3.2l - Cylinder Head, Valvetrain - Engine Code(s): Cala (coupe) (as of 12.2008) Audi A5 I

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.

Scheme 457

1. Bolt Tightening specification and sequence (Scheme 460)
2. Crankshaft Shaft Seal, Transmission Side Replacing, refer to «CRANKSHAFT SEAL, TRANSMISSION SIDE»(/audi/a5/i-2007-2011/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cala-coupe-as-of-122008__crankshaft-seal-transmission-side).
3. Bolt Tightening specification and sequence (Scheme 460)
4. Alignment Bushing 2 pieces
5. Bolt Tightening specifications -item 13- «OIL FILTER HOUSING AND PRESSURE SWITCH OVERVIEW»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-122008)
6. Left Cylinder Head Gasket
7. Left Timing Chain Cover Removing and installing, refer to «LEFT AND RIGHT TIMING CHAIN COVERS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__left-and-right-timing-chain-covers)
8. Bracket For wiring harness
9. Bolt Replace Tightening specification and sequence (Scheme 458)
10. Lower Timing Chain Cover Removing and installing, refer to «LOWER TIMING CHAIN COVER»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__lower-timing-chain-cover)
11. Seals Replace
12. Bolt Tightening specification and sequence (Scheme 459)
13. Bracket For the electrical connectors
14. Bolt Replace Tightening specification and sequence (Scheme 459)
15. Right timing chain cover Removing and installing, refer to «LEFT AND RIGHT TIMING CHAIN COVERS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__left-and-right-timing-chain-covers)
16. Right cylinder head gasket
17. Alignment bushing 2 pieces
18. Bolt Tightening specification and sequence (Scheme 460)
19. Engine speed (RPM) sensor -G28- Removing and installing, refer to «REMOVAL AND INSTALLATION»(ref-520191-S27532932572012123100000)
20. Bolt Tightening specifications, refer to «REMOVAL AND INSTALLATION»(ref-520191-S27532932572012123100000)

Scheme 458

Replace the bolts for the left timing chain cover.

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

Scheme 459

Replace the bolts for the right timing chain cover.

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

Scheme 460

Tighten bolts in 6 stages as follows

CAMSHAFT TIMING CHAINS OVERVIEW

Left Camshaft Timing Chain

Scheme 461

1. Bolt 80 Nm plus an additional 90° turn Replace
2. Bolt 80 Nm plus an additional 90° turn Replace
3. Camshaft Adjuster for Exhaust Camshaft Identification "Exhaust" Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-removing-from-camshafts)
4. Camshaft Adjuster for Intake Camshaft Identification "Intake" Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-removing-from-camshafts)
5. Left Camshaft Timing Chain Before removing, mark the direction of rotation with paint Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-removing-from-camshafts)
6. Bolt 9 Nm
7. Guide Piece
8. Left Camshaft Timing Chain Tensioner Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-removing-from-camshafts)
9. Mounting Bracket For Drive Sprocket
10. Bolt 8 Nm plus an additional 45° turn Replace
11. Left camshaft timing chain drive sprocket
12. Thrust washer for drive sprocket
13. Bolt 6 Nm plus an additional 60° turn Replace

Right Camshaft Timing Chain

Scheme 462

1. Bolt Replace 80 Nm plus an additional 90° turn
2. Camshaft Adjuster for Exhaust Camshaft Identification "Exhaust" Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-removing-from-camshafts)
3. Bolt Replace 80 Nm plus an additional 90° turn
4. Camshaft Adjuster for Intake Camshaft Identification "Intake" Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-removing-from-camshafts)
5. Bolt Replace 30 Nm plus an additional 90° turn
6. Pivot Pin for Drive Sprocket For the right camshaft timing chain Asymmetrical version Installed location (Scheme 464)
7. Right Camshaft Timing Chain Drive Sprocket Installed location (Scheme 464)
8. Right Camshaft Timing Chain Before removing, mark the direction of rotation with paint Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-removing-from-camshafts)
9. Thrust Washer for Drive Sprocket For the right camshaft timing chain Asymmetrical version Installed location (Scheme 464)
10. Right Camshaft Timing Chain Tensioner Removing and installing, refer to «CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-removing-from-camshafts)
11. Guide Piece
12. Bolt 9 Nm

Scheme 463

1. Guide Rail
2. Bolt 10 Nm plus an additional 90° turn further Replace
3. Bolt Tightening specifications -item 13- 13
4. Thrust Washer for Drive Sprocket
5. Drive Sprocket for Left Timing Chain
6. Bolt 10 Nm plus an additional 90° turn Replace
7. Power Take-Off Drive Chain Before removing, mark the direction of rotation with paint Removing and installing, refer to «TIMING MECHANISM DRIVE CHAIN»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__timing-mechanism-drive-chain)
8. Guide Rail
9. Bolt Replace 10 Nm plus an additional 90° turn further
10. Bolt Tightening specifications -item 10- 10
11. Mounting Bracket for Drive Sprocket For the right camshaft timing chain Asymmetrical version Installed location (Scheme 464)
12. Thrust Washer Asymmetrical version Installed location (Scheme 464)
13. Drive Sprocket for Right Timing Chain Installed location (Scheme 464)
14. Pivot Pin for Drive Sprocket Asymmetrical version Installed location (Scheme 464)
15. Bolt Tightening specifications -item 5- 5
16. O-ring Replace
17. Chain Tensioner
18. Bolt 9 Nm
19. Crankshaft
20. Bolt 10 Nm plus an additional 90° turn Replace

Scheme 464

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 465

1. Crankshaft
2. Power Take-Off Drive Chain Before removing, mark the direction of rotation with paint Removing and installing, refer to «POWER TAKE-OFF DRIVE CHAIN»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__power-take-off-drive-chain)
3. Drive Sprocket for Oil Pump Installation position: The labelled side faces the engine
4. Bolt 30 Nm plus an additional 90° turn Replace
5. Spring
6. Bolt 15 Nm plus an additional 90° turn Replace
7. Balance Shaft Chain Sprocket Installation position: The labelled side faces the transmission
8. Chain Tensioner With glide track
9. Bolt 10 Nm plus an additional 45° turn Replace

Scheme 466

1. Balance Shaft Removing and installing, refer to «BALANCE SHAFT»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__balance-shaft)
2. Bolt 60 Nm To loosen and fasten, use a drill bit 8 mm dia. as counter-holder
3. Balance Shaft Transmission Side Can only be placed on the balance shaft in one position
4. Bearing End Bracket
5. Bolt 13 Nm
6. Balance Shaft Belt Pulley Side Can only be placed on the balance shaft in one position
7. Bolt 60 Nm To loosen and fasten, use a drill bit 8 mm diameter as counter-holder

CYLINDER HEAD OVERVIEW

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

Scheme 467

1. Cylinder Head Gasket Replacing, refer to «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__cylinder-heads). Installation position: Part number facing cylinder head After replacing, change coolant and engine oil
2. Cylinder Head Removing, refer to «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__cylinder-heads) (Scheme 470) (Scheme 471)Installing «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__cylinder-heads) After replacing, change coolant and engine oil
3. Bolt Tightening specifications, refer to «Specifications»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#hydraulic-components-brake-system-coupe)
4. Vacuum Pump Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/mechanical-hydraulic/#hydraulic-components-brake-system-coupe)
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-122008__cylinder-heads) Replace Loosening procedure «CYLINDER HEADS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__cylinder-heads) Tighten in 3 stages: -- Tighten to 40 Nm. -- Tighten an additional 90°. -- Tighten an additional 90°.
11. Ignition Coil Use puller for ignition coil T40039 for removal
12. Cylinder Head Cover Removing and installing, refer to: Left «LEFT CYLINDER HEAD COVER»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__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-122008__right-cylinder-head-cover)
13. Gasket Replace if damaged or leaking
14. Cap
15. Bolt Replace if seal is damaged Tightening specifications (Scheme 468)and (Scheme 469).
16. Bolt Tightening specifications, refer to «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 468

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

Scheme 469

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

Scheme 470

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

1. Maximum warpage: 0.05 mm.

Scheme 471

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

1. Minimum dimension -a- = 139.20 mm.

Scheme 472

Tighten bolt -arrow- to 9 Nm.

VALVETRAIN OVERVIEW

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

Scheme 473

1. Sealing Plug Install with sealant
2. Cylinder Head Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__valve-guides-checking)
3. Valve Stem Seal Replacing with the cylinder head installed, refer to «VALVE STEM SEALS, CYLINDER HEAD INSTALLED»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__valve-stem-seals-cylinder-head-installed) Replacing with the cylinder head removed, refer to «VALVE STEM SEALS, WITH CYLINDER HEAD REMOVED»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__valve-stem-seals-with-cylinder-head)
4. Valve Spring Installed location (Scheme 475)
5. Hydraulic Adjusting Elements Checking, refer to «HYDRAULIC ADJUSTING ELEMENTS, CHECKING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__hydraulic-adjusting-elements-checking) Mark the installation position with paint for reinstallation Lubricate the running surfaces before installing
6. Valve Spring Plate
7. Valve Keys
8. Roller Rocker Lever Different versions for the intake and exhaust side, do not interchange them Check roller for easy movement Lubricate the running surfaces before installing Clip to the hydraulic adjusting element -5- with the clip -9
9. Securing Clip Different versions for the intake and exhaust side, do not interchange them Check for secure seat
10. Intake Camshaft With 3 camshaft sliders Do not disassemble Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-measuring-axial-play) Removing and installing, refer to «CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshafts) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-measuring-radial-play) Maximum run-out: 0.04 mm
11. Bolt Replace Tightening order (Scheme 474)
12. Camshaft Adjuster Actuator
13. Bolt 5 Nm
14. O-ring Replace
15. Bearing Bracket With integrated camshaft bearings Removing and installing, refer to «CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshafts)
16. Compression Ring
17. Compression Ring
18. Exhaust Camshaft Measuring axial play, refer to «CAMSHAFT, MEASURING AXIAL PLAY»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-measuring-axial-play) Removing and installing, refer to «CAMSHAFTS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshafts) Radial clearance, measuring, refer to «CAMSHAFT, MEASURING RADIAL PLAY»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-measuring-radial-play) Maximum run-out: 0.04 mm
19. Oil Strainer
20. Intake Valve Do not rework, only lapping is permitted Mark installed position for re-installation Valve dimensions, refer to «VALVE DIMENSIONS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__valve-dimensions) Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__valve-guides-checking)
21. Exhaust Valve Do not rework, only lapping is permitted Mark installed position for re-installation Valve dimensions, refer to «VALVE DIMENSIONS»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__valve-dimensions) Check valve guides, refer to «VALVE GUIDES, CHECKING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__valve-guides-checking)

Scheme 474

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

Replace the guide frame bolts.

Tighten the bolts in 3 stages in the sequence -1 to 21

Install bolts by hand as far as the 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°.

Scheme 475

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

FASTENER TIGHTENING SPECIFICATIONS

Left timing chain cover, tightening specifications and sequence

Replace the bolts for the left timing chain cover.

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

Right timing chain cover, tightening specifications and sequence

Replace the bolts for the right timing chain cover.

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

Lower timing chain cover, tightening specifications and sequence

Tighten bolts in 6 stages as follows

Left Cylinder Head Cover, Tightening Specifications and Sequence

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

Right Cylinder Head Cover, Tightening Specifications and Sequence

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

Oil dipstick guide tube - tightening specifications

Tighten bolt -arrow- to 9 Nm.

Camshaft guide frame tightening specifications and sequence

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

Replace the guide frame bolts.

Tighten the bolts in 3 stages in the sequence -1 to 21

Install bolts by hand as far as the 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°.

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

1. Engine oil temperature at least 30 °C (86 °F).
2. Battery voltage at least 12.5 V.

Remove rear engine cover -top arrows-.

Scheme 476

Remove bolts -arrows-.

Scheme 477

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

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

Scheme 478

Press electrical wiring harness down slightly.

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

Scheme 479

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

Remove air duct -arrows-.

Scheme 480

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

Scheme 481

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

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

Disconnect vacuum line -1-.

Scheme 482

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

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

Scheme 483

Press the electrical wiring harness to the side.

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

Scheme 484

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

Remove all the ignition coils with the T40039.

Scheme 485

Remove the spark plugs with Spark Plug Removal Tool 3122 B.

Check compression pressure using the Compression Tester V.A.G 1763.

Note. Using tester operating instructions.

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

Assembling

1. Tightening specifications. Refer to «CYLINDER HEAD OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__cylinder-head-overview) .

Assembly is in reverse order of removal, note the following

Note. Secure all hose connections with hose clamps appropriate for the model. 8

Install the spark plugs. Refer to Maintenance, Diagnosis .

Install air filter housing. Refer to Description and Operation .

If electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the engine control module. "Generate readiness code" in "Guided Functions" vehicle diagnostic tester.

CAMSHAFT, MEASURING AXIAL PLAY

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6080

PROCEDURE

Camshafts, removing. Refer to CAMSHAFTS .

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

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

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

Scheme 486

Determine the axial play.

1. Axial clearance: 0.100 to 0.191 mm.

CAMSHAFT, MEASURING RADIAL PLAY

Special tools and workshop equipment required

1. Plastigage®

Camshafts, removing. Refer to CAMSHAFTS .

Mark the assignment of the roller rocker lever for installation later.

Remove the roller rocker lever and place it on a clean surface.

Clean the bearing and the bearing journals.

Place Plastigage® over entire width of bearing journal or into bearing.

1. Plastigage® must rest in center of bearing.

Re-install the camshafts, mount the bearing bracket and tighten to 8 Nm. (Scheme 474), do not turn the camshafts while doing this.

Remove the bearing bracket and camshafts.

Compare width of Plastigage® with calibrated scale.

Radial clearance

1. For 24 mm diameter bearings: 0.024 to 0.066 mm
2. For 36 mm diameter bearings: 0.032 to 0.078 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
2. Socket T40058 for vehicles with the multitronic 0AW/automatic transmission 0B6

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

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

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

Remove the cylinder head cover. Refer to: LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

Rotate crankshaft so the cam lobes on that adjuster that must be checked are at the top. To do this

Manual Transmission

Move the vehicle forward with 4th gear engaged and the ignition switched off.

Vehicles with Multitronic Transmission 0AW/Automatic Transmission 0B6

Scheme 487

Remove front noise insulation -1-. Refer to Description and Operation .

Insert T40058 guide pins as follows

Scheme 488

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

Rotate the crankshaft with the T40058 in the direction of engine rotation -arrow-.

Scheme 489

All Vehicles

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

Scheme 490

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

FINAL PROCEDURES

Install the cylinder head cover. Refer to: LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

Install the front noise insulation. Refer to Description and Operation .

VALVE GUIDES, CHECKING

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6079

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.

Scheme 491

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

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 eyewear
3. Sealant

REMOVING

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

Remove rear engine cover -top arrows-.

Vehicles without a secondary air injection system: Remove the plenum chamber bulkhead. Refer to Description and Operation .

Vehicles with secondary air injection system: Remove the affected secondary air injection combination valve

1. Version 1. Refer to: «LEFT SECONDARY AIR INJECTION COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) , «RIGHT SECONDARY AIR INJECTION COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .
2. Version 2. Refer to: «SECONDARY AIR INJECTION LEFT COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) , «SECONDARY AIR INJECTION RIGHT COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

Left Timing Chain Cover

Remove electrical connectors -1 through 4- from the 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 the fuel line -1- and the wire -2- to the EVAP canister at the air guide pipe.

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

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

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

Note. Ignore -arrows-.

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

INSTALLING

1. Tightening specifications (Scheme 458), (Scheme 459).

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

Scheme 492

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

Note. Note the expiration date of the sealing compound.

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

Scheme 493

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

1. Thickness of sealant bead: 2.5 mm.

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

Position the left timing chain cover and tighten the bolts. (Scheme 458)

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

Scheme 494

1. Thickness of sealant bead: 2.5 mm.

Position the right timing chain cover and tighten the bolts. (Scheme 459)

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.

Vehicles without a secondary air injection system: Install the plenum chamber bulkhead. Refer to Description and Operation .

Vehicles with secondary air injection system: Install the secondary air injection combination valve

1. Version 1. Refer to: «LEFT SECONDARY AIR INJECTION COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) , «RIGHT SECONDARY AIR INJECTION COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .
2. Version 2. Refer to: «SECONDARY AIR INJECTION LEFT COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) , «SECONDARY AIR INJECTION RIGHT COMBINATION VALVE»(/audi/a5/i-2007-2011/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-cala-coupe-as-of-122008) .

LOWER TIMING CHAIN COVER

Special tools and workshop equipment required

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

1. Transmission removed.

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

Switch off ignition and remove ignition key.

Disconnect Ground (GND) cable -2- from the battery terminal. Refer to Removal and Installation .

Scheme 495

Remove drive plate. Refer to DRIVE PLATE .

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

Remove oil filter housing. Refer to OIL FILTER HOUSING .

Remove generator. Refer to Removal and Installation .

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

Note. Ignore items -1 to 4-.

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

Scheme 496

Remove electrical wire nut -2- and starter.

Note. Ignore -1 and 4-.

Remove bolts -arrows-.

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

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

1. Tightening specifications (Scheme 460)

Note. Replace seals, gaskets and O-rings.

Remove right upper alignment bushing from the cylinder block.

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

Scheme 497

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

Insert the alignment bushing in the 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 the sealant residue on the cover for the 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 the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

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

Scheme 498

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

Note. A kinked cylinder head seal must be replaced.

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

Scheme 499

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

Note. Note the expiration date of the sealing compound.

Cut the tube nozzle at the 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 the 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 the 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 500

1. The groove of sealing surface must be completely filled with sealant.
2. The 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 the seals -arrows- in the grooves on the lower timing chain cover.

Position the 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 the bolts for the lower timing chain cover. (Scheme 460)

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

Install starter. Refer to Removal and Installation .

Install generator. Refer to Removal and Installation .

Install oil filter housing. Refer to OIL FILTER HOUSING .

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

Install transmission-side crankshaft shaft seal. Refer to CRANKSHAFT SEAL, TRANSMISSION SIDE .

Installing drive plate. Refer to DRIVE PLATE .

Fill the engine oil and check the oil level. Refer to 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. Socket T40058
6. Locking Pin T40069
7. Used Oil Collecting and Extracting Device V.A.G 1782
8. Locking Pin T40071, qty. 2
9. Camshaft Clamp T40133, qty. 2

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

Remove respective cylinder head cover. Refer to: LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

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

Remove noise insulation -1- and -2-. Refer to Description and Operation .

Vehicles without the After-Run Coolant Pump -V51

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

Scheme 501

Place Used Oil Collection and Extraction Device V.A.G 1782 under the engine.

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

Scheme 502

Vehicles with After-Run Coolant Pump -V51

Remove After-Run Coolant Pump -V51-. Refer to After-Run Coolant Pump -V51 and oil cooler OIL COOLER .

All Vehicles

Insert the T40058 guide pins as follows

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

Turn the crankshaft in the direction of engine rotation -arrow- to Top Dead Center (TDC) using the T40058.

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

Scheme 503

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 the T40069. The marking on the vibration damper is only there to help. The exact "TDC" location is only reached by installing the T40069.

Scheme 504

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

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

Scheme 505

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

Scheme 506

Note. The illustration shows the left cylinder head.

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

Scheme 507

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

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

Scheme 508

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

To counterhold at the affected camshaft adjuster, position the T10172 with pins T10172/2 and loosen using T10035.

Scheme 509

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

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

Scheme 510

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

Scheme 511

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

1. Tightening specifications, refer to «CAMSHAFT TIMING CHAINS OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-overview), (Scheme 518)

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

1. Drive chain for timing mechanism installed. Refer to «TIMING MECHANISM DRIVE CHAIN»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__timing-mechanism-drive-chain) .
2. Secure the crankshaft in the TDC position using the T40069.

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

Note. The illustration shows the left cylinder head.

Scheme 512

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

Position the left camshaft timing chain on the drive sprocket and the 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 the T40071.

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

Position the right camshaft timing chain on the drive sprocket and the 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 T40071.

Position T10172 with the pins T10172/2 on the left intake camshaft adjuster.

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

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

Position the T10172 with the T10172/2 on the right exhaust camshaft adjuster.

Scheme 513

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

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

Remove the T40133 on both cylinder heads -arrows-.

Note. The illustration shows the left cylinder head.

Tighten the camshaft adjuster bolts on the left cylinder head as follows

Scheme 514

Tighten camshaft adjuster bolts on the right cylinder head as follows

Scheme 515

Remove T40069.

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

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

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

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

Install T40069 directly in the hole.

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

Remove camshaft locating pins on both cylinder heads.

Remove T40069.

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

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

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

Install after-run coolant pump -V51-. Refer to After-Run Coolant Pump -V51 .

Install oil cooler. Refer to OIL COOLER .

Install lock carrier brace. Refer to Description and Operation .

Install front noise insulation. Refer to Description and Operation .

CAMSHAFT TIMING CHAINS

Special tools and workshop equipment required

1. Locking Pin T40071

1. Transmission removed.

Remove timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

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

Remove T40071 and the left camshaft timing chain.

Scheme 516

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

Scheme 517

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

Scheme 518

Loosen the drive chain sprocket bolt -1- 1 turn.

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

1. Tightening specifications. Refer to «CAMSHAFT TIMING CHAINS OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__camshaft-timing-chains-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 torque.

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

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

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

Tighten mounting pin bolts -1-.

Remove T40071.

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

Fasten bolts -1- and -2-.

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

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

Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

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

TIMING MECHANISM DRIVE CHAIN

Special tools and workshop equipment required

1. Locking Pin T40071

1. Transmission removed.

Remove timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

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

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

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

Scheme 519

Remove bolts -1- and the guide rail.

Remove bolts -2- and the chain tensioner.

Remove timing mechanism drive chain.

1. Tightening specifications. Refer to «TIMING MECHANISM DRIVE CHAIN OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

Position the 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 the bolts -2-.

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

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

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

Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

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

POWER TAKE-OFF DRIVE CHAIN

Special tools and workshop equipment required

1. Key T40049
2. Locking Pin T40071
3. 8 mm diameter drill bit

1. Transmission removed.

Remove timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

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

Scheme 520

Remove locking bolt -arrow- for the Top Dead Center (TDC) marking from the 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 the T40069. The marking on the vibration damper is only there to help. The exact "TDC" location is only reached by installing the T40069.

Install the T40069 in the hole and tighten to 20 Nm. Turn the 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 T40071.

Scheme 521

Remove bolts -3- and the balance shaft chain sprocket.

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

1. Tightening specifications, refer to «TIMING MECHANISM DRIVE CHAIN OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008), (Scheme 518).
2. Secure crankshaft -1- in TDC position using T40069.

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

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

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

Scheme 522

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 the chain sprocket on the balance shaft and it must not tip.

Remove T40071 to release the chain tensioner.

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

Remove drill bit -2- from the balance shaft.

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

Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

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

BALANCE SHAFT

Special tools and workshop equipment required

1. Used Oil Collecting and Extracting Device V.A.G 1782

1. Transmission removed.

Remove belt pulley side sealing flange. Refer to SEALING FLANGE WITH CRANKSHAFT SEAL, BELT PULLEY SIDE .

Remove timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

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

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

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

Scheme 523

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

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

Scheme 524

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

Scheme 525

Remove balance shaft back out of the cylinder block.

1. Tightening specifications. Refer to «BALANCE SHAFT OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008), (Scheme 518).
2. Secure crankshaft -1- in TDC position using 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. Refer to POWER TAKE-OFF DRIVE CHAIN .

Install timing chain lower cover. Refer to LOWER TIMING CHAIN COVER .

Install belt pulley side sealing flange. Refer to SEALING FLANGE WITH CRANKSHAFT SEAL, BELT PULLEY SIDE .

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

LEFT CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Ignition Coil Puller T40039

Remove engine covers -arrows-.

Remove bolts -arrows-.

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

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

Scheme 526

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

Remove Ground (GND) wire bolt -5-.

Note. Ignore -2-.

Press the connector release catches and disconnect connector -1- on the camshaft adjustment valve 1 -N205- and exhaust camshaft adjustment valve 1 -N318-.

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

Move the electrical wiring harness to the side.

Remove the ignition coils using the T40039.

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

1. Tightening specifications (Scheme 468)

Installation is in reverse order of removal, note the following

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

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

Tighten the left cylinder head cover bolts (Scheme 468)

RIGHT CYLINDER HEAD COVER

Special tools and workshop equipment required

1. Ignition Coil Puller T40039

Remove engine covers -arrows-.

Remove air duct -arrows-.

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

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

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

Disconnect vacuum line -1-.

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

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

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

Scheme 527

Note. Ignore items -2, 3, and 4-.

Press the connector release catches and disconnect the connector -1- on the camshaft adjustment valve 1 -N205- and exhaust camshaft adjustment valve 1 -N318-.

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

Press the electrical wiring harness to the side.

Remove ignition coils with the T40039.

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

1. Tightening specifications (Scheme 469)

Installation is in reverse order of removal, note the following

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

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

Tighten the right cylinder head cover bolts. (Scheme 469)

CYLINDER HEADS

Special tools and workshop equipment required

1. Spanner Wrench 3212
2. Socket 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. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

Remove upper coolant pipe. Refer to UPPER COOLANT PIPE .

Remove ribbed belt. Refer to RIBBED BELT .

Remove lower section of the intake manifold. Refer to Removal and Installation .

Disconnect the electrical connectors on the fuel injectors.

Scheme 528

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

Vehicles without a Secondary Air Injection System

Remove left front muffler. Refer to FRONT MUFFLER .

Remove nuts -arrows- and bolt -1-.

Scheme 529

Remove left catalytic converter from the exhaust manifold and lay it aside.

Note. The installation location is shown with the engine removed.

Remove right front muffler. Refer to FRONT MUFFLER .

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

Scheme 530

Note. The installation location is shown with the engine removed.

All Vehicles

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

Scheme 531

Remove bolts -1 and 2- and lay the power steering pump aside.

Scheme 532

Note. The illustration shows the installation location on a vehicle with dynamic steering. Ignore -3- and -arrow-.

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

Scheme 533

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

Note. Ignore -arrows-.

Remove protective plate -1- for the high pressure line -arrows-.

Scheme 534

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

Remove threaded connection -1- and union nuts -2- and -3-.

Scheme 535

Remove bolts -arrows- on the retaining plates and the high pressure line.

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

Scheme 536

Disconnect electrical connectors -1 and 6-.

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

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

Scheme 537

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

Remove cylinder head cover. Refer to LEFT CYLINDER HEAD COVER , RIGHT CYLINDER HEAD COVER .

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

Remove Ground (GND) wire bolt -4-.

Note. Ignore -1, 2 and 5-.

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

Remove bolts -arrows- and the bracket for the left connectors.

Note. Ignore items -1 to 4-.

Remove bolts -arrows- and the bracket for the right connectors.

Note. Ignore items -1 to 4-.

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

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

Scheme 538

Remove bolts -arrows- on the rear of the cylinder head.

Scheme 539

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 the direction of -arrow A- using a plastic wedge to remove the bolt -1-. The slider on the camshaft must be pressed in the direction of -arrow B- using a plastic wedge to remove the bolt -2-.

Insert the T40058 guide pins as follows

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

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

Scheme 540

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

Left Cylinder Head

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

Scheme 541

Right Cylinder Head

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

Scheme 542

Continuation for Both Cylinder Heads

Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using Adapter T40058.

Scheme 543

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

Left Cylinder Head

Remove bolt -1-.

Scheme 544

Right Cylinder Head

Remove bolt -2-.

Scheme 545

Continuation for Both Cylinder Heads

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

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

Left Cylinder Head

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

Scheme 546

Right Cylinder Head

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

Scheme 547

Continuation for Both Cylinder Heads

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

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

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

Left Cylinder Head

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

Scheme 548

Remove cylinder head.

Right Cylinder Head

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

Scheme 549

Remove cylinder head.

1. Tightening specifications. Refer to «CYLINDER HEAD OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-cylinder-head-valvetrain-engine-codes-cala-coupe-as-of-122008__cylinder-head-overview) .

Note. Replace bolts which have been tightened to torque. 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 the cylinder head, set the crankshaft and camshafts to "TDC" and install the T40133 on both cylinder heads and tighten to 25 Nm -arrows-.

Scheme 550

1. The T40133 is correctly positioned when the holes for the cylinder head bolts remain free.

1. T40069 must be screwed into the crankshaft.

Set cylinder head gasket in place.

Scheme 551

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

Position the cylinder head.

Left Cylinder Head

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

Scheme 552

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

Right Cylinder Head

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

Scheme 553

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

Continuation for Both Cylinder Heads

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

Remove the Camshaft Locator T40133 and Locking Pin T40069.

Turn the crankshaft one full revolution (360°) in the direction of engine rotation -arrow- using Adapter T40058.

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

Left Cylinder Head

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

Scheme 554

Right Cylinder Head

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

Continuation for Both Cylinder Heads

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

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

Left Cylinder Head

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

Scheme 555

Right Cylinder Head

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

Scheme 556

Continuation for Both Cylinder Heads

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

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

Left Cylinder Head

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

Scheme 557

Right Cylinder Head

Slide the unloaded camshaft slider -F- as far as the 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 tighten cylinder head bolts after repairs.

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

Install oil dipstick guide tube (Scheme 472)

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

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

Install front coolant pipe. Refer to FRONT COOLANT PIPE .

Install power steering pump. Refer to Removal and Installation .

Install left catalytic converter: For vehicles with manual transmissions. Refer to LEFT CATALYTIC CONVERTER, MANUAL TRANSMISSION . For vehicles with the multitronic 0AW or automatic transmission 0B6. Refer to LEFT CATALYTIC CONVERTER, MULTITRONIC OR AUTOMATIC TRANSMISSION .

Install the right catalytic converter: For vehicles with manual transmissions or the multitronic 0AW. Refer to RIGHT CATALYTIC CONVERTER, MANUAL OR MULTITRONIC TRANSMISSION . For vehicles with the automatic transmission 0B6. Refer to RIGHT CATALYTIC CONVERTER, AUTOMATIC TRANSMISSION .

Install front muffler. Refer to FRONT MUFFLER .

Install the plenum chamber bulkhead. Refer to Description and Operation .

Install high pressure line, fuel supply line and the lower section of the intake manifold. Refer to Removal and Installation .

Install ribbed belt. Refer to RIBBED BELT .

Install upper coolant pipe. Refer to UPPER COOLANT PIPE .

Change engine oil. Refer to Maintenance, Diagnosis .

Replace coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

CAMSHAFTS

Special tools and workshop equipment required

1. Impact Puller T10133/3 from the Tool Set T10133
2. Locating Pins T40116
3. Hand drill with plastic brush attachment
4. Protective eyewear
5. Sealant

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

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

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

Remove bolts -arrows- and the camshaft adjuster valves.

Scheme 558

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

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

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

Remove T40133.

Mark camshafts and remove.

1. Secure crankshaft -1- using T40069.

Note. Replace the seals and gaskets.

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

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

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

Scheme 559

Oil running surfaces of both camshafts.

Insert the camshafts in the guide frame.

Scheme 560

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

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

Rotate camshafts until the threaded holes -arrows- face upward.

Check if the camshafts still lie in the guide frame axial bearings.

Install the T40133 and tighten the bolts -arrows- to 25 Nm.

Note. Note the expiration date of the sealing compound.

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

Rotate guide frame again.

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

Scheme 561

1. Thickness of sealant bead: 2.0 mm.

Apply sealant beads -1 through 3- to the clean sealing surfaces on the 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 the cylinder head.

Insert T40116 in the guide frame and cylinder head.

Scheme 562

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

Tighten guide frame bolts in the sequence -1 to 21-. (Scheme 474)

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

Scheme 563

Coat outer circumference of the sealing plug -arrow- with sealant

Drive in the sealing plugs until they are flush.

Remove T40116 with the impact puller T10133/3.

Scheme 564

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

Install the camshaft adjustment valves. Refer to CYLINDER HEAD OVERVIEW .

Install the brake booster vacuum pump. Refer to Removal and Installation .

Install the high pressure pump motor housing and the high pressure pump. Refer to Removal and Installation .

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

VALVE STEM SEALS, 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
6. Drift VAS 5161/3

Procedure

Camshafts, removing. Refer to CAMSHAFTS .

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

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

Remove the spark plugs with 3122 B.

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

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

Scheme 565

Place the guide plate VAS 5161/19B from the VAS 5161 on the cylinder head.

Scheme 566

Secure the guide plate with the knurled screws VAS 5161/12.

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

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

1. Minimum pressure: 6 bar (87 psi) positive pressure.

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

Scheme 567

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 the 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.

1. Pressurized air hose remains connected.

Remove valve spring with valve spring plate.

Remove valve stem seal with the 3364.

Scheme 568

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

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

Scheme 569

Position the lower part of the 3364 on the valve stem seal.

Scheme 570

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

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

Scheme 571

Lightly oil valve stem seal.

Slide valve shaft seal onto plastic sleeve.

Carefully press valve stem seal onto valve guide with 3365.

Remove plastic sleeve again.

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

Scheme 572

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 the cylinder head.

Install guide plate on the cylinder head.

Insert installation cartridge in guide plate.

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

Release pressure fork with the knurled screw still raised.

Repeat the procedure on each valve.

Assembling

Assembly is in reverse order of removal, note the following

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

Install camshafts. Refer to CAMSHAFTS .

Install spark plugs.

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. Cylinder Head Tension Device VAS 6419

Procedure

Camshafts, removing. Refer to CAMSHAFTS .

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

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

Mount the VAS 6419 into the VAS 6095.

Tension the cylinder head on the cylinder head tensioning device, as illustrated.

Scheme 573

Connect the cylinder head tensioning device to the compressed air.

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

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

Position the Drift on the valve spring plate and loosen the stuck valve keepers with a plastic mallet.

Place the guide plate VAS 5161/19B from the VAS 5161 on the cylinder head.

Scheme 574

Secure guide plate with the knurled screws VAS 5161/12.

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

Scheme 575

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 the 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 the valve stem seal with the 3364.

Position the valve lever on the puller and remove the 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 3365.

Remove plastic sleeve again.

When the valve keepers were removed from the installation cartridge, they must be inserted in the 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 the cylinder head.

Install guide plate on the cylinder head.

Insert installation cartridge in guide plate.

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

Release the pressure fork with the knurled screw still raised.

Repeat the procedure on each valve.

Assembling

Assembly is in reverse order of removal, note the following

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

Install camshafts. Refer to CAMSHAFTS .

Scheme 576

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

Scheme 577

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. Socket T40058
6. Locking Pin T40069

Scheme 578

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

Special tools and workshop equipment required

Scheme 579

Scheme 580

Scheme 581

Scheme 582

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

Scheme 590

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6080
3. Adapter T40058
4. Used Oil Collecting and Extracting Device V.A.G 1782
5. Locking Pin T40071
6. Camshaft Clamp T40133, qty. 2
7. Key T40049
8. Used Oil Collecting and Extracting Device V.A.G 1782
9. Spanner Wrench 3212
10. Adapter T40058
11. Locking Pin T40069
12. Camshaft Locator T40133
13. Impact Puller T10133/3 from the Tool Set T10133
14. Locating Pins T40116
15. Engine and Transmission Holder VAS 6095
16. Cylinder Head Tension Device VAS 6419

See also:
• CRANKSHAFT SEAL, TRANSMISSION SIDE
• OIL FILTER HOUSING AND PRESSURE SWITCH OVERVIEW
• Specifications
• Maintenance, Diagnosis
• Description and Operation
• Description and Operation
• Description and Operation
• LEFT SECONDARY AIR INJECTION COMBINATION VALVE
• Removal and Installation
• DRIVE PLATE
• OIL FILTER HOUSING
• ENGINE OIL, CHECKING LEVEL
• After-Run Coolant Pump -V51
• OIL COOLER
• SEALING FLANGE WITH CRANKSHAFT SEAL, BELT PULLEY SIDE
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• UPPER COOLANT PIPE
• RIBBED BELT
• FRONT COOLANT PIPE
• Removal and Installation
• COOLING SYSTEM, DRAINING AND FILLING
• LEFT AND RIGHT TIMING CHAIN COVERS
• LOWER TIMING CHAIN COVER
• CAMSHAFT TIMING CHAINS, REMOVING FROM CAMSHAFTS
• TIMING MECHANISM DRIVE CHAIN
• POWER TAKE-OFF DRIVE CHAIN
• BALANCE SHAFT
• CYLINDER HEADS
• LEFT CYLINDER HEAD COVER
• RIGHT CYLINDER HEAD COVER
• VALVE GUIDES, CHECKING
• VALVE STEM SEALS, CYLINDER HEAD INSTALLED
• VALVE STEM SEALS, WITH CYLINDER HEAD REMOVED
• HYDRAULIC ADJUSTING ELEMENTS, CHECKING
• CAMSHAFT, MEASURING AXIAL PLAY
• CAMSHAFTS
• CAMSHAFT, MEASURING RADIAL PLAY
• VALVE DIMENSIONS
• CYLINDER HEAD OVERVIEW
• CAMSHAFT TIMING CHAINS OVERVIEW
• TIMING MECHANISM DRIVE CHAIN OVERVIEW