaust pipe/turbocharger from below.

Fig 13: Front Exhaust Pipe/Turbocharger Nuts

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-- Remove exhaust system bracket and tunnel brace -arrows-.

Fig 14: Crossbrace Bolts -Arrows-

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NOTE:

Do not bend the flex joint in the front exhaust pipe more than 10° or it could be damaged.

-- Disconnect the exhaust system at the clamping sleeve -arrows-.

Fig 15: Clamping Sleeve -Arrows-

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-- Remove front exhaust pipe with catalytic converter and front muffler.

-- Remove right drive axle. Refer to Removal and Installation .

-- Disconnect air guide pipe -arrow- from charge air cooler.

Fig 16: Charge Air Cooler Air Guide Pipe

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-- Unfasten air duct from turbocharger -arrows-.

Fig 17: Turbocharger Air Duct And Connector

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-- Disconnect the connector -1 and 2- and free up the cable.

-- Remove bolts -arrows- and remove air guide pipe.

Fig 18: Identifying Charge Air Pipe Bolts

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NOTE:

The illustration depicts the engine removed from behind.

-- Unfasten turbocharger oil supply line at cylinder block -1-.

Fig 19: Cylinder Block And Turbocharger Oil Supply Line

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-- Remove turbocharger oil supply line -2-.

-- Unfasten turbocharger coolant supply line at cylinder block -1-.

Fig 20: Turbocharger Coolant Supply Line Connections

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-- Remove coolant supply line to turbocharger -2-.

-- Remove the coolant supply line for turbocharger -3- at the cylinder block.

-- Disconnect oil return line -arrows- on turbocharger.

Fig 21: Identifying Oil Return Line

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-- Remove bolts -1- and -2- and remove support for turbocharger.

Fig 22: Identifying Bolts And Support For Turbocharger

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-- Remove the toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

-- Loosen the bolt for camshaft sprocket using the 3036.

Fig 23: Loosening Bolt For Camshaft Sprocket Using Retainer 3036

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-- Pull off the camshaft sprocket using the T40001 and claws T40001/6 and T40001/7.

Fig 24: Identifying Puller T40001, Claw T40001/6 And Claw T40001/7

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-- Remove rear toothed belt guard from cylinder head -arrows-.

Fig 25: Rear Toothed Belt Housing And Cylinder Head

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-- Remove the cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Loosen the cylinder head bolts using a T10070, paying attention to the sequence of the cylinder head bolts.

Fig 26: Cylinder Head Bolt Loosening Sequence

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NOTE:

Verify that all hose and line connections between engine, transmission and body have been disconnected.

-- Remove cylinder head.

Cylinder Head, Installing

Tightening specifications and tightening sequence, refer to CYLINDER HEAD ASSEMBLY OVERVIEW
For the correct tightening specifications, refer to EXHAUST SYSTEM OVERVIEW

NOTE:

Replace the cylinder head bolts.

Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings.

Secure all hose connections using hose clamps appropriate for the model type.

Carefully remove residual sealant from cylinder head and cylinder block. Make sure that no long scrapes or scratches result.

Carefully remove all grinding and sanding residue.

Only unpack new cylinder head gasket immediately prior to installation.

Handle gasket carefully. Damages to the silicone layer and in areas of recesses may result in leaks.

There must be no oil or coolant in the blind holes for the cylinder head bolts in the cylinder block.

Hot bolt paste.

WARNING:

Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).

NOTE:

Turning over the engine is performed at the center bolt of the crankshaft.

-- Bring marking on camshaft gear to alignment with marking on toothed belt guard. The notches of the camshafts -arrows- now face toward each other vertically.

Fig 27: Bringing Marking On Camshaft Gear To Alignment With Marking On Toothed Belt Guard

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-- In the event the crankshaft has been rotated in the meantime: Set piston of cylinder 1 to TDC and turn crankshaft back again slightly.

-- Set cylinder head gasket in place.

Pay attention to alignment pins in cylinder block -arrows-.

Fig 28: Cylinder Block Centering Pins
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Observe cylinder head seal location, identification: Replacement part number must be visible from intake side.