3.2l - Cylinder Head, Valvetrain - Engine Code(s): Cala (coupe) (as of 11.2007) Audi A5 I

Scheme 332

1. Bolt Tightening specification and sequence (Scheme 335)
2. Crankshaft seal, drive plate side Replacing «CRANKSHAFT SEAL, DRIVE PLATE SIDE»(/audi/a5/i-2007-2011/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cala-coupe-as-of-112007__crankshaft-seal-drive-plate-side).
3. Bolt Tightening specification and sequence (Scheme 335)
4. Alignment bushing 2 pieces
5. Bolt Tightening specifications: 16 Nm
6. Left cylinder head gasket
7. Left timing chain cover Removing and installing «LEFT AND RIGHT TIMING CHAIN COVERS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__left-and-right-timing-chain-covers).
8. Bracket For wiring harness
9. Bolt Replace Tightening specification and sequence (Scheme 333)
10. Lower timing chain cover Removing and installing «LOWER TIMING CHAIN COVER»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__lower-timing-chain-cover)
11. Seals Replace
12. Bolt Tightening specification and sequence (Scheme 334)
13. Bracket For electrical connectors
14. Bolt Replace Tightening specification and sequence (Scheme 334)
15. Right timing chain cover Removing and installing «LEFT AND RIGHT TIMING CHAIN COVERS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__left-and-right-timing-chain-covers).
16. Right cylinder head gasket
17. Alignment bushing 2 pieces
18. Bolt Tightening specification and sequence (Scheme 335)
19. Engine speed (RPM) sensor -G28- Removing and installing «Removal and Installation»(ref-520191-S27532932572012123100000)
20. Bolt Tightening specifications «Removal and Installation»(ref-520191-S27532932572012123100000)

Scheme 333

Replace bolts for left timing chain cover.

Tighten bolts in 2 stages in -1 to 8- sequence as follows

Scheme 334

Replace bolts for right timing chain cover.

Tighten bolts in 2 stages in -1 to 8- sequence as follows

Scheme 335

Tighten bolts in 6 stages as follows

CAMSHAFT TIMING CHAINS ASSEMBLY OVERVIEW

Left Camshaft Timing Chain

Scheme 336

1. Bolt Replace 80 Nm + an additional 90° turn
2. Bolt Replace 80 Nm + an additional 90° turn
3. Camshaft adjuster for exhaust camshaft Identification "Exhaust" Removing and installing «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-removing-from-camshafts) .
4. Camshaft adjuster for intake camshaft Identification "Intake" Removing and installing «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-removing-from-camshafts) .
5. Left camshaft timing chain Removing and installing «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-removing-from-camshafts) .
6. Bolt 9 Nm
7. Guide piece
8. Left camshaft timing chain tensioner Removing and installing «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-removing-from-camshafts) .
9. Mounting bracket for drive sprocket
10. Bolt Replace 8 Nm + additional 45° turn
11. Left camshaft timing chain drive sprocket
12. Thrust washer for drive sprocket
13. Bolt Replace 6 Nm + an additional 60° turn

Right Camshaft Timing Chain

Scheme 337

1. Bolt Replace 80 Nm + an additional 90° turn
2. Camshaft adjuster for exhaust camshaft Identification "Exhaust" Removing and installing «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-removing-from-camshafts).
3. Bolt Replace 80 Nm + an additional 90° turn
4. Camshaft adjuster for intake camshaft Identification "Intake" Removing and installing «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-removing-from-camshafts).
5. Bolt Replace 30 Nm + an additional 90° turn
6. Pivot pin for drive sprocket For right camshaft timing chain Asymmetrical version Installed location (Scheme 339)
7. Right camshaft timing chain drive sprocket Installed location (Scheme 339)
8. Right camshaft timing chain Removing and installing «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-removing-from-camshafts).
9. Thrust washer for drive sprocket For right camshaft timing chain Asymmetrical version Installed location (Scheme 339)
10. Right camshaft timing chain tensioner Removing and installing «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-removing-from-camshafts).
11. Guide piece
12. Bolt 9 Nm

Scheme 338

1. Guide rail
2. Bolt Replace 10 Nm + an additional 90° turn
3. Bolt Tightening specifications: 6 Nm + an additional 60° turn
4. Thrust washer for drive sprocket
5. Drive sprocket for left timing chain
6. Bolt Replace 10 Nm plus an additional 90° turn
7. Timing Mechanism Drive Chain Removing and installing «TIMING MECHANISM DRIVE CHAIN»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__timing-mechanism-drive-chain).
8. Guide rail
9. Bolt Replace 10 Nm plus an additional 90° turn
10. Bolt Tightening specifications, item 10 10
11. Mounting bracket for drive sprocket For right camshaft timing chain Asymmetrical version Installed location (Scheme 339)
12. Thrust washer Asymmetrical version Installed location (Scheme 339)
13. Drive sprocket for right timing chain Installed location (Scheme 339)
14. Pivot pin for drive sprocket Asymmetrical version Installed location (Scheme 339)
15. Bolt Tightening specifications, item 5 5
16. O-ring Replace
17. Chain tensioner
18. Bolt 9 Nm
19. Crankshaft
20. Bolt Replace 10 Nm plus an additional 90° turn

Scheme 339

1. The alignment bushings in the right camshaft timing chain drive sprocket mounting pins -3- must engage in the holes in the thrust washer -1- and cylinder block.

2 - Right camshaft timing chain drive sprocket

4 - Bolt

Scheme 340

1. Crankshaft
2. Power take-off drive chain Before removing, mark direction of rotation with paint Removing and installing «POWER TAKE-OFF CHAIN»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__power-take-off-chain) .
3. Drive sprocket for oil pump Installation position: The labelled side faces the engine
4. Bolt Replace 30 Nm + an additional 90° turn
5. Spring
6. Bolt Replace 15 Nm + an additional 90° turn
7. Balance shaft chain sprocket Installation position: The labelled side faces transmission
8. Chain tensioner With guide rail
9. Bolt Replace 10 Nm + an additional 45° turn

Scheme 341

1. Balance shaft Removing and installing «BALANCE SHAFT»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__balance-shaft) .
2. Bolt 60 Nm To loosen and fasten, use 8 mm dia. drill bit as counter-holder
3. Balance shaft weight, drive plate side Can only be placed on balance shaft in one position
4. Bearing end bracket
5. Bolt 13 Nm
6. Balance shaft weight, belt pulley side Can only be placed on balance shaft in one position
7. Bolt 60 Nm To loosen and fasten, use 8 mm dia. drill bit as counter-holder

CYLINDER HEAD ASSEMBLY OVERVIEW

Note. The illustration shows the cylinder bank 2 cylinder head (left).

Scheme 342

1. Cylinder head gasket Replacing «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__cylinder-heads). Installation position: Part number facing cylinder head After replacing, change coolant and engine oil
2. Cylinder head Removing «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__cylinder-heads). Checking for distortion (Scheme 345) Checking reworking dimension (Scheme 346) Installing «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__cylinder-heads). After replacing, change coolant and engine oil
3. Bolt Tightening specifications «Brake Booster/Master Brake Cylinder Overview»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#hydraulic-components-brake-system-coupe__brake-boostermaster-brake-cylinder-overview)
4. Vacuum pump Removing and installing «Vacuum Pump V192 Overview»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#hydraulic-components-brake-system-coupe__vacuum-pump-v192-overview)
5. O-ring Replace
6. Bolt 20 Nm
7. Engine lifting eye
8. Camshaft position sensor, intake camshaft Cylinder bank 1 (right) Camshaft Position (CMP) sensor -G40- Cylinder bank 2 (left) Camshaft Position (CMP) sensor 2 -G163
9. Bolt 9 Nm
10. Bolt Loosening procedure «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__cylinder-heads). Replace Loosening procedure «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__cylinder-heads). Tighten in 3 stages: -- Tighten to 40 Nm. -- Tighten an additional 90° turn. -- Tighten an additional 90° turn.
11. Ignition coil Use ignition coil puller T40039 for removal
12. Cylinder head cover Removing and installing: Left «LEFT CYLINDER HEAD COVER»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__left-cylinder-head-cover), right «RIGHT CYLINDER HEAD COVER»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__right-cylinder-head-cover)
13. Gasket Replace if damaged or leaking
14. Cap
15. Bolt Replace if seal is damaged Tightening specifications (Scheme 343) and (Scheme 344).
16. Bolt Tightening specifications «Removal and Installation»(ref-520191-S27532932572012123100000)
17. Connector strip For ignition coils
18. Cylinder head cover gasket Replace if damaged or leaking
19. Bolt 2.5 Nm
20. Solenoid valve for camshaft adjustment - exhaust side Cylinder bank 1 (right) exhaust camshaft control valve 1 -N318- Cylinder bank 2 (left) camshaft adjustment valve 2 (exhaust) -N319
21. Solenoid valve for camshaft adjustment - intake side Cylinder bank 1 (right) camshaft adjustment valve 1 -N205- Cylinder bank 2 (left) camshaft adjustment valve 2 -N208
22. O-rings Replace
23. O-ring Replace
24. Bolt 9 Nm
25. Camshaft position sensor, exhaust camshaft Cylinder bank 1 (right) Camshaft Position (CMP) sensor 3 -G300- Cylinder bank 2 (left) Camshaft Position (CMP) sensor 4 -G301

Scheme 343

Tighten bolts to 9 Nm in sequence -1 to 12-.

Scheme 344

Tighten bolts to 9 Nm in sequence -1 to 12-.

Scheme 345

Check cylinder head for distortion with the straight edge and feeler gauge in several places.

1. Maximum warpage: 0.05 mm.

Scheme 346

Resurfacing cylinder head (face grinding) is only permissible to minimum dimension -a-.

1. Minimum dimension -a- = 139.20 mm.

Scheme 347

Tighten bolt -arrow- to 9 Nm.

VALVETRAIN ASSEMBLY OVERVIEW

Note. Cylinder heads with cracks between the valve seats, or between the valve seat and the spark plug threads, can continue to be used without reducing the service life, as long as the cracks have a width of max. 0.3 mm, or only the first 4 threads of the spark plug threads are cracked.

Note. Cylinder head for cylinder bank 2 (left) is shown in illustration.

Scheme 348

1. Sealing plug Install with sealant
2. Cylinder head Check valve guides «VALVE GUIDES, CHECKING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__valve-guides-checking).
3. Valve stem seal Replacing with cylinder head installed «VALVE STEM SEALS, WITH CYLINDER HEAD INSTALLED»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__valve-stem-seals-with-cylinder-head). Replacing with cylinder head removed «VALVE STEM SEALS, WITH CYLINDER HEAD REMOVED»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__valve-stem-seals-with-cylinder-head).
4. Valve spring Installed location (Scheme 350)
5. Hydraulic adjusting elements Checking «HYDRAULIC ADJUSTING ELEMENTS, CHECKING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__hydraulic-adjusting-elements-checking). Mark installation position with paint for reinstallation Lubricate running surfaces before installing
6. Valve spring plate
7. Valve keys
8. Roller rocker lever Different versions for intake and exhaust side, do not interchange them Check roller for easy movement Lubricate running surfaces before installing Clip to hydraulic adjusting element -5- with securing clip -9
9. Securing clip Different versions for intake and exhaust side, do not interchange them Check for secure seat
10. Intake camshaft With 3 camshaft sliders Do not disassemble Checking axial play «CAMSHAFTS, CHECKING AXIAL CLEARANCE»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshafts-checking-axial-clearance). Removing and installing «CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshafts). Check radial clearance using Plastigage (roller rocker lever removed) Radial clearance at bearing - dia. 24 mm: 0.024 to 0.066 mm Radial clearance at bearing - dia. 36 mm: 0.032 to 0.078 mm Maximum run-out: 0.04 mm
11. Bolt Replace Tightening sequence (Scheme 349)
12. Camshaft adjuster actuator
13. Bolt 5 Nm
14. O-ring Replace
15. Bearing bracket With integrated camshaft bearings Removing and installing «CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshafts).
16. Compression ring
17. Compression ring
18. Exhaust camshaft Checking axial play «CAMSHAFTS, CHECKING AXIAL CLEARANCE»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshafts-checking-axial-clearance). Removing and installing «CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshafts). Check radial clearance using Plastigage (roller rocker lever removed) Radial clearance at bearing - dia. 24 mm: 0.024 to 0.066 mm Radial clearance at bearing - dia. 36 mm: 0.032 to 0.078 mm Maximum run-out: 0.04 mm
19. Oil strainer
20. Intake valve Do not rework, only lapping is permitted Mark installed position for reinstallation Valve dimensions «VALVE DIMENSIONS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__valve-dimensions). Check valve guides «VALVE GUIDES, CHECKING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__valve-guides-checking).
21. Exhaust valve Do not rework, only lapping is permitted Mark installed position for reinstallation Valve dimensions «VALVE DIMENSIONS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__valve-dimensions). Check valve guides «VALVE GUIDES, CHECKING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__valve-guides-checking).

Scheme 349

Note. The illustration shows the guide frame for the left cylinder head.

Replace guide frame bolts.

Tighten bolts in 3 stages in sequence -1 to 21

Install bolts by hand as far as stop.

1. The guide frame must be in contact with the entire contact surface of the cylinder head.

Tighten to 8 Nm.

Tighten an additional 90° turn.

Scheme 350

1. The tight spring coils -arrow- face toward cylinder head.

FASTENER TIGHTENING SPECIFICATIONS

LEFT TIMING CHAIN COVER BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Replace bolts for left timing chain cover.

Tighten bolts in 2 stages in -1 to 8- sequence as follows

Tighten to 5 Nm.

Tighten an additional 90° turn.

RIGHT TIMING CHAIN COVER BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Replace bolts for right timing chain cover.

Tighten bolts in 2 stages in -1 to 8- sequence as follows

Tighten to 5 Nm.

Tighten an additional 90° turn.

LOWER TIMING CHAIN COVER BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Tighten bolts in 6 stages as follows

Insert bolts -arrows- and tighten them to 5 Nm.

Tighten bolts -1 to 10- in a diagonal sequence to 9 Nm.

Tighten bolts -arrows- to 9 Nm.

Tighten bolts -8, 9 and 10- to 22 Nm.

Tighten bolt -3- to 16 Nm.

Tighten bolt -6- to 70 Nm.

LEFT CYLINDER HEAD COVER BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Tighten bolts to 9 Nm in sequence -1 to 12-.

RIGHT CYLINDER HEAD COVER BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Tighten bolts to 9 Nm in sequence -1 to 12-.

LEFT CYLINDER HEAD BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Insert bolts -1 through 7- while sliding unloaded camshaft slider -A- accordingly.

Scheme 351

Tighten bolts in 3 stages in sequence -1 to 7- CYLINDER HEAD ASSEMBLY OVERVIEW .

Insert bolt -15- and tighten it in a total of 3 stages CYLINDER HEAD ASSEMBLY OVERVIEW .

Scheme 352

RIGHT CYLINDER HEAD BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Insert bolts -8 through 14- while sliding unloaded camshaft sliders -D- and -E- accordingly.

Scheme 353

Tighten bolts in 3 stages in sequence -8 to 14- CYLINDER HEAD ASSEMBLY OVERVIEW .

Insert bolt -16- and tighten it in a total of 3 stages CYLINDER HEAD ASSEMBLY OVERVIEW .

Scheme 354

GUIDE FRAME BOLT TIGHTENING SEQUENCE AND SPECIFICATION

Note. The illustration shows the guide frame for the left cylinder head.

Replace guide frame bolts.

Tighten bolts in 3 stages in sequence -1 to 21

Install bolts by hand as far as stop.

1. The guide frame must be in contact with the entire contact surface of the cylinder head.

Tighten to 8 Nm.

Tighten an additional 90° turn.

VALVE DIMENSIONS

Note. Intake and exhaust valves must not be refaced by grinding. Only lapping is permitted.

COMPRESSION, CHECKING

Special tools and workshop equipment required

1. Spark plug removal tool 3122 B
2. Compression tester V.A.G 1763
3. Ignition coil puller T40039

PROCEDURE

Proceed as follows

1. Engine oil temperature at least 30° C.
2. Battery voltage at least 12.5 V.

Remove rear engine cover -top arrows-.

Scheme 355

Remove bolts -arrows-.

Scheme 356

Disconnect electrical connector on Engine Coolant Level (ECL) warning switch -F66- and lay coolant reservoir aside with coolant hoses -1, 2 and 3- connected.

Remove bolts -arrows- and disconnect electrical connectors to ignition coils on left cylinder head.

Scheme 357

Press electrical wiring harness down slightly.

Disconnect electrical connector -3- to fuel injectors on rear of left cylinder head.

Scheme 358

Note. Ignore -1, 2 and 4- and -arrows-.

Remove air duct -arrows-.

Scheme 359

Free up fuel line -1- and wire -2- to EVAP canister at the air guide pipe.

Scheme 360

Remove vacuum hose -3- from connection on air guide pipe.

Remove air guide pipe by loosening hose clamp -4- and opening clips -arrows-.

Disconnect vacuum line -1-.

Scheme 361

Remove air filter housing and, if applicable, disconnect electrical connector -2- on rear side at intake air switch-over valve -N335-.

Remove bolts -arrows- and disconnect electrical connectors to ignition coils on right cylinder head.

Scheme 362

Press electrical wiring harness to side.

Disconnect electrical connector -3- to fuel injectors on rear of right cylinder head.

Scheme 363

Note. Ignore -1, 2 and 4- and -arrows-.

Remove all ignition coils using ignition coil puller T40039.

Scheme 364

Remove spark plugs with spark plug removal tool 3122 B.

Check compression pressure using compression tester V.A.G 1763.

Note. Using tester operating instructions.

Have a second technician press accelerator pedal down all the way while operating the starter until pressure increase is no longer displayed on the tester.

ASSEMBLING

1. Tightening specifications «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__cylinder-head-assembly-overview) .

Assembly is in reverse order of removal, note the following

Note. Secure all hose connections with hose clamps appropriate for the model.

Install spark plugs

Faults are saved in ECM when electrical connectors are disconnected

Connect vehicle diagnosis, testing and information system VAS 5051B.

Start "Guided Functions" operating mode.

Generate readiness code in ECM.

CAMSHAFTS, CHECKING AXIAL CLEARANCE

Special tools and workshop equipment required

1. Dial gauge holder VW 387
2. Dial gauge VAS 6080

Procedure

Proceed as follows

Perform measurement with roller rocker levers and hydraulic adjusting elements removed.

Secure dial gauge holder VW 387 with dial gauge VAS 6079 on cylinder head as shown in the illustration.

Scheme 365

Determine axial play.

1. Axial clearance: 0.100 to 0.191 mm.

HYDRAULIC ADJUSTING ELEMENTS, CHECKING

Note. The hydraulic adjusting elements cannot be repaired. Irregular valve noises are normal while starting the engine.

Special tools and workshop equipment required

1. Feeler gauge

Procedure

Proceed as follows

Start engine and let it run until coolant fan switches on once.

Increase engine speed for about 2 minutes to approximately 2500 RPM, perform a road test if necessary.

If hydraulic adjusting elements are still loud, determined which one is faulty as follows.

Remove cylinder head cover: Left LEFT CYLINDER HEAD COVER , right RIGHT CYLINDER HEAD COVER .

Rotate crankshaft until cam lobes on adjusting element that will be checked face upward. To do this, move vehicle forward with 4th gear engaged and ignition switched off.

To determine the play between cam lobes and roller rocker lever, press lever down -arrow-.

Scheme 366

If a 0.20 mm feeler gauge can slide between cam lobes and roller rocker lever, replace hydraulic adjusting element CAMSHAFTS .

Final Procedures

Install cylinder head cover: Left LEFT CYLINDER HEAD COVER , right RIGHT CYLINDER HEAD COVER .

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

1. Dial gauge holder VW 387
2. Dial gauge VAS 6079

Procedure

Proceed as follows

Note. If valve is replaced during repair, use new valve for measurement. Due to different stem diameters, only use an intake valve in the intake guide and an exhaust valve in the exhaust guide.

Place valve in valve guide.

1. Valve stem tip must seal with valve guide.

Determine tip clearance.

1. Wear limit: 0.8 mm.

If wear limit is exceeded, re-measure using new valves.

If wear limit is still exceeded, replace cylinder head.

Note. The valve guides cannot be replaced.

VALVES, CHECKING

Proceed as follows

Check valves at stem and seating surface for traces of wear.

If there are clear traces of wear, replace valve.

LEFT AND RIGHT TIMING CHAIN COVERS

Special tools and workshop equipment required

1. Hand drill with plastic brush attachment
2. Protective glasses
3. Sealant

REMOVING

Proceed as follows

Note. During installation, all cable ties must be reinstalled at the same location.

Remove rear engine cover -top arrows-.

Remove plenum chamber bulkhead Description and Operation .

Left Timing Chain Cover

Remove electrical connectors -1 through 4- from bracket and press to the side.

Note. Ignore -arrows-.

Free up electrical wires.

Remove bolts -1 through 8- and remove left timing chain cover.

Right Timing Chain Cover

Free up fuel line -1- and wire -2- to EVAP canister at the air guide pipe.

Remove vacuum hose -3- from connection on air guide pipe.

Remove air guide pipe by loosening hose clamp -4- and opening clips -arrows-.

Remove electrical connectors -1 through 4- from bracket and press to the side.

Note. Ignore -arrows-.

Remove bolts -1 through 8- and remove right timing chain cover.

INSTALLING

1. Tightening specifications (Scheme 333), (Scheme 334)

Remove sealant residue on covers for timing chain, cylinder block and cylinder head, for example using a rotating plastic brush.

Scheme 367

Clean sealing surfaces, must be free of oil and grease.

Cut tube nozzle at front marking (nozzle diameter approximately 2 mm).

Scheme 368

Apply sealant bead -arrow- to clean sealing surfaces on left timing chain cover as shown in the illustration.

Scheme 369

1. Thickness of sealant bead: 2.5 mm.

Note. Covers for timing chain must be installed within 5 minutes after applying sealant.

Position left timing chain cover and tighten bolts in sequence -1 to 8- (Scheme 333)

Apply sealant bead -arrow- to clean sealing surfaces on the right timing chain cover as shown in the illustration.

1. Thickness of sealant bead: 2.5 mm.

Position right timing chain cover and tighten bolts in sequence -1 to 8- (Scheme 334)

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

Note. Secure all hose connections with hose clamps appropriate for the model.

Install plenum chamber bulkhead Description and Operation .

LOWER TIMING CHAIN COVER

Special tools and workshop equipment required

1. Old oil collecting and extracting device V.A.G 1782
2. Hand drill with plastic brush attachment
3. Protective glasses
4. Sealant

Proceed as follows

1. Transmission removed.

Note. During installation, all cable ties must be re-installed at the same location.

Disconnect battery Removal and Installation .

Place used oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.

Remove drive plate DRIVE PLATE .

Remove left and right timing chain covers LEFT AND RIGHT TIMING CHAIN COVERS .

Remove oil filter housing OIL FILTER HOUSING .

Remove generator Removal and Installation .

Remove left and right bolts -arrows- and electrical connector bracket.

Disconnect starter electrical connector -3- by sliding retainer back and pressing release down.

Scheme 370

Remove electrical wire nut -2- and starter.

Note. Ignore -1 and 4-.

Remove bolts -arrows-.

Remove bolts -1 through 10- and remove lower timing chain cover.

Press transmission side of crankshaft shaft seal out of lower timing chain cover.

1. Tightening specifications (Scheme 335)

Note. Replace seals, gaskets and O-rings.

Remove right upper alignment bushing from cylinder block.

Grind alignment bushing down at an angle as shown in the illustration.

Scheme 371

1. Dimension -x- = 6.5 mm.
2. Dimension -y- = 8 mm.

Insert alignment bushing in cylinder block so the angled side faces up.

Note. Because of the chamfer, the lower timing chain cover can be positioned more easily when the cylinder head is installed.

Remove sealant residue on cover for timing chain, cylinder block and cylinder head, for example using a rotating plastic brush.

Clean sealing surfaces, must be free of oil and grease.

Clean threaded holes in cylinder block for connecting engine and transmission using a thread tap before installing the transmission.

Clean old sealant out of holes -arrow- in cylinder head seals.

Scheme 372

Note. With cylinder head installed, holes in cylinder head seal are only half visible.

Note. A kinked cylinder head seal must be replaced.

Bend end of the cylinder head seals down slightly -arrows- until the upper sealing surface of the seals and cylinder head can be cleaned.

Scheme 373

Clean top and bottom of the cylinder head seals so they are free of oil and grease.

Cut tube nozzle at front marking (nozzle diameter approximately 2 mm).

Note. The sealant must be applied to several places on the engine, as described in the following.

Lightly coat top and bottom cylinder head seal sealing surfaces with lubricant by bending seals down slightly again -arrows-.

Use a flat object such as a feeler gauge to coat the surface between the cylinder head and seal.

Fill cleaned cylinder head seal holes -arrow- with sealant.

Apply sealant beads -1 through 4- on the clean lower timing chain cover sealing surfaces as shown in the illustration.

Scheme 374

1. The groove of sealing surface must be completely filled with sealant.
2. Sealant beads must be 1.5 to 2.0 mm above the sealing surface.
3. The sealant bead -2- must be drawn through as shown in the illustration even though the groove is intermittent.

Note. The sealant only needs to cure for approximately 5 minutes after applying.

Insert seals -arrows- in the grooves on the lower timing chain cover.

Position lower timing chain cover, guiding it diagonally from below to the sealing surface on the cylinder block and cylinder head.

When positioning, ensure the cylinder head seals are not damaged.

Tighten bolts for the lower timing chain cover (Scheme 335)

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

Install starter Removal and Installation .

Install generator Removal and Installation .

Install oil filter housing OIL FILTER HOUSING .

Install left and right timing chain covers LEFT AND RIGHT TIMING CHAIN COVERS .

Install transmission-side crankshaft shaft seal CRANKSHAFT SEAL, DRIVE PLATE SIDE .

Installing drive plate DRIVE PLATE .

Fill engine oil and check oil level ENGINE OIL, CHECKING LEVEL .

CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS

Special tools and workshop equipment required

1. Torque wrench V.A.G 1332
2. Assembly tool V.A.G 1332/9
3. Multi-point socket T10035
4. Counter-holder tool T10172
5. Adapter T40058
6. Locking pin T40069
7. Old oil collecting and extracting device V.A.G 1782
8. Locking pin T40071, qty. 2
9. Camshaft clamp T40133, qty. 2

Proceed as follows

Note. The camshaft timing chains remain on the engine in the following description.

Remove the respective cylinder head cover: Left LEFT CYLINDER HEAD COVER , right RIGHT CYLINDER HEAD COVER .

Remove left and right timing chain covers LEFT AND RIGHT TIMING CHAIN COVERS .

Remove noise insulation by loosening fasteners -1 through 4-.

Scheme 375

Note. Ignore -arrow-.

Without After-Run Coolant Pump -V51

Remove bolt -1- and nut -3- and lock carrier left brace -2-.

Scheme 376

Place used oil collecting and extracting device V.A.G 1782 under engine.

Scheme 377

Remove bolts -arrows- and lay aside oil cooler with coolant hoses -1- and -2- connected.

With After-Run Coolant Pump -V51

Remove after-run coolant pump -V51- AFTER-RUN COOLANT PUMP , and oil cooler OIL COOLER .

Continuation for All+

Insert adapter T40058 guide pins as follows

Scheme 378

1. The large diameter -arrow 1- faces engine.
2. Small diameter -arrow 2- points to adapter.

Turn crankshaft in direction of engine rotation -arrow- to "TDC" using adapter T40058.

Scheme 379

Remove locking bolt -arrow- for "TDC" marking from cylinder block.

Scheme 380

Note. The crankshaft locating hole is difficult to find when the engine is installed. Rotate engine until the small notch -1- on the vibration damper aligns at the left of the housing separation point -2- between the cylinder block and the guide frame. This makes it easier to install the locking pin T40069. The marking on the vibration damper is only there to help. The exact "TDC" location is only reached by installing the locking pin T40069.

Scheme 381

1. The threaded holes -arrows- in the camshafts must face upward.

Install crankshaft holder T40069 in hole and tighten to 20 Nm. Turn crankshaft back slightly to completely center bolt, if necessary.

Scheme 382

Install camshaft clamp T40133 in both cylinder heads and tighten bolts -arrows- to 25 Nm.

Scheme 383

Note. The illustration shows the left cylinder head.

Press left camshaft timing chain tensioner guide rails in as far as stop using a screwdriver -1- and secure chain tensioner with a locking pin T40071.

Scheme 384

Note. The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

Press right camshaft timing chain tensioner guide rails in as far as stop using a screwdriver -1- and secure chain tensioner with a locking pin T40071.

Scheme 385

Note. The toothed belt tensioner is lubricated with oil and should only be compressed slowly by applying constant pressure.

To counter hold at the affected camshaft adjuster, position counter hold tool T10172 with pins T10172/2 and loosen using socket T10035.

Scheme 386

Mark installation position of camshaft adjuster with paint for installation later.

Scheme 387

Remove bolts -1- and -2- on left cylinder head and remove both camshaft adjusters.

Mark installation position of camshaft adjuster with paint for installation later.

Scheme 388

Remove bolts -1- and -2- on right cylinder head and remove both camshaft adjusters.

1. Tightening specifications «CAMSHAFT TIMING CHAINS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-assembly-overview), see scheme 98

Note. Replace bolts which have been tightened to torque. Replace O-ring for "TDC" marking locking bolt.

1. Drive chain for timing mechanism installed «TIMING MECHANISM DRIVE CHAIN»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__timing-mechanism-drive-chain) .
2. Secure crankshaft in "TDC" position using crankshaft holder T40069.

1. Camshaft clamp T40133 mounted on both cylinder heads and fastened to 25 Nm -arrows-.

Note. The illustration shows the left cylinder head.

Note. Reinstall camshaft adjuster on left cylinder head according to the mark applied during removal.

Position left camshaft timing chain on drive sprocket and camshaft adjuster and loosely install bolts -1- and -2-.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

Remove locking pin T40071.

Note. Reinstall camshaft adjuster on right cylinder head according to the mark applied during removal.

Position right camshaft timing chain on drive sprocket and camshaft adjuster and loosely install bolts -1- and -2-.

1. Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

Remove locking pin T40071.

Position counter hold tool T10172 with pins T10172/2 on left intake camshaft adjuster.

Have a second technician hold camshaft timing chain tensioned by pressing counter hold tool in direction of -arrow-.

Tighten bolts as follows while camshaft adjuster is still held under tension.

Position counter hold tool T10172 with pins T10172/2 on right exhaust camshaft adjuster.

Scheme 389

Have a second technician hold camshaft timing chain tensioned by pressing counter hold tool in direction of -arrow-.

Tighten bolts as follows while camshaft adjuster is still held under tension.

Remove camshaft clamp T40133 on both cylinder heads -arrows-.

Note. The illustration shows the left cylinder head.

Tighten camshaft adjuster bolts on left cylinder head as follows

Scheme 390

Tighten camshaft adjuster bolts on right cylinder head as follows

Scheme 391

Remove crankshaft holder T40069.

Using adapter T40058, turn crankshaft two turns in direction of engine rotation -arrow- until it is back at "TDC".

Note. If it is accidentally rotated beyond "TDC", rotate it back approximately 30 degrees and set it to "TDC" again.

1. The threaded holes -arrows- in camshafts must face upward.

Install camshaft clamp T40133 in both cylinder heads and tighten bolts -arrows- to 25 Nm.

Install locking pin T40069 directly in hole.

1. The crankshaft holder T40069 must engage in locating hole of crankshaft -1-, otherwise repeat the adjustment.

Remove camshaft locating pins on both cylinder heads.

Remove crankshaft holder T40069.

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

Install left and right timing chain covers LEFT AND RIGHT TIMING CHAIN COVERS .

Install cylinder head covers: Left LEFT CYLINDER HEAD COVER , right RIGHT CYLINDER HEAD COVER .

Install after-run coolant pump -V51- AFTER-RUN COOLANT PUMP .

Install oil cooler OIL COOLER .

Install lock carrier brace Description and Operation .

Install front noise insulation Description and Operation .

Proceed as follows

1. Transmission removed.

Remove timing chain lower cover LOWER TIMING CHAIN COVER .

Remove camshaft timing chains from camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Remove locking pin T40071 and left camshaft timing chain.

Scheme 392

Remove bolts -1- and -2- and right chain tensioner.

Scheme 393

Press timing mechanism chain tensioner guide rail in direction of -arrow- and secure chain tensioner using a locking pin T40071.

Scheme 394

Loosen drive chain sprocket bolt -1- 1 turn.

Tilt drive chain sprocket with mounting pins to side slightly and remove right camshaft timing chain upward.

1. Tightening specifications «CAMSHAFT TIMING CHAINS ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__camshaft-timing-chains-assembly-overview) .

Note. If the tensioning element was removed from the chain tensioner, note installation position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail. Replace bolts which have been tightened to specifications.

Position left camshaft timing chain according to markings made during removal as shown in the illustration.

Press guide rail for left camshaft timing chain tensioner down and secure chain tensioner using a locking pin T40071.

Guide right camshaft timing chain on drive sprocket mounting pins while noting markings made during removal.

Tighten mounting pin bolts -1-.

Remove locking pin T40071.

Insert chain tensioner at right cylinder head and position camshaft timing chain.

Fasten bolts -1- and -2-.

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

Position camshaft timing chain on camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Install timing chain lower cover LOWER TIMING CHAIN COVER .

Fill engine oil and check oil level ENGINE OIL, CHECKING LEVEL .

TIMING MECHANISM DRIVE CHAIN

Special tools and workshop equipment required

1. Securing pin T40071

Proceed as follows

1. Transmission removed.

Remove timing chain lower cover LOWER TIMING CHAIN COVER .

Remove camshaft timing chains from camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Remove power take-off drive chain POWER TAKE-OFF CHAIN .

Press drive chain tensioner guide rail in direction of -arrow- and secure chain tensioner with a locking pin T40071.

Scheme 395

Remove bolts -1- and guide rail.

Remove bolts -2- and chain tensioner.

Remove timing mechanism drive chain.

1. Tightening specifications «TIMING MECHANISM DRIVE CHAIN ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to specification.

Position timing mechanism drive chain according to the markings made on the drive chain sprockets during removal.

Install guide rail and tighten the bolts -1-.

Install chain tensioner and tighten bolts -2-.

Press drive chain tensioner guide rail in direction of -arrow- and pull securing pin T40071 out of chain tensioner.

Install power take-off drive chain POWER TAKE-OFF CHAIN .

Position camshaft timing chain on camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Install timing chain lower cover LOWER TIMING CHAIN COVER .

Fill engine oil and check oil level ENGINE OIL, CHECKING LEVEL .

POWER TAKE-OFF CHAIN

Special tools and workshop equipment required

1. Wrench T40049
2. Securing pin T40071
3. Drill bit dia. 8 mm

Proceed as follows

1. Transmission removed.

Remove timing chain lower cover LOWER TIMING CHAIN COVER .

Scheme 396

Install key T40049 at rear of crankshaft using two old drive plate bolts -arrows-.

Remove locking bolt -arrow- for "TDC" marking from cylinder block.

Rotate crankshaft in direction of engine rotation to "TDC".

Note. The crankshaft locating hole is difficult to find when the engine is installed. Rotate the engine until the small notch -1- on the vibration damper aligns at the left of the housing separation point -2- between the cylinder block and the guide frame. This makes it easier to install locking pin T40069. The marking on the vibration damper is only there to help. The exact "TDC" location is only reached by installing the locking pin T40069.

Install locking pin T40069 in hole and tighten to 20 Nm. Turn crankshaft back slightly to completely center the bolt, if necessary.

Press chain tensioner guide rail in direction of -arrow- and secure chain tensioner using a locking pin T40071.

Scheme 397

Remove bolts -3- and balance shaft chain sprocket.

Remove bolts -1- and -2- and chain tensioner with drive chain.

1. Tightening specifications «TIMING MECHANISM DRIVE CHAIN ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007), see scheme 98
2. Secure crankshaft -1- in "TDC" position using crankshaft holder T40069.

Install chain tensioner with drive chain and balance shaft chain sprocket.

To protect against cuts, wrap point and cutting edges on an 8 mm diameter drill bit with insulating tape.

Secure balance shaft in "TDC" position using an 8 mm diameter drill bit -2-.

Scheme 398

1. The slots in the balance shaft sprocket must be at the middle position in relation to the threaded holes of the balance shaft. If necessary, adjust chain by one tooth.

Tighten chain tensioner bolts.

Loosely install chain sprocket bolts -1- and -3-.

1. It must still be possible to rotate chain sprocket on the balance shaft and it must not tip.

Remove locking pin T40071 to release chain tensioner.

Press against chain tensioner guide rail -arrow- using a screwdriver while tightening chain sprocket bolts -1- and -3-.

Remove drill bit -2- from balance shaft.

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

Install timing chain lower cover LOWER TIMING CHAIN COVER .

Fill engine oil and check oil level ENGINE OIL, CHECKING LEVEL .

BALANCE SHAFT

Special tools and workshop equipment required

1. Old oil collecting and extracting device V.A.G 1782

Proceed as follows

1. Transmission removed.

Remove belt pulley side sealing flange SEALING FLANGE AND CRANKSHAFT SEAL, BELT PULLEY SIDE .

Remove timing chain lower cover LOWER TIMING CHAIN COVER .

Remove power take-off drive chain POWER TAKE-OFF CHAIN .

To protect against cuts, wrap point and cutting edges on an 8 mm diameter drill bit with insulating tape.

Secure balance weight -2- at rear of engine with an 8 mm diameter drill bit -1-.

Scheme 399

Remove bolt -3- and remove balance weight from balance shaft.

Remove bolt -2- while counter holding balance weight using drift and remove balance weight -1- from balance shaft at front of the engine.

Scheme 400

Remove bolts -arrows- and balance shaft and bearing end bracket at rear of the engine.

Scheme 401

Remove balance shaft back out of cylinder block.

1. Tightening specifications «BALANCE SHAFT ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007), see scheme 98
2. Secure crankshaft -1- in "TDC" position using crankshaft holder T40069.

Installation is in reverse order of removal, note the following

Note. The balance weights can only be positioned one way on balance shaft.

Install power take-off drive chain POWER TAKE-OFF CHAIN .

Install timing chain lower cover LOWER TIMING CHAIN COVER .

Install belt pulley side sealing flange SEALING FLANGE AND CRANKSHAFT SEAL, BELT PULLEY SIDE .

Fill engine oil and check the oil level ENGINE OIL, CHECKING LEVEL .

LEFT CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Ignition coil puller T40039

Proceed as follows

Remove engine covers -arrows-.

Remove bolts -arrows-.

Disconnect electrical connector on Engine Coolant Level (ECL) warning switch -F66- and lay coolant reservoir aside with coolant hoses -1, 2 and 3- connected.

Remove bolts -arrows- on left cylinder head and disconnect electrical connectors to ignition coils.

Scheme 402

Disconnect electrical connector -1- on Camshaft Position (CMP) sensor 2 -G163- and -4- on Camshaft Position (CMP) sensor 4 -G301-.

Remove ground (GND) wire bolt -5-.

Note. Ignore -2-.

Disconnect electrical connectors -3- on camshaft adjustment valve 2 -N208- and camshaft adjustment valve 2 (exhaust) -N319-, while following the note below.

Note. The connecting bracket -3- on the camshaft adjustment valve electrical connectors -1- and -2- prevents them from being exchanged and must not be removed from the connectors.

To disconnect, press both connectors -arrows- and remove them both together from camshaft adjustment valve 2 -N208- and camshaft adjustment valve 2 (exhaust) -N319-.

Move electrical wiring harness to side.

Remove ignition coils with ignition coil puller T40039.

Remove bolts in sequence -12 to 1- and lay left cylinder head aside with crankcase ventilation hose -arrow- connected.

1. Tightening specifications (Scheme 343).

Installation is in reverse order of removal, note the following

Note. Replace cylinder head seal if it is damaged. Replace cylinder head cover bolts when replacing the damaged seal.

Clean sealing surfaces, must be free of oil and grease.

Tighten left cylinder head cover bolts (Scheme 343)

RIGHT CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Ignition coil puller T40039

Proceed as follows

Remove engine covers -arrows-.

Remove air duct -arrows-.

Free up fuel line -1- and wire -2- to EVAP canister at air guide pipe.

Remove vacuum hose -3- from connection on air guide pipe.

Remove air guide pipe by loosening hose clamp -4- and opening clips -arrows-.

Disconnect vacuum line -1-.

Remove air filter housing and, if applicable, disconnect electrical connector -2- on rear side at intake air switch-over valve -N335-.

Remove bolts -arrows- on right cylinder head and disconnect electrical connectors to ignition coils.

Disconnect electrical connector -5- on Camshaft Position (CMP) sensor 3 -G300-.

Scheme 403

Note. Ignore -2, 3 and 4-.

Disconnect electrical connectors -1- on camshaft adjustment valve 1 -N205- and camshaft adjustment valve 1 (exhaust) -N318-, while following the note below.

Note. The connecting bracket -3- on the camshaft adjustment valve electrical connectors -1- and -2- prevents them from being exchanged and must not be removed from the connectors.

To disconnect, press both connectors -arrows- and remove them both together from camshaft adjustment valve 1 -N205- and camshaft adjustment valve 1 (exhaust) -N318-.

Press electrical wiring harness to side.

Remove ignition coils with ignition coil puller T40039.

Remove bolts in sequence -12 to 1- and lay right cylinder head aside with crankcase ventilation hose -arrow- connected.

1. Tightening specifications (Scheme 344)

Installation is in reverse order of removal, note the following

Note. Replace cylinder head seal if it is damaged. Replace cylinder head cover bolts when replacing damaged seal.

Clean sealing surfaces, must be free of oil and grease.

Tighten right cylinder head cover bolts (Scheme 344)

CYLINDER HEADS

Special tools and workshop equipment required

1. Pin wrench 3212
2. Adapter T40058
3. Locking pin T40069
4. Camshaft locator T40133

1. Engine installed.

Note. The following information describes how to remove both cylinder heads at the same time. If only one cylinder head will be removed, follow the applicable instructions in the following description.

Reduce fuel pressure in high pressure area BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

Remove upper coolant pipe UPPER COOLANT PIPE .

Remove ribbed belt RIBBED BELT .

Remove lower section of intake manifold Removal and Installation .

Disconnect electrical connectors on the fuel injectors.

Remove left catalytic converter LEFT CATALYTIC CONVERTER .

Remove right front muffler FRONT MUFFLER .

Remove nuts -arrows- and bolt -1- and press right catalytic converter to the side.

Scheme 404

Note. The installation location is shown with engine removed.

Remove bolts -arrows- for coolant pump ribbed belt pulley using a spanner wrench 3212 to counter hold.

Scheme 405

Remove bolts -1- and -2-, loosen bolt -3- and move power steering pump to side.

Scheme 406

Disconnect electrical connector -3- for Engine Coolant Temperature (ECT) sensor -G62-.

Scheme 407

Remove bolts -1, 2, 4 and 5- on front coolant pipe.

Note. Ignore -arrows-.

Remove threaded connection -2- and move fuel supply line to side.

Scheme 408

Disconnect electrical connectors -1- and -6-.

Note. Ignore -3, 4 and 5- and the -arrows-.

Disconnect right and left electrical connectors -arrows- on camshaft adjuster actuators.

Scheme 409

Remove bolts -1- and -2- and free up electrical wiring harness.

Remove cylinder head cover: Left LEFT CYLINDER HEAD COVER , right RIGHT CYLINDER HEAD COVER .

Disconnect electrical connector -3- on Camshaft Position (CMP) sensor -G40-.

Remove ground (GND) wire bolt -4-.

Note. Ignore -1, 2, 5-.

Remove left and right timing chain covers LEFT AND RIGHT TIMING CHAIN COVERS .

Remove bolts -arrows- and bracket for left connectors.

Note. Ignore -1 through 4-.

Remove bolts -arrows- and bracket for right connectors.

Note. Ignore -1 through 4-.

Remove bolt -arrow- and remove oil dipstick with guide tube.

Remove vacuum hose from vacuum pump -arrow- and free it up.

Scheme 410

Remove bolts -arrows- on rear of cylinder head.

Scheme 411

1. Left cylinder head: 3 bolts.
2. Right cylinder head: 4 bolts.

Note. The cams on the intake camshaft partially restrict access to the cylinder head bolts, such as bolts -1- and -2- shown in this example. The slider on the camshaft must be pressed in direction of -arrow A- using a plastic wedge to remove the bolt -1-. The slider on the camshaft must be pressed in direction of -arrow B- using a plastic wedge to remove the bolt -2-.

Insert adapter T40058 guide pins as follows

1. The large diameter -arrow 1- faces engine.
2. Small diameter -arrow 2- points to adapter.

Rotate crankshaft in direction of engine rotation -arrow- using adapter T40058 until camshaft position shown in the following illustration is reached.

Scheme 412

1. The openings -arrows- on exhaust camshafts must face toward outer side of engine as shown in the illustration.

Left Cylinder Head

Slide unloaded camshaft slider -B- as far as stop in direction of -arrow-.

Scheme 413

Right Cylinder Head

Slide unloaded camshaft slider -F- as far as the stop in direction of -arrow-.

Scheme 414

Continuation for Both Cylinder Heads

Turn crankshaft one full revolution (360 degrees) in direction of engine rotation -arrow- using adapter T40058.

Scheme 415

1. The threaded holes -arrows- in camshafts must face upward.

Left Cylinder Head

Remove bolt -1-.

Scheme 416

Right Cylinder head

Remove bolt -2-.

Scheme 417

Continuation for Both Cylinder heads

Turn crankshaft one full revolution (360 degrees) in direction of engine rotation -arrow- using adapter T40058.

1. The openings -arrows- on exhaust camshafts must face toward outer side of the engine.

Left Cylinder Head

Slide unloaded camshaft sliders -B- and -C- as far as stop in direction of -arrow-.

Scheme 418

Right Cylinder Head

Slide unloaded camshaft slider -F- as far as stop in direction of -arrow-.

Scheme 419

Continuation for Both Cylinder Heads

Turn crankshaft one full revolution (360 degrees) in direction of engine rotation -arrow- using adapter T40058.

1. The threaded holes -arrows- in camshafts must face upward.

Remove camshaft timing chains from camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Left Cylinder Head

Remove bolts -3 through 9- while sliding unloaded camshaft slider -A- accordingly.

Scheme 420

Remove cylinder head.

Right Cylinder Head

Remove bolts -10 through 16- while sliding unloaded camshaft sliders -D- and -E- accordingly.

Scheme 421

Remove cylinder head.

1. Tightening specifications «CYLINDER HEAD ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-112007__cylinder-head-assembly-overview) .

Note. Replace bolts which have been tightened to specifications. Replace self-locking nuts, sealing rings, seals and O-rings. Note different sealant for cylinder head sealing surfaces and bolts. If a replacement cylinder is installed, the contact surfaces between the hydraulic adjusting elements, roller rocker levers and cam running surfaces must be lubricated before installing the cylinder head cover. Secure all hose connections with hose clamps appropriate for the model. The engine oil and coolant must be changed if the cylinder head or cylinder head seal are replaced.

Before installing cylinder head, set crankshaft and camshafts to "TDC" and install camshaft locator T40133 on both cylinder heads and tighten to 25 Nm -arrows-.

Scheme 422

1. The camshaft locating tool T40133 is correctly positioned when holes for cylinder head bolts remain free.

1. Crankshaft holder T40069 must be installed into the crankshaft.

Set cylinder head gasket in place.

Scheme 423

1. Pay close attention to centering pins -arrows- in cylinder block.
2. Cylinder head seal installation position: Marking "oben" or part number must face toward cylinder head.

Position cylinder head.

Left Cylinder Head

Insert bolts -1 through 7- while sliding unloaded camshaft slider -A- accordingly.

Tighten bolts in 3 stages in sequence -1 to 7- CYLINDER HEAD ASSEMBLY OVERVIEW .

Right Cylinder Head

Insert bolts -8 through 14- while sliding unloaded camshaft sliders -D- and -E- accordingly.

Tighten bolts in 3 stages in sequence -8 to 14- CYLINDER HEAD ASSEMBLY OVERVIEW .

Continuation for Both Cylinder Heads

Position camshaft timing chain on camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

Remove camshaft locator T40133 and locking pin T40069.

Turn crankshaft one full revolution (360 degrees) in direction of engine rotation -arrow- using adapter T40058.

1. The openings -arrows- on exhaust camshafts must face toward outer side of the engine.

Left Cylinder Head

Slide unloaded camshaft sliders -B- and -C- as far as stop in direction of -arrow-.

Scheme 424

Right Cylinder Head

Slide unloaded camshaft slider -F- as far as stop in direction of -arrow-.

Continuation for Both Cylinder Heads

Turn crankshaft one full revolution (360 degrees) in direction of engine rotation -arrow- using adapter T40058.

1. The threaded holes -arrows- in camshafts must face upward.

Left Cylinder Head

Insert bolt -15- and tighten it in a total of 3 stages CYLINDER HEAD ASSEMBLY OVERVIEW .

Right Cylinder Head

Insert bolt -16- and tighten it in a total of 3 stages CYLINDER HEAD ASSEMBLY OVERVIEW .

Continuation for Both Cylinder Heads

Turn crankshaft one full revolution (360 degrees) in direction of engine rotation -arrow- using adapter T40058.

1. The openings -arrows- on exhaust camshafts must face toward outer side of engine.

Left Cylinder Head

Slide unloaded camshaft slider -B- as far as stop in direction of -arrow-.

Scheme 425

Right Cylinder Head

Slide unloaded camshaft slider -F- as far as stop in direction of - arrow-.

Continuation for Both Cylinder Heads

Tighten bolts -arrows-.

1. Left cylinder head: 3 bolts.
2. Right cylinder head: 4 bolts.

Note. Do not retighten cylinder head bolts after repairs.

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

Install oil dipstick guide tube (Scheme 347)

Install left and right timing chain covers LEFT AND RIGHT TIMING CHAIN COVERS .

Install cylinder head cover: Left LEFT CYLINDER HEAD COVER , right RIGHT CYLINDER HEAD COVER .

Install front coolant pipe FRONT COOLANT PIPE .

Install power steering pump Removal and Installation .

Install catalytic converter: Left LEFT CATALYTIC CONVERTER , right RIGHT CATALYTIC CONVERTER .

Install front muffler FRONT MUFFLER .

Install plenum chamber bulkhead Description and Operation .

Install fuel supply line and lower section of intake manifold Removal and Installation .

Install ribbed belt RIBBED BELT .

Install upper coolant pipe UPPER COOLANT PIPE .

Change engine oil => 811.

Replace coolant COOLING SYSTEM, DRAINING AND FILLING .

CAMSHAFTS

Special tools and workshop equipment required

1. Impact puller T10133/3 from tool set T10133
2. Securing pins 1 set = qty. 2 T40116
3. Camshaft locator T40133
4. Hand drill with plastic brush attachment
5. Protective glasses
6. Sealant

Remove camshaft timing chains from camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

To remove camshafts in left cylinder head, remove brake booster vacuum pump Removal and Installation .

To remove the camshafts in the right cylinder head, remove the high pressure pump and pump motor housing Removal and Installation .

Remove bolts -arrows- and camshaft adjuster valves.

Scheme 426

Loosen guide frame bolts in sequence -21 to 1-.

Note. The illustration shows guide frame for left cylinder head.

Carefully remove guide frame and lay it on a soft surface on the workbench.

Remove locking pin T40133.

Mark camshafts and remove.

1. Tightening specifications (Scheme 349)
2. Secure crankshaft -1- using crankshaft holder T40069.

Note. Replace seals and gaskets.

Using a rotating plastic brush, remove any remaining sealant from cylinder head and guide frame.

Clean sealing surfaces, must be free of oil and grease.

Check screen -arrow- for dirt and clean it if necessary.

Scheme 427

Oil running surfaces of both camshafts.

Insert camshafts in guide frame.

Scheme 428

1. The placement of camshafts must be exactly within axial bearings -arrows- of guide frame.
2. The compression ring ends -1, 2 and 3- must face upward or downward and must never face sideways.

Rotate guide frame with camshafts inserted while holding them securely in frame.

Rotate camshafts until threaded holes -arrows- face upward.

Check if camshafts still lie in guide frame axial bearings.

Install camshaft locator T40133 and tighten bolts -arrows- to 25 Nm.

Cut tube nozzle at front marking (nozzle diameter approximately 2.0 mm).

Rotate guide frame again.

Apply sealant beads -4 through 8- to clean sealing surfaces on guide frame as shown in the illustration.

Scheme 429

1. Thickness of sealant bead: 2.0 mm.

Apply sealant beads -1 through 3- to clean sealing surfaces on guide frame as shown in the illustration.

1. Thickness of sealant bead: 2.5 mm.

Note. Because the sealant begins hardening immediately, guide frame must be promptly positioned and tightened.

Place guide frame on cylinder head.

Insert locating pins T40116 in guide frame and cylinder head.

Scheme 430

Note. The sealant must dry for approximately 30 minutes after installing guide frame.

Tighten guide frame bolts in sequence -1 to 21- (Scheme 349)

Clean sealing plug hole in cylinder head. It must be free of oil and grease.

Scheme 431

Coat outer circumference of sealing plug -arrow- with sealant

Drive in sealing plugs until they are flush.

Remove locating pins T40116 with impact puller T10133/3.

Scheme 432

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

Install camshaft adjustment valves CYLINDER HEAD ASSEMBLY OVERVIEW .

Install brake booster vacuum pump Removal and Installation .

Install high pressure pump motor housing and high pressure pump Removal and Installation .

Position camshaft timing chain on camshafts CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS .

VALVE STEM SEALS, WITH CYLINDER HEAD INSTALLED

Special tools and workshop equipment required

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Valve cotter disassembly and assembly device VAS 5161 with guide plate VAS 5161/19B
5. Adapter T40012

Procedure

Proceed as follows

Remove camshafts CAMSHAFTS .

Mark allocation of roller rocker lever and hydraulic adjusting elements so they can be installed again.

If necessary, remove roller rocker levers with hydraulic adjusting elements and place them on a clean surface.

Remove spark plugs using spark plug removal tool 3122 B.

Move piston for respective cylinder to "Bottom Dead Center (BDC) position".

Position drift VAS 5161/3 on valve spring plate and loosen stuck valve keepers with a plastic mallet.

Scheme 433

Place guide plate VAS 5161/19B from valve cotter assembly/disassembly device VAS 5161 on cylinder head.

Scheme 434

Secure guide plate with knurled screws VAS 5161/12.

Install adapter T40012 with sealing ring in respective spark plug thread and hand tighten.

Connect adapter to compressed air using a commercially available intermediate piece and give steady pressure.

1. Minimum pressure: 6 bar positive pressure.

Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

Scheme 435

Slide installation cartridge VAS 5161/8 in guide plate.

Engage pressure fork VAS 5161/2 on engaging device and press installation cartridge down.

At the same time, rotate installation cartridge knurled screw right until points engage in valve keeper.

Move knurled wheel left and right slightly. This presses the valve keepers apart and captures them in installation cartridge.

Release pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

1. Pressurized air hose remains connected.

Remove valve spring with valve spring plate.

Remove valve stem seal using valve seal removal tool 3364.

Scheme 436

If valve seal removal tool 3364 cannot be used, on several valve stem seals due to restricted clearance, proceed as follows

Scheme 437

Drive out roll pin -arrow- on puller with a drift and remove impact puller attachment.

Position lower part of puller 3364 on valve stem seal.

Scheme 438

Secure puller with a drift or cotter pin drive -1- as shown in the illustration.

Position valve lever on puller and remove valve stem seal -arrow-.

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with valve stem seal drive 3365.

Scheme 439

Remove plastic sleeve again.

When valve keepers were removed from the installation cartridge, they must be inserted in the valve keeper inserting tool next VAS 5161/18.

Scheme 440

1. The large diameter of valve keepers point upward.

Press installation cartridge from above onto valve keeper inserting tool and capture keepers.

Insert valve spring and valve spring plate.

1. Installation position: The tight spring coils -arrow- face toward cylinder head.

Install guide plate on cylinder head.

Insert installation cartridge in guide plate.

Press pressure fork down and pull the knurled screw up while turning left and right. This inserts the valve keepers.

Release pressure fork with knurled screw still raised.

Make sure all roller rocker levers lie on ends of the valve stems correctly and are clipped onto respective hydraulic adjusting elements.

Install camshafts CAMSHAFTS .

Install spark plugs => 811.

VALVE STEM SEALS, WITH CYLINDER HEAD REMOVED

Special tools and workshop equipment required

1. Valve seal removal tool 3364
2. Valve stem seal driver 3365
3. Valve cotter disassembly and assembly device VAS 5161 with guide plate VAS 5161/19B
4. Engine and transmission holder VAS 6095
5. Tensioning element VAS 6419

Proceed as follows

Remove camshafts CAMSHAFTS .

Mark allocation of roller rocker lever and hydraulic adjusting elements so they can be installed again.

If necessary, remove roller rocker levers with hydraulic adjusting elements and place them on a clean surface.

Insert tensioning element VAS 6419 in engine and transmission holder VAS 6095.

Scheme 441

Tension cylinder head on tensioning element VAS 6419 as shown in the illustration.

Connect tensioning element VAS 6419 to compressed air.

Slide air cushion with lever -arrow- under cylinder onto valve stem seals that will be removed.

Let enough compressed air flow into air cushion until it contacts valve plate.

Position drift VAS 5161/3 on valve spring plate and loosen stuck valve keepers with a plastic mallet.

Place guide plate VAS 5161/19B from valve cotter assembly/disassembly device VAS 5161 on cylinder head.

Scheme 442

Secure guide plate with knurled screws VAS 5161/12.

Install engaging device VAS 5161/6 with installation fork VAS 5161/5 in guide plate.

Scheme 443

Slide installation cartridge VAS 5161/8 in guide plate.

Engage pressure fork VAS 5161/2 on engaging device and press installation cartridge down.

At the same time, rotate installation cartridge knurled screw right until points engage in valve keeper.

Move knurled wheel left and right slightly. This presses the valve keepers apart and captures them in the installation cartridge.

Release pressure fork.

Remove installation cartridge.

Unfasten guide plate and turn it aside.

Remove valve spring with valve spring plate.

Remove valve stem seal using valve seal removal tool 3364.

Position valve lever on puller and remove valve stem seal.

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with valve stem seal drive 3365.

Remove plastic sleeve again.

When valve keepers were removed from installation cartridge, they must be inserted in valve keeper inserting tool VAS 5161/18 next.

1. The large diameter of the valve keepers point upward.

Press installation cartridge from above onto valve keeper inserting tool and capture keepers.

Insert valve spring and valve spring plate.

1. Installation position: The tight spring coils -arrow- face toward cylinder head.

Install guide plate on cylinder head.

Insert installation cartridge in guide plate.

Press pressure fork down and pull knurled screw up while turn left and right. This inserts the valve keepers.

Release pressure fork with knurled screw still raised.

Repeat procedure on each valve.

Assembly is in reverse order of removal, note the following

Make sure all roller rocker levers lie on ends of valve stems correctly and are clipped onto respective hydraulic adjusting elements.

Install camshafts CAMSHAFTS .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 444

Scheme 445

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

1. Tensioning element VAS 6419
2. Dial gauge holder VW 387
3. Dial gauge VAS 6080
4. Old oil collecting and extracting device V.A.G 1782
5. Locking pin T40071, qty. 2
6. Camshaft clamp T40133, qty. 2
7. Wrench T40049
8. Pin wrench 3212
9. Impact puller T10133/3 from tool set T10133
10. Securing pins 1 set = qty. 2 T40116
11. Engine and transmission holder VAS 6095

Scheme 454

Special tools and workshop equipment required

1. Spark plug removal tool 3122 B
2. Compression tester V.A.G 1763
3. Ignition coil puller T40039

Scheme 455

Special tools and workshop equipment required

1. Torque wrench V.A.G 1332
2. Assembly tool V.A.G 1332/9
3. Multi-point socket T10035
4. Counter-holder tool T10172
5. Adapter T40058
6. Locking pin T40069

Scheme 456

Special tools and workshop equipment required

1. Spark plug removal tool 3122 B
2. Valve seal removal tool 3364
3. Valve stem seal driver 3365
4. Valve cotter disassembly and assembly device VAS 5161 with guide plate VAS 5161/19B
5. Adapter T40012

See also:
• CRANKSHAFT SEAL, DRIVE PLATE SIDE
• Brake Booster/Master Brake Cylinder Overview
• Vacuum Pump V192 Overview
• Description and Operation
• Removal and Installation
• DRIVE PLATE
• OIL FILTER HOUSING
• ENGINE OIL, CHECKING LEVEL
• AFTER-RUN COOLANT PUMP
• OIL COOLER
• Description and Operation
• SEALING FLANGE AND CRANKSHAFT SEAL, BELT PULLEY SIDE
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• UPPER COOLANT PIPE
• RIBBED BELT
• Removal and Installation
• LEFT CATALYTIC CONVERTER
• FRONT COOLANT PIPE
• Removal and Installation
• COOLING SYSTEM, DRAINING AND FILLING
• Removal and Installation
• LEFT AND RIGHT TIMING CHAIN COVERS
• LOWER TIMING CHAIN COVER
• CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS
• TIMING MECHANISM DRIVE CHAIN
• POWER TAKE-OFF CHAIN
• BALANCE SHAFT
• CYLINDER HEADS
• LEFT CYLINDER HEAD COVER
• RIGHT CYLINDER HEAD COVER
• VALVE GUIDES, CHECKING
• VALVE STEM SEALS, WITH CYLINDER HEAD INSTALLED
• HYDRAULIC ADJUSTING ELEMENTS, CHECKING
• CAMSHAFTS, CHECKING AXIAL CLEARANCE
• CAMSHAFTS
• VALVE DIMENSIONS
• CYLINDER HEAD ASSEMBLY OVERVIEW
• CAMSHAFT TIMING CHAINS ASSEMBLY OVERVIEW
• TIMING MECHANISM DRIVE CHAIN ASSEMBLY OVERVIEW