Cylinder Head

Cylinder Head

Special tools, testers and auxiliary items required

• Pry Lever - Rmv Outside Mirror (80 - 200)

• Engine Sling (2024 A)

• Diesel Injection Pump Locking Pin (3359)

• Shop Crane (VAS 6100)

• Camshaft Gear Counter-Holder (T10051)

• Puller (T10052)

• Socket Insert XZN 10 (T10385)

Removing

- Drain coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Remove fan shroud. Refer to => [ Fan Shroud ] Service and Repair.

- Remove the air filter housing.

- Remove the battery.

- Remove the bolts - arrows - and remove the battery tray - 1 -.

- Loosen the hose clamp - 2 -, lift the retaining clamp - 1 - and remove the air guide hose.

- Remove bolts - 1 - and - 3 -.

- Open the clamp - 5 - on the intake flap motor (V157) or on the throttle valve control module (J338) and then remove the air guide pipe - 2 -.

• Ignore - 4 -.

- Remove nuts - 2 - and bolts - 3 - and remove the EGR pipe.

• Ignore - 1 -.

- Remove the bolts - arrows - and remove the right drive axle heat shield.

- Remove the bolts - 1 and 2 - and the banjo bolt - 3 -.

- Remove the turbocharger support and the oil return pipe.

- Remove the nuts - 2 -.

• Ignore - 1 -.

- Press the release buttons and remove the crankshaft housing ventilation hose - 1 - from the cylinder head cover.

- Free up the vacuum hoses - arrows - on the air guide pipe.

- Loosen the hose clamp - 2 - and remove the air guide pipe.

- Disconnect the connector - 1 - on the charge pressure actuator position sensor (G581).

- Remove the vacuum hose - 2 - from the turbocharger vacuum diaphragm.

- Disconnect the vacuum hose - 3 -.

- Remove exhaust gas temperature sensor 1 (G235). Refer to => [ Exhaust Temperature Control Assembly Overview ] Exhaust Temperature Control Assembly Overview.

- Loosen the bolt - 2 - and remove the clamp.

• Ignore - 1 and 3 -.

- Free up the wires on the turbocharger.

- Disconnect the connector - 2 - and the exhaust pressure sensor.

- Remove the bolt - 3 - and pull exhaust pressure sensor 1 (G450) of its mount - arrow -.

- Remove the bolt - 1 - at the top of the particulate filter mount and secure the particulate filter to the rear.

• The installed position may differ depending on the date of manufacture.

- Disconnect the connectors - 1 - on the EGR vacuum regulator solenoid valve (N18) and - 3 - on the intake flap motor (V157) or throttle valve control module (J338).

- Remove the bolt - arrow - on the oil dipstick guide tube.

- Remove the bolts - 2 - on the EGR pipe.

• Ignore - 4 -.

- Remove the wiring harness from the bracket - arrow -.

- Loosen the hose clamps - arrows - and remove the coolant hoses from the transmission fluid cooler.

- Free up the wiring harness - arrows - and the connector - 1 - on the bracket.

- Remove the bolts - 2 and 5 - and - arrows -.

- Free up the electrical wires and the hoses on the left air guide pipe using the (80 - 200).

- Loosen the hose clamp - 3 - and remove the left air guide pipe.

• Ignore - 1 and 4 -.

- Remove the vacuum hose - 1 - from the vacuum pump.

• Ignore - arrows -.

- Disconnect the electrical connector - 2 - on the engine coolant temperature sensor (G62).

- Loosen the hose clamps - arrows - and remove the coolant hoses from the connections.

• Ignore - 1 -.

Danger of cracking the coupling.

• Do not bend coupling inside the EGR pipe.

- Remove the nuts - 1 - and bolts - 2 - and remove the EGR pipe.

- Loosen the union nut by counterholding it with an open-end wrench - 3 - and remove the oil supply line from the oil filter bracket connection.

• Ignore - 1 and 2 -.

- Remove the nut - 2 - on the vacuum line clamp.

- Remove bolt - 1 -.

- Loosen the union nut by counterholding it with an open-end wrench - 3 - and remove the oil supply line from the turbocharger connection.

- Remove the bolt - arrow - from the rear toothed belt guard.

- Remove the toothed belt from the camshaft toothed belt gear. Refer to => [ Toothed Belt ] Toothed Belt.

- Remove the nuts - 1 -.

• Disregard - arrow -.

- Disconnect the electrical connector - arrow - on the camshaft position sensor (G40).

- Remove cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

- Disconnect the connectors on the glow plugs.

- Remove the bolts - 1 - and remove the camshaft toothed belt gear.

- Remove the bolt - 1 - for the camshaft hub while counterholding it with the (T10051).

- Remove the bolt approximately 2 turns.

- Mount the (T10052) on the camshaft hub and install the bolts - 1 - in the hub.

- To remove the camshaft hub, install the bolt - 2 - and counterhold it on the hex (30 mm) on the puller.

- Remove the hub from the camshaft cone.

- Loosen the cylinder head bolts in the sequence - 1 through 10 -.

- Attach the (2024 A) to the cylinder head.

Loose engine support bridge components could cause an accident.

• Lifting hooks and alignment pins on lifting tackle must be secured with securing pins - arrows -.

- Slightly lift the cylinder head using the (VAS 6100).

- Move the cylinder head from the rear toothed belt guard toward the left and remove the tensioning roller at the same time.

- Be careful not to damage the turbocharger oil return line.

- Lay the cylinder head down being careful not to bend the oil return line. Place a piece of wood under the exhaust manifold if necessary.

Danger of damaging the glow plugs when removing the cylinder head.

• Do not lay the removed cylinder head on the sealing surface with the glow plugs installed otherwise the glow plugs will protrude slightly past the sealing surface

• The Audi A3 with a 2.0L 4V TDI CR engine only has steel glow plugs.

Installing

• Tightening specifications, refer to => [ Cylinder Head Assembly Overview ] Cylinder Head Assembly Overview.

The sealing surfaces could be damaged.

• Carefully remove sealant residue from cylinder head and cylinder block.

• Make sure that no long scrapes or scratches result.

Risk of damaging cylinder block.

• No oil or coolant must be in the cylinder head bolt blind holes in the cylinder block.

Risk of leaks in cylinder head seal.

• Carefully remove sealant residue 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.

• To prevent cylinder head seal silicone layer and recessed area from being damaged, always handle seal extremely carefully.

Risk of damaging open valves.

• If a replacement cylinder is installed, only remove plastic base right before cylinder head is installed to protect open valves.

Risk of damaging valves and piston heads after working on valvetrain.

• To ensure valves do not strike pistons when starting, carefully rotate the crankshaft at least 2 turns.

• Replace bolts which have been tightened to an additional torque.

• Replace self-locking nuts, sealing rings, seals and O-rings.

• It is not permitted to re-work the cylinder heads on TDI engines

• When installing a replacement cylinder head, oil the contact surfaces between roller cam followers and cam lubricating surface.

• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

• Secure all hose connections with hose clamps appropriate for the model. Refer to the electronic parts catalog ETKA.

• In order to be able to securely mount the air guide hoses on their connectors, spray the bolts on the previously used clamps with a rust remover.

• When replacing the cylinder head or cylinder head seal, all of the coolant and engine oil must be replaced.

- Before positioning the cylinder head, remove the (T10050) and rotate the crankshaft back opposite the direction of engine rotation until all of the pistons are nearly even under TDC.

- Install alignment bushings for centering the cylinder block and cylinder head if they are missing.

- Note the marking on the cylinder head gasket:

1. Part number:

2. Holes

3. ignore.

• If the cylinder head gasket or the cylinder head were replaced, select a new cylinder head gasket with the same number of holes as the old gasket.

• If parts of the crank drive were replaced, then the new cylinder head gasket must be determined by measuring the piston projection in TDC. Refer to => [ Piston Projection, Measuring at TDC ] Testing and Inspection.

- Install the cylinder head gasket on the alignment bushings - arrows - in the cylinder block.

• Cylinder head gasket installation position: oben marking or part number toward cylinder head.

- Attach the (2024 A) to the cylinder head and (VAS 6100).

Loose engine support bridge components could cause an accident.

• Lifting hooks and alignment pins on lifting tackle must be secured with securing pins - arrows -.

- Move the cylinder head with the stud bolt for the toothed belt tensioning roller into the hole in the rear toothed belt guard and mount the tensioning roller at the same time.

• Pay attention to the camshaft position sensor (G40) wire.

- Set cylinder head in place.

- Install the cylinder bolts all the way in by hand.

- Tighten the cylinder head bolts => [ Cylinder Head Gasket Identification ] Cylinder Head Assembly Overview.

• There is no requirement to tighten the cylinder head bolts after repairs.

- Install the rear toothed belt guard, the hub and the camshaft toothed belt sprocket. Refer to => [ Toothed Belt Assembly Overview ] Toothed Belt Assembly Overview.

- Secure the camshaft hub with the (3359).

• Ignore - 1 - and - arrow -.

- Secure the high pressure pump hub with the (3359).

• Ignore - 1 -.

- Turn the crankshaft in direction of engine rotation, until the tip - arrow - on the (T10050) fits into the sealing flange.

- Install toothed belt (adjust timing) => [ Installing (Adjusting valve
timing) ] Toothed Belt.

The rest of installation is in reverse order of removal, note the following:

- Install cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover

- Install the oil supply line. Refer to - 6 - => [ Oil Supply Line ] Service and Repair.

- Install the exhaust gas recirculation pipes. Refer to => [ EGR with EGR Cooling System Assembly Overview ] EGR With EGR Cooling System Assembly Overview.

- Install the left air guide pipe. Refer to => [ Charge Air Cooler Assembly Overview ] Charge Air Cooler Assembly Overview.

- Install oil dipstick guide tube => [ Oil Dipstick Guide Tube - Tightening
Specifications ] Service and Repair.

- Install the particulate filter. Refer to => [ Particulate Filter ] Particulate Filter.

- Install the exhaust gas temperature sensor 1 (G235). Refer to => [ Exhaust Temperature Control Assembly Overview ] Exhaust Temperature Control Assembly Overview.

- Install the battery tray and the battery.

- Install air filter housing.

- Install the turbocharger support. Refer to => [ Turbocharger Assembly Overview ] Turbocharger Assembly Overview.

- Install the air guide hose with the connector coupling => [ Install the Air Guide Hoses
with the Coupling ] Charge Air Cooler Assembly Overview.

- Install fan shroud. Refer to => [ Fan Shroud ] Service and Repair.

- Change engine oil.

- Replace coolant => [ Filling ] Procedures.